description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/010,913, filed on Jan. 11, 2008, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This disclosure relates to fencing for residential and commercial use to support low and high voltage electrical devices.
[0004] 2. Description of Related Art
[0005] Traditionally, fences that are used for wildlife abatement have been chain-link fences, welded/woven wire fences, or wooden fences. While these fences may be effective to varying degrees to prevent the encroachment of wildlife, they can also limit visibility and/or interfere with aesthetic vistas. There is a benefit to keeping unwanted wildlife outside of a yard, while still maintaining visibility beyond the yard. In addition to being a physical barrier for animals, fences must also be used for residential and commercial use to maintain compliance with safety codes and regulations. In both the residential and commercial setting, around pools, for example, fences are required equipment.
[0006] Additionally, fences are often located at regions where surveillance and/or lighting may be desired, such as airports or other site-sensitive locations, residential properties, along a traveled thoroughfare or near public parks. In these often remote locations, powering electrical equipment is often difficult and/or expensive.
[0007] Accordingly, there is a need for a fence that has the durability to abate or control wildlife, yet not restrict visibility, while providing a single platform from which electrical appliances may be used for additional uses such as surveillance, safety and/or lighting.
SUMMARY OF THE INVENTION
[0008] The present disclosure provides for a fence having a hexagonal twist mesh configuration that is capable of supporting both low and high voltage electrical devices.
[0009] The present disclosure also provides for a fence having a hexagonal twist mesh configuration that has conductive wires extending therethrough to support electrical applications.
[0010] The present disclosure further provides for a fence having a hexagonal twist mesh configuration that has steel wires running therethrough in a horizontal orientation to provide stability and support.
[0011] The present disclosure yet further provides for a fence having a hexagonal twist mesh configuration that has conductive wires and steel wires therethrough.
[0012] The present disclosure still yet further provides for a fence having a hexagonal twist mesh configuration that after installation is almost invisible to the eye from several feet away and therefore does not impede viewing of the landscape.
[0013] The present disclosure yet further provides for a fence having a hexagonal twist mesh configuration in which the steel and conductive wires extend through the horizontal wound ends of each hexagonal member in an unwound configuration.
[0014] The present disclosure still yet further provides for a fence having a hexagonal twist mesh configuration that supports plumbing for plant irrigation.
[0015] The present disclosure yet still further provides for twist mesh hexagonal fencing for residential and commercial uses that incorporates reinforcement and conductive wires to provide a single platform for electrical appliances that may be used for wildlife abatement, site-sensitive security, swimming pool security and audio and video equipment.
[0016] The fence provides for a plurality of wires that are twisted together in pairs at a plurality of spaced elongated windings and spread to form openings. The spaced elongated windings lying in spaced parallel lines extending longitudinally in the mesh fence. The fence also includes a plurality of spaced apart parallel wires, wherein each of the plurality of spaced apart parallel wires extend through the spaced elongated windings lying in a line. Ones of the plurality of spaced apart parallel wires are conductive wires that are coupled to a connector to power at least one electrical device.
[0017] A mesh fence having a plurality of wires twisted together in pairs at a plurality of spaced elongated windings and being spread between each of the plurality of spaced elongated windings to form openings. The spaced elongated windings lying in spaced parallel lines extending longitudinally in the mesh fence. A plurality of spaced apart parallel elongate members, the extends through ones of the plurality of spaced elongated windings lying in a line. Ones of the plurality of spaced apart parallel elongate members being capable of transmitting electricity to at least one electrical device or being capable of providing irrigation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Other and further benefits, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like elements of structure and:
[0019] FIG. 1 illustrates a portion of a hexagonal fence according to the present invention;
[0020] FIG. 2 illustrates a portion of a hexagonal fence according to a second configuration of the present invention; and
[0021] FIG. 3 illustrates a fence according to the present invention having wiring, tubing and connectors.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring to the drawings and in particular to FIG. 1 , a portion of the fence according to the present invention is shown and generally referenced by reference numeral 10 . Fence 10 contains a plurality of adjacent wires 19 that are twisted or wound together at elongated windings 20 and 25 and spread or spaced. Elongated windings 20 and 25 lie in a spaced parallel relationship and extend longitudinally along fence 10 to form a mesh. A plurality of adjacent wires 19 includes individual wires 21 , 22 , 23 and 24 . For example, wires 22 and 23 are wound at elongated winding 20 and spread apart to be wound with adjacent wires 21 and 24 , respectively. Wires 22 and 23 may again be wound at elongated winding 25 to form a hexagonal shape therebetween. Alternatively, wires 22 and 23 may each be wound with a different wire after being wound at elongated winding 20 . Plurality of wires 19 are spread and wound with an adjacent wire to form a plurality of hexagonal shaped members 15 that interconnect to form mesh fence 10 . This hexagonal configuration provides substantial flexibility to fence 10 .
[0023] In FIG. 1 , each hexagonal shaped member 15 has a wire extending therethrough. Wires are steel wires 30 or conductive wires 35 or other cabling/tubing discussed below. Significantly, wires 30 , 35 remain straight through each hexagonal member 15 , and windings 20 and 25 during the winding process. When fence 10 is formed, steel wires 30 and conductive wires 35 remain straight and under tension, as plurality of wires 19 that form each hexagonal shaped member 15 are wound or twisted around wires 30 and 35 , thereby minimizing stress on wires 30 and 35 . Wires 30 and 35 are secured to supports 36 at edges of fence 10 to maintain tension in wires 30 and 35 . While FIG. 1 shows a single vertical support 36 , it should be understood that the opposite side of fence 10 is supported by a second support to which wires 19 , 30 and 35 are connected.
[0024] Further, by being secured within the fence in a non-wound configuration, the non-wound conductive wires 35 and steel wires 30 are not subject to the stress of being wound with the other mesh wires. Were wires 30 and 35 wound as wires 19 , the potential for electrical failure would damage the integrity of fences 50 or 60 . The straight configuration of wires 30 and 35 provides necessary reliability to the fence 10 .
[0025] Operatively associated with wires 35 are one or a plurality of connectors 40 . Connectors 40 permit appliances or devices to be connected to conductive wires 35 . Fence 10 is includes a coupling for connection to a locally supplied power source that would also supply power to a residence, for example. In this way, fence 10 serves as a platform to enable power to be provided to appliances that are connected thereto. When electrical appliances are connected to the one the plurality of connectors 40 , fence 10 serves as a single platform to provide multiple power to a wide range of appliances that can be powered by low voltage conductive wires, for example. Connectors 40 associated with mesh fence 10 allow 12 volt or 24 volt connections for the lighting, cameras, speakers, controllers and sensors to provide remote access to power sources that had previously not been available with such fencing.
[0026] Referring to FIG. 1 , conductive wires 35 , preferably copper, have a parallel horizontal configuration. While copper is preferable, other metals that offer the same conductive ability could also be used for conductive wires 35 . Conductive wires 35 are preferably pre-coated with an insulating material prior to incorporation into mesh fence 10 . The steel wires 30 provide support and stability to hexagonal fence 50 and prevent elongation.
[0027] Further, the wires 30 can be of any desired gauge based upon the required strength of the fence. The hexagonal twist mesh configuration, steel wires 30 and conductive wires 35 are all coated with a thermoplastic polymer, such as, for example, black polyvinylchloride (PVC) to minimize visibility, enhance flexibility and increase both durability and longevity. Conductive wires 35 of the instant invention are preferably low voltage wires that can be used to power electrical appliances of many types.
[0028] While the FIG. 1 shows eight conductive wires 35 paralleled by two heavier gauge steel wires 30 , any configuration of wires 30 , 35 can be used to achieve the user's needs. For example, in FIG. 2 , according to an alternative configuration of the present invention, fence 60 has two steel wires 30 that parallel six conductive wires 35 . Steel wires 30 are spaced more frequently across fence 60 to provide added stability and strength. Conductive wires 35 cannot be used for support; therefore, a fence with more steel wires 30 per a number of conductive wires 35 is stronger than a fence with fewer steel wires per the same number of conductive wires. Additionally, steel wires 30 relieve any stress that may be imparted to conductive wires 35 to ensure fence reliability and longevity.
[0029] Referring to FIG. 2 , there are three types of elongated windings in fence 60 . Elongated windings 70 include mesh wires 65 that form the hexagonal mesh of fence 60 . Elongated windings 75 include mesh wires 65 that are wound around conductive wires 35 . Elongated windings 80 include mesh wires 65 that are wound around steel wires 30 . Mesh wires 65 would also be wound around tubing for irrigation tubing and any cables for lighting, camera and surveillance equipment. Similar, to the configuration of FIG. 1 , wires 35 are powered by an appropriate power source have connectors to serve as a platform and power electrical outdoor appliances such as lighting, cameras and surveillance equipment, such as alarms, sensors or motion detectors.
[0030] Referring to FIG. 3 , a fence 50 using different parallel wires 55 and tubing 54 , collectively called elongated members, are used to power audio and video equipment, such as speakers, cameras and video surveillance equipment and irrigation equipment. Fence 50 has a similar mesh configuration as fences 10 and 60 of FIGS. 1 and 2 , respectively. Intercom communications, paging systems and intruder messaging systems can also be connected to fence 50 with the appropriate cabling. Wires 55 can be 12 volt wires, 24 volt wires, 110 volt wires, coaxial or cable wires. Thus the present invention has applicability for wires and/or cables that are capable providing power to many different devices. In additional to providing a platform for electrical applications/appliances, the hexagonal fence could also be a platform for tubing for irrigation using irrigation tubing 54 . By using irrigation tubing 54 , such as, for example, cross-linked polyethylene tubing of various diameters, drip irrigation and/or sprinkler systems, can be incorporated into mesh 18 . The tubing 54 can be activated with timers and integrated into the upper or lower course of the mesh cabling. Tubing 54 has ports that are coupled to water sources to provide water for irrigation purposes.
[0031] Fence 50 merges electrical/irrigation capability using wires, cabling and or tubing, that are integrated into hexagonal mesh fencing. Operatively associated with wires 55 are one or a plurality of connectors 40 . When electrical appliances are connected to the one the plurality of connectors 40 , fence 10 serves as a single platform to provide multiple power to a wide range of appliances that can be powered by low voltage wires. Connectors 40 on the hexagonal fencing allow 12 volt or 24 volt connections for the lighting, cameras, speakers, controllers and sensors to provide remote access to power sources that had previously not been available with such fencing. Similar to fences 10 and 50 of FIGS. 1 and 2 , respectively, a power source is also coupled to fence 50 to permit service as a platform for electronic devices.
[0032] Fence 50 of the present disclosure has residential and commercial application. Fence 50 can be used wherever there is a need to secure a boundary or to prevent entry into a property. In the residential setting, hexagonal twist mesh fences are desirable for wildlife abatement and help eliminate safety concerns at a boundary that may contain a pool or other similar structure or sensitive area.
[0033] Further, fence 50 can stretch and contort in ways that other fences are not able to because of the hexagonal mesh configuration. Hexagonal shaped members 15 make fence 50 inherently flexible and prone to elongation under tension. Accordingly, fence 50 can sustain a degree of damage, without causing an actual breach in the mesh, potentially compromising the protected area. Additionally, the flexible configuration of fence 50 permits a secure interface with the ground so that gaps between the fence and the ground can be eliminated. Even where there is moderate to severe undulation in the terrain, complete installation capability is achieved by the fence because of its flexibility.
[0034] Additionally, the black PVC coating makes the fence ideal for a residential setting such as near a pool because the fence does not diminish the view or block out views of trees and shrubbery. The camouflaged fence allows the feeling of openness but does not allow access. The fence becomes essentially invisible to the eye at a close distance. Even through a user may want to secure a perimeter, visibility beyond the perimeter is still desirable and possible.
[0035] Further, conductive wires 35 and 55 that are integral to the hexagonal mesh fence 50 have particular applicability to the residential environment. The ability to provide video, lighting, surveillance, or motion sensor capability at remote locations from the residence is very valuable and convenient. In particular, around pools the fence of the present disclosure offers the appropriate strength and security by providing a single platform for motion sensors for monitoring the deck and water. Such sensors are required by many state laws. In the commercial setting, the same benefits are also provided by the embedded conductive wires.
[0036] The present disclosure having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the disclosure.
|
The fence provides for a plurality of wires that are twisted together in pairs at a plurality of spaced elongated windings and spread to form openings. The spaced elongated windings lie in spaced parallel lines extending longitudinally in the mesh fence. The fence also includes a plurality of spaced apart parallel wires, wherein each of the plurality of spaced apart parallel wires extend through the spaced elongated windings lying in a line. Ones of the plurality of spaced apart parallel wires are conductive wires that are coupled to a connector to supply electricity to at least one electrical device.
| 0
|
STATEMENT OF GOVERNMENT INTEREST
The invention described was made in the performance of official duties by one or more employees of the Department of the Navy, and thus, the invention herein may be manufactured, used or licensed by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND
The invention relates generally to a hold-and-release mechanism. In particular, the mechanism maintains a thrust-generating missile within a deployment canister until release by command.
Select munitions can be launched from canister platforms, such as torpedoes and ship-launched missiles. Vertically launched missiles may be held in place by releasable clamps or shearable pins. A missile deployed within a launch tube and equipped with a solid rocket motor booster may be ejected from its canister by gas (e.g., steam) subsequently propelled by its booster. For launch from a submarine, the motor firing may be initiated after rising above the water's surface.
SUMMARY
Conventional mechanisms for restraining a canisterized missile yield disadvantages addressed by various exemplary embodiments of the present invention. These various exemplary embodiments provide a device for holding and releasing a missile within a canister. In particular, the device includes a housing attached to the canister, a latch mechanism extending from the housing into the canister, a tension applier disposed in the housing to restrain the missile in the canister, a release mechanism disposed on the housing, an interface mechanism and a compression applier.
The tension applier forces the latch mechanism against the housing to withdraw from the missile. The interface mechanism initially couples the release mechanism and the tension applier. The compression applier anchors to the interface mechanism and forces the latch mechanism against the housing to engage the missile and counteract said tension applier. On command, the release mechanism disengages from the housing to release the compression applier from the interface mechanism. This action enables the tension applier to withdraw the latch mechanism from the missile.
In various exemplary embodiments, the release mechanism is an electrically activated threaded explosive bolt. In alternate embodiments, the interface mechanism is a plate pivotably connected to the housing by a hinge. In various exemplary embodiments, the compression applier is an adjustable threaded compression bolt. Alternate embodiments provide for the housing to include a base that attaches to the canister, a chamber that contains the tension applier and a stub that attaches to the release mechanism. Various preferred embodiments provide for the release mechanism to include a sealing mechanism to inhibit leakage. The tension applier may be represented by a helical spring, and the latch mechanism may be represented by a push-rod.
BRIEF DESCRIPTION OF THE DRAWINGS
These and various other features and aspects of various exemplary embodiments will be readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which like or similar numbers are used throughout, and in which:
FIG. 1 is shows an exploded perspective view of components for a hold release mechanism;
FIG. 2 is an assembly perspective view of the hold release mechanism;
FIG. 3 is a perspective view of a push-rod assembly;
FIG. 4 is a see-through perspective view of the hold release mechanism;
FIG. 5 is an elevation view of the hold release mechanism in operation;
FIG. 6 is an elevation view of time-elapsed travel positions for components of the hold release mechanism;
FIG. 7 is a perspective side view of the hold release mechanism as installed on a canister;
FIG. 8 is a perspective aft view of the canister with four hold release mechanisms installed;
FIG. 9 is a perspective side view of the canister prior to launch initiation;
FIG. 10 is a perspective side view of the release mechanism subsequent to launch initiation; and
FIG. 11 is an elevation diagram of time-elapsed missile positions in the canister.
DETAILED DESCRIPTION
In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized, and logical, mechanical, and other changes may be made without departing from the spirit or scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
One submarine-based missile launch platform under consideration for operational depths is the Water Piercing Missile Launcher (WPML), which uses the rocket motor's exhaust to pierce the water. Upon production of an exhaust gas column that reaches the surface, the missile can be released to traverse the surface and continue towards its target. Various exemplary embodiments provide a hold and release mechanism (HRM) to restrain the missile during initial motor firing until conditions merit the missile to be released.
FIG. 1 shows an exploded perspective view of components 100 for the HRM. A base plate 110 may be welded or bolted to a missile canister (to be subsequently described in more detail). Along the exposed surface of the plate 110 opposite the canister are disposed a pair of hollow cylinders: a larger-diameter barrel 120 and a smaller-diameter explosive tube 125 . A helical release spring 130 may be disposed into the barrel 120 along their common longitudinal axes. A push-rod or pin 140 may be inserted within the release spring 130 along the common axis as installed. The barrel 120 and explosive tube 125 may be welded to the base plate 110 and together form the HRM housing.
A hinge plate 150 may be disposed over the hollow cylinders 120 , 125 , with a corresponding pair of through-holes aligned thereto. The hinge plate 150 may be characterized as having a substantially circular platform (having a center through-hole) and flanked by (nonsymmetrical) wing tabs (one of which includes a distal through-hole). An end plate or flat washer 155 having a center through-hole may be disposed between the hinge plate 150 and the open end of the barrel 120 . A compression bolt 160 may be inserted through the center through-holes of the hinge plate 150 and the end plate 155 . A threaded bolt 165 disposed between the plates 150 , 155 may secure the bolt 160 in position to restrain the pin 140 . The compression bolt 160 may have a predetermined length depending on design requirements.
An explosive bolt 170 may be disposed through the distal through-hole of the hinge plate 150 for insertion into the explosive tube 125 . The explosive bolt 170 includes an energetic primer triggered to explode in response to electric current through circuit wires 175 that extend from the bolt's top. The distal wire 175 a represents the hot wire typically colored red. The proximal wire 175 b represents the neutral wire typically colored black. In the exemplary embodiments shown herein, the bolts 160 , 170 are threaded for adjustably screwing in place.
A bracket 180 may be disposed adjacent to the open end of the barrel 120 opposite from the explosive tube 125 . The bracket 180 may include a pair of axial through-holes yielding an axis substantially parallel to the base plate 110 and substantially perpendicular to a plane formed by the longitudinal axes of the cylinders 120 , 125 . A clevis pin 185 passes through the bracket's through-holes and a hinge sleeve 190 disposed on the hinge plate 150 . The clevis pin 185 may be secured by a cotter pin. The barrel 120 and explosive tube 125 may be welded to the base plate 110 and together with the bracket 180 form the HRM housing.
FIG. 2 shows a perspective view of the HRM as an assembly 200 . The push-rod 140 extends opposite the exposed surface of the base plate 110 (and into the canister). The barrel 120 and explosive tube 125 extend from the base plate 110 . The hinge plate 150 with the bolts 160 , 170 extending there-through is disposed over the open end of the cylinders 120 , 125 , and the bracket 180 enables the hinge plate 150 to swing open upon commanded rupture of the explosive bolt 170 .
FIG. 3 shows a perspective view of a push-rod assembly 300 for sealing the barrel 120 . The push-rod 140 may be secured to a stem 310 for connection to the base plate 110 and enveloped proximate to the stem 310 by a coil seal spring 320 terminated at each end by a pair of rubber tap washers 330 and 340 . The proximal washer 330 may be disposed adjacent to the stem 310 , while an o-ring 350 may form an annular seal around the push-rod 140 . Upon assembly, the stem 310 , spring 320 , washers 330 , 340 and o-ring 350 may be contained within the barrel 120 , with the push-rod 140 protruding beyond the o-ring 350 . This design inhibits leaking of liquid into the barrel 120 , thereby enabling a water tight seal between the HRM and the WPML.
FIG. 4 shows a partially see-through perspective view of the HRM assembly 400 , featuring internal components from FIGS. 1 and 3 as installed and assembled in FIG. 2 . This configuration illustrates the compression bolt 160 prior to being fully screwed in the hinge plate 150 to squeeze the release spring 130 , with the seal spring 320 and distal washer 340 nestled within and around the push-rod 140 . The explosive bolt 170 visibly shows the scored region for separation, with its distal portion (inserted into the tube 125 and opposite the wires 175 ) containing the primer for command release via electric current.
The HRM represents as a cost effective mechanism to restrain a missile for a predetermined time before enabling its exit from the launcher. The mechanism assembly 200 engages the push-rod 140 through the canister (along its cylindrical wall) and into the missile. Four of these mechanisms may be disposed in a cruciform pattern, for example, to ensure force balance along the missile's longitudinal centerline. Upon firing the missile's rocket motor, the push-rod 140 restrains the missile from flying out until a column of exhaust gas punches a hole through the water. Once this column has formed, all push-rods 140 are pulled for each of the assemblies 200 pulled, thereby enabling the missile to fly through the column unabated.
Scale tests were conducted in which the push-rods 140 were pulled with explosive pin pullers. Such a puller includes a piston disposed over an explosive charge and attached to a heavy pin. Upon initiating the charge, the rapidly expanding gasses move the piston, thereby pulling the push-rod 140 to release the missile. Typically, these must explosively tailored to the application, are single-use only and can be quite expensive. The HRM may serve as a pin puller for missile launch applications with advantages of design flexibility and repeatable operations with substantially the same equipment, except for the explosive bolt 170 that is consumed at launch.
Assembly instructions for the HRM based on the views in FIGS. 1-3 are listed as follows:
(1) Attach the hinge plate 150 to the barrel 120 of the HRM housing by inserting the clevis pin 185 secured with a cotter pin. The hinge plate 150 preferably rotates freely about the clevis pin 185 , disposed at rest preferably flush with the barrel's open end.
(2) Install the release spring 130 in the barrel 120 .
(3) Assemble the push-rod 140 within its assembly 300 . This includes the operations:
(a) Thread the push-rod 140 into stem 310 and secure with a nut.
(b) Install the proximal washer 330 under the stem 310 .
(c) Install the seal spring 320 .
(d) Install the distal washer 340 over the seal spring 320 .
(e) Install the o-ring 350 under the distal washer 340 .
(4) Install push-rod assembly 300 into the barrel 120 , such that the push-rod 140 protrudes beyond the base plate 110 .
(5) Install a grade-8 bolt in place of the explosive blot 170 and tighten, but not excessively. A torque of 50 inch-pounds may be used as an example reference.
(6) Install 1¼ inch grade-8 compression bolt 160 with the end plate 165 .
(7) Tighten the bolt 160 until being in contact with hinge plate 150 then torque to 150 inch-pounds.
(8) Measure length of the push-rod 140 extending from the base plate 110 . Slight adjustments may be made by threading the push-rod 140 farther into stem 310 .
After the hinge plate 150 contacts the barrel 120 and the explosive bolt 170 is disposed in place and tightened, the compression bolt 160 can be tightened down and torqued. When tightened, the compression bolt 160 presses against the push-rod 140 threaded into the stem 310 to push against and restrain the missile in the canister. The end plate 155 (connected to the hinge plate 150 ) uniformly presses against the distal end of the release spring 130 to compress it. Upon initiating the explosive bolt 170 , the hinge plate 150 rotates about the clevis pin 185 releasing the push-rod 140 to be pushed out by the force of the release spring 130 .
FIG. 5 shows an example of the HRM operation 500 during initiation of the explosive bolt 170 . The position sequences are shown in four (4) stages: loaded 510 , activated 520 , travel 530 and release 540 . In the loaded position 510 , the explosive bolt 170 is fastened in place and the central bolt 160 is fully engaged, thereby compressing the release spring 130 .
Upon initiation of the explosive bolt 170 in the activated position 520 , the tensile force by the release spring 130 against the compression bolt 160 causes the hinge plate 150 to rotate about the clevis pin 185 in an involute curve trajectory, which continues into the travel position 530 . The compression bolt 160 can be screwed a substantial distance into the barrel 120 to fully deflect the release spring 130 , and nonetheless withdraw in the release position 540 without contacting the interior side of the barrel 120 upon ejection. As the compression bolt 160 rotates in the release position 540 , the release spring 130 extends within the barrel 120 towards its open end, thereby withdrawing the push-rod 140 (at least partially) from the canister to release the missile.
FIG. 6 shows an elevation view of travel trajectory positions 600 of select components for a 0.50 inch diameter compression bolt 160 . The hinge plate 150 follows an offset rotation path 610 around the clevis pin 185 . The plate's inner surface (initially facing the open end of the barrel 120 in the loaded position 510 ) is depicted along the rotation path 610 as a series of swinging path plate positions 620 . The hinge plate 150 is pushed by the release spring 130 in response to retreat by the compression bolt 160 along a swinging bolt path 630 within an inner cylindrical diameter 640 of the barrel 120 .
Dimensions as shown in FIG. 6 indicate an exemplary embodiment for recently conducted tests. In this example, the barrel 120 has an internal cylindrical diameter of 1.60 inches, and the compression bolt 160 extends 1.50 inches into the barrel 120 (which may be 3.50 inches in length).
FIG. 7 shows an installed configuration 700 in perspective view from the side with the base plate 110 of the HRM assembly 200 disposed on a canister. The compression bolt 160 is shown prior to being screwed into the barrel 120 . The wires 175 (attached to the explosive bolt 170 in the tube 125 ) are wrapped within an insulation cable 710 . The FIG. 8 shows an installed configuration 800 in perspective from the rear with each HRM assembly 200 securely attached to an outer annulus (attach ring) 810 of the canister that contains a simulated missile 820 within an inner annulus 830 . A cruciform set of plates 840 secures the inner annulus 830 to the outer annulus 810 . The push-rods 140 from the HRM assemblies 200 pass through the plates 840 to restrain the (simulated) missile 820 .
FIG. 9 shows another perspective view 900 of the canister's outer annulus 810 and the attached HRM assemblies 200 from the side (prior to the compression bolt 160 being tightened). FIG. 10 shows a perspective view 1000 of the HRM assembly 200 after initiation, in which the compression plate 160 has been hinged away from the barrel's opening after the explosive bolt's discharge.
FIG. 11 shows an elevation view 1100 of launching stages for the WPML into the atmosphere 1110 from deployment under water 1120 between the water's surface 1125 and the submarine-deployed canister 1130 . The missile 1135 can be ejected by firing its motor to produce exhaust gas 1140 thereby producing a gas column 1145 thereby piercing the water 1120 to its surface 1125 . The stages include pre-launch 1150 , motor firing 1160 , column production 1170 , missile release 1180 and missile fly-out 1190 beyond the surface 1125 . The HRM assemblies 200 restrain the missile 1135 until the gas column 1145 reaches the surface 1125 (and the motor's thrust is sufficient to propel the missile 1135 ) out of the canister 1130 .
The HRM was tested successfully in design mode at least sixteen times. The final test (to date) in September 2007 incorporating four (4) HRM units produced a successful missile fly-out and proof-of-concept for the WPML. Further tests are expected as the WPML program evolves.
In general, the time from initiation of the rocket motor to the time when the HRM is activated, varies with application and rocket motor type. For the September 2007 successful WPML missile fly-out test, experimental data indicated that the missile 1135 should be held within the canister 1130 for approximately one second to form a stable column 1145 . At this time, the explosive bolt 170 was initiated through a time-delay switch, enabling the push-rod 140 to release the missile 1135 .
The HRM assembly 200 is flexible in design, such that stronger or weaker springs 130 , 320 may be used. The HRM assembly 200 can be made dimensionally smaller or larger depending on the application. For example, an upcoming WPML program may employ a Tomahawk rocket motor, which has substantially greater thrust than the Jato rocket motor used in the September 2007 test. Artisans of ordinary skill will recognize that substituting springs of different strength and/or scaling particular dimensions may augment the HRM design for specific applications without departing from the inventive concept.
In principle, the HRM assembly 200 can be described as including a housing, a pivotable interface, a latching mechanism, a tension applier, an adjustable compression applier and a release mechanism. The housing may include the base plate 110 with the barrel 120 (e.g., chamber for the latching mechanism and tension applier) and the tube 125 (e.g., stub for the release mechanism).
In the configuration shown, the barrel 120 and tube 125 may be connected (e.g., by welding) on the base plate's outer surface. Similarly, the plate's lower surface may connected to the canister 1130 (by welding), and the bracket 180 may be attached near the open end of the barrel 120 . The pivotable (i.e., swingable on a pivot) interface may be represented by the hinge plate 150 coupled with the end plate 155 and the nut 165 . The interface may be hinged, for example, on the sleeve 190 to the clevis pin 185 . This interface couples the tube 125 with the barrel 120 to be secured and released concurrently.
The latching mechanism (or latch) may be represented by the push-rod 140 that restrains the missile 1135 in the canister 1130 . The adjustable compression applier may be represented by the compression bolt 160 to dispose the latch against the missile 1135 . The release mechanism may be represented by the explosive bolt 170 that initially secures the interface to the housing for its subsequent withdrawal on command. The tension applier may be presented by the release spring 130 to drive the latch away from the missile 1135 for its launch from the canister 1130 upon activation of the release mechanism.
The HRM includes various advantages, such as being inexpensive as compared with the alternate explosive pin pullers. The HRM can be manufactured from off-the-shelf materials, and explosive bolts 170 are readily available and easily manufactured items. The HRM is reusable, with the exception of the explosive bolts. The HRM can be scaled in size and strength to function in different configurations and to overcome different load requirements.
While certain features of the embodiments of the invention have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the embodiments.
|
A device is provided for holding and releasing a missile within a canister. The device includes a housing attached to the canister, a latch mechanism extending from the housing into the canister, a tension applier disposed in the housing to restrain the missile in the canister, a release mechanism disposed on the housing, an interface mechanism and a compression applier. The tension applier forces the latch mechanism against the housing to withdraw from the missile. The interface mechanism initially couples the release mechanism and the tension applier. The compression applier anchors to the interface mechanism and forces the latch mechanism against the housing to engage the missile and counteract said tension applier. On command, the release mechanism disengages from the housing to release the compression applier from the interface mechanism. This action enables the tension applier to withdraw the latch mechanism from the missile.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of provisional application Ser. No. 60/510,259 filed Oct. 10, 2003.
TECHNICAL FIELD
[0002] This invention relates to a stent graft for use in the human or animal body and more particularly to a stent graft which can be used as a side branch stent graft from a main vessel stent graft.
BACKGROUND OF THE INVENTION
[0003] There is a problem with the deployment of a branch stent graft from a main stent graft into a side artery for instance. If a branch stent graft is made substantially flexible, that is, for instance, manufactured with all self expanding stents, then there is a danger that, where a graft extends from a main graft through an aneurysed space within, for instance an aneurysed aorta and then into a side branch artery, such as a renal artery, as the main graft moves the side branch can kink which can close off the lumen through the branch stent graft.
[0004] If, however, an essentially rigid stent graft such as a balloon expandable graft is used then the distal end of the stent graft can cause significant distortion of the side branch vessel and there can be a considerable problem with fibrosis, stenosis or damage to the side branch artery at the distal end of the stent graft.
[0005] Applicant has found that this problem can be solved by providing greater flexibility of the branch stent graft within the side branch but having a degree of rigidity in the main vessel region.
[0006] There is also a problem with holding the branch stent graft into a fenestration in a main graft and this present invention proposes ways to satisfy this requirement.
[0007] There can also be problems with stenosis at the distal end of the side graft and this invention proposes methods by which ingrowth at the end of a balloon expandable stent can be reduced.
SUMMARY OF THE INVENTION
[0008] In one form, therefore, the invention is said to reside in a composite stent graft having a tubular body with a lumen therethrough, the tubular body comprising a balloon expandable stent portion, a tubular graft material portion disposed inside or outside of the balloon expandable stent portion and extending from one end of the balloon expandable stent portion and self expanding stents associated with the tubular graft material portion disposed at least in the tubular graft material portion extending from the balloon expandable stent portion.
[0009] It will be seen that by this invention there is provided an arrangement by which the balloon expandable stent portion which is substantially rigid can extend from a main graft across an aneurysed space to the side branch artery or vessel and then within the side branch artery the device has self expanding stents disposed within or outside the tubular graft material which provide a degree of flexibility to reduce the incidence of stenosis or fibrosis.
[0010] Preferably, there is a portion of the balloon expandable stent portion which extends beyond the proximal end of the tubular graft material portion. This extension portion allows for expansion of the balloon expandable stent beyond the diameter of the tubular graft material in that extension portion. This enables the extension portion of the balloon expandable stent to be flared to enable it to be connected into a fenestration in a main graft so that it is securely received in it.
[0011] The tubular graft material can include polytetrafluoroethylene, THORALON™, Dacron, polyamide or any other suitable biocompatible graft material.
[0012] While DACRON, THORALON expanded polytetrafluoroethylene (ePTFE), or other synthetic biocompatible materials can be used for the tubular graft material for the stent graft, a naturally occurring biomaterial, such as collagen, is highly desirable, particularly a specially derived collagen material known as an extracellular matrix (ECM) material, such as small intestinal submucosa (SIS). Besides SIS, examples of ECM's include pericardium, stomach submucosa, liver basement membrane, urinary bladder submucosa, tissue mucosa, and dura mater.
[0013] SIS is particularly useful, and can be made in the fashion described in Badylak et al., U.S. Pat. No. 4,902,508; Intestinal Collagen Layer described in U.S. Pat. No. 5,733,337 to Carr and in 17 Nature Biotechnology 1083 (November 1999); Cook et al., WIPO Publication WO 98/22158, dated 28 May 1998, which is the published application of PCT/US97/14855, the teachings of which are incorporated herein by reference. Irrespective of the origin of the material (synthetic versus naturally occurring), the material can be made thicker by making multilaminate constructs, for example SIS constructs as described in U.S. Pat. Nos. 5,968,096; 5,955,110; 5,885,619; and 5,711,969. In addition to xenogenic biomaterials, such as SIS, autologous tissue can be harvested as well, for use in forming the tubular graft material. Additionally Elastin or Elastin-Like Polypetides (ELPs) and the like offer potential as a material to fabricate the tubular graft material to form a device with exceptional biocompatibility.
[0014] SIS is available from Cook Biotech, West Lafayette, Ind., USA.
[0015] The self expanding stent can include nitinol, stainless steel or any other suitable material.
[0016] The balloon expandable stent portion can include a shape memory material such as titanium, magnesium, nickel, alloys and the like.
[0017] When the tubular graft material is disposed inside the balloon expandable portion the portion of the self expanding stents extending into the balloon expandable portion will assist to hold the tubular graft material against the balloon expandable stent portion. Stitching can be provided to retain the tubular graft material to each of the self expanding stents and the balloon expanding stents.
[0018] The self expanding stents can be provided either inside or outside the tubular graft material. For instance they can be provided outside along part of the length and inside at the distal end so that the outside surface of the tubular graft material provides a good seal against the wall of the branch artery or vessel when deployed.
[0019] In a further form the invention can be said to reside in a composite stent graft having tubular body with a lumen therethrough, a first portion at one end of the tubular body that can be flared to retain the stent in a fenestration in another stent graft that can be positioned in a main vessel, a second central portion that is relatively rigid and can bridge from the fenestration to a branch vessel of the main vessel and a third portion that is relatively flexible and can extend into a branch vessel to conform thereto.
[0020] Preferably the second and third portions include a covering or lining of biocompatible graft material.
[0021] In a preferred embodiment of the invention the first and second portions comprise or include a balloon expandable stent. The third portion may comprise or include self expanding stents.
[0022] In a further form the invention comprises a composite stent graft comprising a biocompatible graft material tube, a balloon expandable stent disposed inside or outside a first part of the graft material tube and extending from one end of the graft material tube and at least one self expanding stent associated with a second part of the graft material tube.
[0023] Preferably the at least one self expanding stent associated with the second part of the graft material tube comprises a plurality of external self expanding stents and at least one terminal internal self expanding stent.
[0024] In a further form the invention comprises a method of retaining a side branch stent graft into a fenestration in a main graft, the side branch stent graft having a tubular body with a lumen therethrough, a first portion at one end thereof being balloon expandable, a second relatively rigid central portion that can bridge from the fenestration and a third relatively flexible portion, the method including the steps of; deploying the side branch stent graft through the fenestration such that at least part of the first portion remains within the main stent graft; and expanding a balloon in the region of the fenestration whereby to flare that part of the first portion which is within the main stent graft, whereby to assist with retention of the side branch stent graft into the fenestration in the main graft.
[0025] Preferably the step of expanding the balloon includes the step of expanding a first balloon in the second portion to retain the position of the side branch stent graft and expanding a second balloon in the region of the fenestration whereby to flare that part of the first portion which is within the main stent graft. Preferably the first balloon is a non-compliant balloon and the second balloon is a compliant balloon.
[0026] U.S. Pat. No. 6,206,931 entitled “Graft Prosthesis Materials” discloses graft prosthesis materials and a method for implanting, transplanting, replacing and repairing a part of a patient and particularly the manufacture and use of a purified, collagen based matrix structure removed from a submucosa tissue source. These features and other features disclosed in U.S. Pat. No. 6,206,931 could be used with the present invention and the disclosure of U.S. Pat. No. 6,206,931 is herewith incorporated in its entirety into this specification.
[0027] U.S. Pat. No. 5,387,235 entitled “Expandable Transluminal Graft Prosthesis For Repair Of Aneurysm” discloses apparatus and methods of retaining grafts onto deployment devices. These features and other features disclosed in U.S. Pat. No. 5,387,235 could be used with the present invention and the disclosure of U.S. Pat. No. 5,387,235 is herewith incorporated in its entirety into this specification.
[0028] U.S. Pat. No. 5,720,776 entitled “Barb and Expandable Transluminal Graft Prosthesis For Repair of Aneurysm” discloses improved barbs with various forms of mechanical attachment to a stent. These features and other features disclosed in U.S. Pat. No. 5,720,776 could be used with the present invention and the disclosure of U.S. Pat. No. 5,720,776 is herewith incorporated in its entirety into this specification.
[0029] U.S. Pat. No. 6,206,931 entitled “Graft Prosthesis Materials” discloses graft prosthesis materials and a method for implanting, transplanting replacing and repairing a part of a patient and particularly the manufacture and use of a purified, collagen based matrix structure removed from a submucosa tissue source. These features and other features disclosed in U.S. Pat. No. 6,206,931 could be used with the present invention and the disclosure of U.S. Pat. No. 6,206,931 is herewith incorporated in its entirety into this specification.
[0030] U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 entitled “Endoluminal Aortic Stents” disclose a fenestrated prosthesis for placement where there are intersecting arteries. This feature and other features disclosed in U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 could be used with the present invention and the disclosure of U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 is herewith incorporated in its entirety into this specification.
[0031] U.S. patent application Ser. No. 10/280,486, filed Oct. 25, 2002 and published on May 8, 2003 as U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 entitled “Prostheses For Curved Lumens” discloses prostheses with arrangements for bending the prosthesis for placement into curved lumens. This feature and other features disclosed in U.S. patent application Ser. No. 10/280,486, and U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 could be used with the present invention and the disclosure of U.S. patent application Ser. No. 10/280,486, and U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 is herewith incorporated in its entirety into this specification.
[0032] U.S. Provisional Patent Application Ser. No. 60/392,667, filed Jun. 28, 2002, and U.S. patent application Ser. No. 10/609,846, filed Jun. 30, 2003, and Published on May 20, 2004, as US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 entitled “Thoracic Deployment Device” disclose introducer devices adapted for deployment of stent grafts particularly in the thoracic arch. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,667, U.S. patent application Ser. No. 10/609,846, and US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/392,667, U.S. patent application Ser. No. 10/609,846, and US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 is herewith incorporated in its entirety into this specification.
[0033] U.S. Provisional Patent Application Ser. No. 60/392,599, filed Jun. 28, 2002, and U.S. patent application Ser. No. 10/609,835, filed Jun. 30, 2003, and published on Jun. 3, 2004, as U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 entitled “Thoracic Aortic Aneurysm Stent Graft” disclose stent grafts that are useful in treating aortic aneurysms particularly in the thoracic arch. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,599, U.S. patent application Ser. No. 10/609,835, and U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 could be used with the present invention, and the disclosure of U.S. Provisional Patent Application Ser. No. 60/392,599, U.S. patent application Ser. No. 10/609,835, and U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 is herewith incorporated in its entirety into this specification.
[0034] U.S. Provisional Patent Application Ser. No. 60/391,737, filed Jun. 26, 2002, U.S. patent application Ser. No. 10/602,930, filed Jun. 24, 2003, and published on Mar. 18, 2004, as U.S. Patent Application Publication No. US-2004-0054396-A1, and PCT Patent Publication No. WO 2004/002365 entitled “Stent-Graft Fastening” disclose arrangements for fastening stents onto grafts particularly for exposed stents. This feature and other features disclosed in U.S. Provisional Patent Application No. 60/391,737, U.S. patent application Ser. No. 10/602,930, and U.S. Patent Application Publication No. US-2004-0054396-A1, and PCT Patent Publication No. WO 2004/002365 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/391,73, U.S. patent application Ser. No. 10/602,930, and U.S. Patent Application Publication No. US-2004-0054396-A1, and PCT Patent Publication No. WO 2004/002365 is herewith incorporated in its entirety into this specification.
[0035] U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and published on Apr. 15, 2004, as U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 entitled “Asymmetric Stent Graft Attachment” disclose retention arrangements for retaining onto and releasing prostheses from introducer devices. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 is herewith incorporated in its entirety into this specification.
[0036] U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as Publication No. US2003-0120332, and PCT Patent Publication No. W003/053287 entitled “Stent Graft With Improved Adhesion” disclose arrangements on stent grafts for enhancing the adhesion of such stent grafts into walls of vessels in which they are deployed. This feature and other features disclosed in U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as Publication No. US2003-0120332, and PCT Patent Publication No. W003/053287 could be used with the present invention and the disclosure of U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as Publication No. US2003-0120332, and PCT Patent Publication No. W003/053287 are herewith incorporated in its entirety into this specification.
[0037] U.S. Provisional Patent Application Ser. No. 60/405,769, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/645,095, filed Aug. 23, 2003, and published on Apr. 29, 2004, as U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 entitled “Composite Prostheses” discloses prostheses or stent grafts suitable for endoluminal deployment. These prostheses and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/405,769, U.S. patent application Ser. No. 10/645,095, and U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/405,769, U.S. patent application Ser. No. 10/645,095, and U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 is herewith incorporated in its entirety into this specification.
BRIEF DESCRIPTION OF THE DRAWING
[0038] This then generally describes the invention but to assist with understanding reference will now be made to the accompanying drawings which show a preferred embodiment of the invention.
[0000] In the drawings;
[0039] FIG. 1 shows a longitudinal cross-sectional view of a composite stent graft according to one embodiment of this invention;
[0040] FIG. 2 shows the composite stent graft of FIG. 1 compressed and received in a deployment device;
[0041] FIG. 3 shows a schematic view of deployment of side branch stent grafts from a main graft;
[0042] FIGS. 4 to 7 show various stages of deployment of the composite stent graft according to this invention into a side branch artery from a main graft; and
[0043] FIG. 8 shows an alternative method of expansion of part of the composite stent graft.
DETAILED DESCRIPTION
[0044] Now looking more closely at FIGS. 1 and 2 , it will be seen that the composite stent graft includes a tubular graft material 1 and within the tubular graft material there is an balloon expandable stent 3 (shown in an expanded configuration in FIG. 1 and in a radially compressed condition in FIG. 2 ) and a number of self expanding stents 5 . The balloon expandable stent 3 has a particular configuration of struts shown but the invention is not limited to any one configuration of struts. The balloon expandable stent 3 has an extension portion 7 which extends beyond the proximal end 9 of the tubular graft material 1 . The tubular graft material 1 is stitched at 11 to the balloon expandable stent. Further stitching can also be provided. The self expanding stents 5 are positioned on the outside of the tubular graft material in the region 13 and the final self expanding stent 15 is positioned on the inside of the tubular graft material 1 at the distal end 17 of the tubular graft material 1 .
[0045] The extension portion 7 comprises the first portion discussed above, the remainder of the balloon expandable stent 3 comprises the second portion and the self expanding stents 5 and 5 comprise the relatively flexible portion of the composite stent graft.
[0046] The balloon expandable stent 3 may be a radially expandable surgical stent formed from a shape memory material such as a nickel-titanium alloy. The stent can include a series of wave-like struts spaced apart by gaps. Each gap can be spanned by tie bars at a maximum width portion of the gap and/or by angled links or straight links at a minimum width portion of a gap. Hence, axial expansion or contraction of the stent is avoided when the stent is radially expanded.
[0047] The self expanding stents 5 and 15 can be zig zag Gianturco style Z stents having a plurality of struts with bends between the struts and formed into a substantially cylindrical form.
[0048] FIG. 2 shows the stent graft of FIG. 1 compressed and received within a deployment device.
[0049] The deployment device includes a guide wire catheter 20 with a nose cone 22 at one end and sheath 24 covering the stent graft and holding the self expanding stents 5 and 15 in a radially compressed or collapsed condition.
[0050] On the guide wire catheter 20 is an inflatable balloon 26 which can be inflated with suitable material to expand the balloon expandable stent portion of the stent graft as required. It will be realized that in some embodiments the balloon can be provided on a separate balloon catheter deployed over the guide wire 21 after the deployment of the device as will be discussed later.
[0051] FIG. 3 shows a schematic view of the deployment of a main graft into a aneurysed aorta and the deployment of side branch grafts from the main graft into renal arteries. The aorta 30 has an aneurysm 31 and a main graft 33 has been deployed into the aneurysed space. The main graft 33 has super-renal uncovered stent 35 which is received in a non-aneurysed region of the aorta and provides a top support for the main graft 33 . The main aneurysed region 31 , however, extends up past the renal arteries 37 and 39 and as such is necessary to provide side branch grafts to these arteries.
[0052] For this purpose there are fenestrations 41 provided into the main graft and it is through these fenestrations that the side branch or composite stent grafts 43 are deployed as will be discussed in more detail in respect to FIGS. 4-7 .
[0053] It will be noted, however, that the side branch stent grafts 43 extending from the main graft to the renal arteries 37 and 39 cross a region of aneurysed region 31 . If there was movement of the main graft 33 with respect to the aneurysm and if there was a non-rigid portion of stent graft in this space the lumen of the side branch graft could be closed off by kinking. The expanded balloon expandable portion of the stent graft in this region will act to prevent this occurring.
[0054] FIGS. 4-7 show the various stages in deployment of a branched composite stent graft from a main graft into a side branch artery for instance.
[0055] As can be seen in FIG. 4 a main graft 33 has been deployed into an aorta and extends through an aneurysed space 31 . The main graft has a fenestration 41 with radiopaque markers 45 around its periphery which assist a surgeon in locating the fenestration with respect to the side branch artery 37 after the main graft 33 has been deployed. The side branch artery 37 has had a guide wire 47 deployed into it and a deployment catheter with the stent graft according to this invention mounted onto it of the type shown in FIG. 2 has been deployed over the guide wire 47 . The sheath 24 has been withdrawn. This allows the self expanding stents 5 and 15 to expand within the side branch artery 37 so that the tubular graft material 1 is engaged against the wall of the artery.
[0056] The balloon 26 , however, has not been expanded and therefore the balloon expandable stent 3 of the stent graft is not expanded.
[0057] As can be seen in FIG. 5 , the balloon 26 has been expanded by known means and the balloon expandable stent 3 has expanded to engage against the walls of the side branch artery 37 .
[0058] The balloon 26 is then deflated and the deployment device on guide wire 20 is then removed leaving the guide wire 20 in place. As depicted in FIG. 6 , another balloon catheter 50 is then deployed over the guide wire 20 and the balloon 52 on the balloon catheter 50 is positioned so that it is partially within the proximal end of the stent graft and partially outside the stent graft in the region of the fenestration 41 and then it is expanded. Expansion causes the extension portion 7 to be flared so that the proximal end of the stent graft 7 is firmly received within the fenestration 41 of the main graft 33 .
[0059] As shown in FIG. 7 the flaring can be extended to the extent that the extension portion 7 is completely flared against the inside wall of the stent graft.
[0060] A blood flow path is therefore provided from the main graft into the branch artery 37 which includes a rigid portion across the aneurysed space 31 and a more flexible portion within the branch artery 37 . This will assist with prevention of stenosis at the junction between the stent graft and the side branch artery.
[0061] FIG. 8 shows an alternative method to that shown in FIG. 6 for the expansion and flaring of the extension portion 7 of the composite stent graft so that the proximal end of the stent graft 7 is firmly received within the fenestration 41 of the main graft 33 .
[0062] For this method a dual balloon catheter 60 is used. The dual balloon catheter 60 has a first balloon 62 near its proximal end and a second balloon 64 just distal of the first balloon 62 . Both the balloons are separately inflatable by the use of multiple lumens in the catheter. The dual balloon catheter 60 is deployed over the guide wire 20 so that the balloon 62 is fully received within the balloon expanded portion 3 of the composite stent. This balloon 62 can be used to expand the balloon expanded portion 3 as discussed in relation to FIG. 5 or can be used after the stage discussed in relation to FIG. 5 has been performed. The balloon 62 is expanded or left expanded and then the balloon 64 is expanded to cause the flaring of the balloon expanded portion 3 of the composite stent so that the proximal end of the stent graft 7 is firmly received within the fenestration 41 of the main graft 33 .
[0063] Preferably the balloon 62 used to hold the composite stent in place while the flaring takes place is a non-compliant balloon so that excess force is not placed on the composite stent graft and the balloon 64 is of a compliant nature so that it can expand enough to flare the end 7 against the inner wall of the main graft 33 .
[0064] It will be realized that the relative lengths of the balloon expandable portion and the self expanding portion can be varied depending upon the size of the aneurysm to be treated, the desired extension of the more rigid section into the side branch artery and the morphology of the side branch vessel.
[0065] Throughout this specification various indications have been given as to the scope of this invention but the invention is not limited to any one of these but may reside in two or more of these combined together. The examples are given for illustration only and not for limitation.
[0066] Throughout this specification and the claims that follow unless the context requires otherwise, the words ‘comprise’ and ‘include’ and variations such as ‘comprising’ and ‘including’ will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.
|
A composite stent graft has a balloon expandable stent portion ( 3 ), a tubular graft material portion ( 1 ) inside or outside of the balloon expandable stent portion and self expanding stents ( 5 ) associated with the tubular graft material portion. Part ( 7 ) of the balloon expandable stent portion can extend beyond the proximal end ( 9 ) of the tubular graft material portion. The tubular graft material can be polytetrafluoroethylene, Dacron, Thoralon™, polyamide, small intestine submucosa, collagenous extracellular matrix material, or any other suitable biocompatible material. A method of deploying which includes flaring a part ( 7 ) of the balloon expandable stent portion is also discussed.
| 0
|
BACKGROUND OF THE INVENTION
In modern switched telecommunications systems (in particular, modern PSTNs) it has become common practice to provide two related but separate network infrastructures: a bearer or transmission network for carrying end-user voice and data traffic, and a signaling network for controlling the setup and release of bearer channels through the bearer network in accordance with control signals transferred through the signaling network. In practice, such signaling networks comprise high-speed computers interconnected by signaling links, wherein procedures control the computers to provide a set of operational and signaling functions in accordance with a standardized protocol. One example of such a signaling protocol is the Common Channel Signaling System No. 7 (often referred to as SS7 or C7) that is being extensively deployed for control of telephone and other data transmission networks.
SS7 is a global standard for telecommunications defined by the International Telecommunication Union (ITU) Telecommunication Standardization Sector (ITU-T). The standard defines the procedures and protocol by which network elements in the public switched telephone network (PSTN) exchange information over a digital signaling network to effect wireless (cellular) and wireline call setup, routing and control. The ITU definition of SS7 allows for national variants such as the American National Standards Institute (ANSI) and Bell Communications Research (Telcordia Technologies) standards used in North America and the European Telecommunications Standards Institute (ETSI) standard used in Europe.
An SS7 network basically comprises various types of signaling points, namely, Signaling End Points (SEPs), for example an end office or local exchange, and Signaling Transfer Points (STPs) interconnected by signaling links. The SEPs typically comprise Signaling Switching Points (SSPs); Mobil Switching Centers (MSPs); and Service Control Points (SCPs).
The signaling information is passed over the signaling links in messages, which are called signal units (SUs). There are three types of SUs: message signal units (MSUs), link status signal units (LSSUs) and fill-in signal units (FISUs). The MSU is the workhorse in that signaling associated with call setup and tear down, database query and response, and SS7 management is carried by Message Signal Units (MSUs).
Many switches, including SS7 compliant switches, generate Call Detail Records (CDRs) which are data structures containing information about a call. CDRs are analyzed to provide information that can assist with service assurance, fulfillment and billing problems.
Non-SS7 switches generate CDRs by monitoring the actual call and typically have a vendor specified format. Know SS7 operations support systems (OSS systems), such as the AGILENT TECHNOLOGIES ACCESS7 system, extract data from the MSUs to generate Call detail Records (CDRs). Because the data collection is independent of the network elements, SS7 CDRs may be presented in a consistent format across various OSS systems. In fact, there is at least one serious attempt to standardize the format of SS7 CDRs. This interoperability, among other benefits, has spurred the growth of SS7 networks and has led to an increasing amount of traffic over SS7 networks. As the volume of CDRs increases, users seek to extract more and more useful information from the data contained in the CDRs.
The desire for advanced analysis of CDRs has lead to the creation of a class of systems, termed Business Intelligence systems (BI systems), such as the Agilent Technologies, Inc. acceSS7 Business Intelligence system, that provide enrichment and analytical studies on CDRs. Known BI systems analyze SS7 CDRs to provide a variety of information about the SS7 network, for example: identification of signaling problems, location of network problems, service assurance data, billing data, quality of service monitoring, regulatory monitoring, and verifying compliance of inter-carrier agreements regarding billing and service level.
The differentiator between competing OSS and BI systems is the ability of the system to reduce operating cost or generate revenue for the users, including Local Exchange Carriers (LECs) and Inter-exchange Carriers (IXCs). To date, most of the focus of development has been on identifying problems with the network and verifying billing data. The present inventors have identified method and apparatus for deriving marketing data from collected SS7 CDRs that allows the targeting of customers for new services.
BRIEF DESCRIPTION OF THE DRAWINGS
An understanding of the present invention can be gained from the following detailed description of the invention, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a block diagram of a signaling network.
FIG. 2 is a block diagram of a Business Intelligence system in accordance with a preferred embodiment of the present invention.
FIG. 3 is a flow chart of a method according to an embodiment of the present invention adapted to identify work-at-home users.
FIG. 4 is a screen shot of a report produced using a method in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
The detailed description that follows is presented in terms of general procedures and symbolic representations of operations of data within a computer memory, associated computer processors, networks, and network devices. These procedure descriptions and representations are the means used by those skilled in the data processing art to convey the substance of their work to others skilled in the art. As used herein the term “procedure” refers to a series of operations performed by a processor, be it a central processing unit of a computer, or a processing unit of a network device, and as such, encompasses such terms of art as: “software,” “objects,” “functions,” “subroutines” and “programs.”
The apparatus set forth in the present application may be specifically constructed for the required purposes or it may comprise a general-purpose computer or terminal selectively activated or reconfigured by a computer program stored in the computer. The procedures presented herein are not inherently related to any particular computer or other apparatus. In fact, many of the procedures described herein may be implemented on a general-purpose computing device.
The present invention, as described, can be implemented using AGILENT's ACCESS7 OSS system, BI system, and associated hardware. The ACCESS7 OSS system integrates with and monitors an SS7 network as described above. Those of ordinary skill in the art will recognize that there exist other platforms and languages for creating software for performing the procedures outlined herein. Further, the present invention is useable with a variety of signaling systems. For example, the present invention can be implemented on any switched system that produces CDRs with the base data described herein. Those of ordinary skill in the art also recognize that the choice of the exact platform and language is often dictated by the specifics of the actual system constructed, such that what may work for one type of signaling system may not be efficient on another type of signaling system.
FIG. 1 is a block diagram of a signaling network 100 . FIG. 2 is a block diagram of a Business Intelligence system (BI system) 200 in accordance with a preferred embodiment of the present invention. The structure illustrated in FIGS. 1 and 2 and the method illustrated in FIG. 3 emphasize certain features of the present invention while simplifying other features to aid in explanation. As such, the figures and associated discussion are to be regarded as illustrative and exemplary and not limiting as regards the invention described herein or the claims attached hereto. It will also be appreciated by those of ordinary skill in the relevant arts that the apparatus, as illustrated in FIGS. 1 and 2 , and the methods of use thereof as described hereinafter with reference to FIG. 3 , are intended to be representative of such structures and methods. Further, any given system may differ significantly from that shown, particularly in the details of construction and operation of such system, as still fall within the spirit and scope of the invention.
The signaling network 100 supports an SS7 signaling protocol and comprises a wireless network terminating device such as PCS handset 102 coupled to a MSC 104 . The MSC 104 is capable of establishing a connection 106 with a SSP 108 and vice versa, the SSP 108 being coupled to a network-terminating device such as a telephone handset 110 . The details of such connection are outside the scope of the present invention and are omitted to avoid obscuring the present invention.
The MSC 104 is coupled to a first STP 112 by a first A link 114 and a second STP 116 by a second A link 118 . The first STP 112 is coupled to the second STP 116 by a first C link 113 and, together, the first and second STPs 112 , 116 constitute a first mated pair of STPs 120 . A first Agilent® acceSS7 Network Monitoring System (NMS) comprises a first secondary collector unit 122 and a first primary collector unit 115 . The first primary collector unit 115 is, although not essentially, co-located with the first STP 112 and coupled to first links (not shown) provided by the first STP 112 by a first number of electrical connections 117 corresponding to the first links. Similarly, although not essentially co-located, in this example the first secondary collector unit 122 is co-located with the second STP 116 and coupled to second links (not shown) provided by the second STP 116 by a second number of electrical connection 124 corresponding to the second links.
The first STP 112 is coupled to a third STP 126 by a first B link 128 and a fourth STP 130 by a second B link 132 . The second STP 116 is also coupled to the third STP 126 by a third B link 134 and the fourth STP 130 by a fourth B link 136 . The third STP 126 is coupled to the fourth STP 130 by a second C link 138 and, together, the third and fourth STPs 126 , 130 constitute a second mated pair of STPs 140 . The third STP 126 is coupled to the SSP 108 by a third A link 146 and an SCP 148 by a fourth A link 150 . The fourth STP 130 is also coupled to the SSP 108 and the SCP 148 , but by a fifth A link 152 and a sixth A link 154 , respectively.
A second Agilent® acceSS7 NMS comprises a second primary collector unit 141 and a second secondary collector unit 142 . For the purposes of the present invention, the structure of the second primary collector 141 may be considered (although not always) identical to the structure of the first primary collector 115 and the structure of the second secondary collector 142 may be considered (although not always) identical to the structure of the first secondary collector 122 . The second primary collector unit 141 , although not essentially, is co-located with the third STP 126 and coupled to third links (not shown) provided by the third STP 126 by a third number of electrical connection 143 corresponding to the third links. Similarly, although not essentially co-located, in this example the second secondary collector unit 142 is co-located with the fourth STP 130 and coupled to fourth links (not shown) provided by the fourth STP 130 by a fourth number of electrical connection 144 corresponding to the fourth links.
The first and second primary collectors 115 and 141 are coupled to a wide area network (WAN) 156 through which connections to any number and variety of computing devices can be made. In the example shown in FIG. 1 , two servers, 158 and 160 , are shown. Generally, the collectors 115 , 122 , 141 , and 142 collect data regarding messaging traffic on the SS7 network and create CDRs. Analysis of the CDRs can be performed by any number of capable units, for example the collectors 115 , 122 , 141 , and 142 along with any computing device connected to the WAN 156 , such as the servers 158 and 160 .
FIG. 2 is a block diagram of a Business Intelligence (BI) system 200 in accordance with a preferred embodiment of the present invention. While shown as a single logical entity, the BI system 200 may be physically distributed, or centralized, to any available storage and processor resources connected to the network. It may prove useful to distribute the functions of the BI system 200 among the first and second primary collectors 115 and 141 and at least one server, such as the server 158 .
The BI system 200 receives Call Detail Record (CDRs) from a CDR feed 202 . The CDR feed 202 is connected to a network (not shown), such as the SS 7 network shown in FIG. 1 , via connection 201 . In the example shown in FIG. 2 , the CDR feed 202 is embodied in software and is programmable to configure, manage and control the collection and delivery of CDRs from the SS7 network. The CDR feed 202 can be configured to collect data from a single site, a number of sites or network-wide.
The CDR feed 202 feeds CDRs to one or more Data Management Components (DMC) 204 , where the data is stored. This DMC 204 provides data storage and management for CDRs delivered by the CDR Feed 202 . Using the Agilent Technologies' ACCESS7 OSS as an example, the DMC 204 provides a consistent open interface for a wide range of acceSS7 Business Intelligence applications, enabling them to be designed independently of the underlying network infrastructure. While only a single DMC 204 is shown, it is fairly typically to set up a plurality of DMCs 204 . For example, it is not uncommon to assign an individual DMC 204 for each separate yet concurrent analysis tasks or for each business unit. DMCs are known by a variety of names, which varies by vendor, such as a data management center, data management system, management site, etc . . . The CDR feed 202 and the DMC 204 are known parts of the Agilent® acceSS7 and will not be described further.
Business Intelligence applications 206 and Real-Time Business Intelligence applications 208 are sets of procedures that turn raw data into business information. The Business Intelligence applications 206 sit on top of the DMC and process the CDR data in large batches, typically every 24 hours. However, some requirements can only be met with data available in real-time. In some cases this can be accomplished by reducing the batch collection time, to say five minutes. If true real-time is required, the Real-Time BI applications 208 are configured to accept a direct feed from the CDR Feed 202 . The BI applications 206 and Real-Time BI applications 208 output a variety of reports 210 and 212 respectively. The report varies with each application 206 and 208 , and based on the function thereof. Additionally, the BI applications 206 and Real-Time BI applications 208 may be provided with dedicated storage space 214 , for example of any of the servers 158 , 160 connected to the network.
Currently, a wide variety of BI application and Real-Time BI applications are available from AGILENT TECHNOLOGIES. For example, an Interconnect Analysis application performs direct, accurate measurements of inter-carrier traffic, with measures of total calls and total MOU for each jurisdiction (e.g. local, toll, etc.). Bills and Rating Factors submitted by interconnecting carriers for jurisdictional reporting on originating, terminating and transit traffic can be validated and hard evidence provided with which to challenge estimates. ISP traffic can be identified and reported separately, which supports both separate rates for ISP traffic and the generation of data with which to build a case for ISP tariffs. Another BI application, the Call Performance Manager, provides detailed data on the call completion performance of interconnected carriers, including performance to specific destinations and services identified by leading digits. Yet another example is the Traffic Analysis application that provides detailed analysis of traffic flows between parts of the network with analysis by geographic region.
Of particular relevance to at least one embodiment of the present invention is the ISP Finder. The ISP finder is a BI application that identifies ISPs on a connected network and on interconnected networks by matching the call profile of every called number against the typical profile of ISPs. This data is currently used for network planning purposes by identifying a major source of network congestion.
An understanding of the type of data contained in a CDR may prove helpful to understand the present invention. Table 1 is an example of a CDR specification used by business intelligence applications associated with AGILENT's ACCESS7 OSS.
TABLE 1
Field Name
Description
CDR_DATE
The date that the CDR was loaded into the repository.
CDR_ID
A sequence numbers for the CDR. This can be used
to link this table row to a row in another table. This is
useful for enriching a CDR with rating information,
etc.
DMC_ID
Each Data Management Center (DMC) in the world
has an identifier that is encrypted in the product
activation license. Tagging a CDR with this identifier
allows the originating DMC to be determined in
situations where data is handed off between DMC
systems.
PARTITION_ID
Each Oracle partition has an identifier. This field is
used primarily to bin CDRs into the correct partition
and has little user value.
STUDY_ID
A sequence number for a specific acceSS7 filter
configuration over a specified period of time.
Tagging a CDR with this identifier allows the
determination of the exact acceSS7 configuration
(filters, links...) that caused this CDR to be collected.
CLASS_ID
The acceSS7 class ID that is associated with this
CDR.
SITE_ID
Specifies the acceSS7 site number that collected this
CDR.
TIMEZONE
Specifies the time zone upon which all times in the
CDR are based.
INCOMPLETE_FLG
A flag that specifies that acceSS7, was not able to
completely populate the CDR.
CALL_IN_PROGRESS_FLG
A flag that specifies a call that is still in progress.
CALL_TIMEOUT_FLG
A flag that specifies that an acceSS7 timeout
occurred before all parts of a call were collected.
REPEATING_CALL_IN_PROGRESS —
FLG
FORCED_DELIVERY_FLG
OPC_1
The 1st component of the originating point code.
OPC_2
The 2nd component of the originating point code.
OPC_3
The 3rd component of the originating point code.
DPC_1
The 1st component of the destination point code.
DPC_2
The 2nd component of the destination point code.
DPC_3
The 3rd component of the destination point code.
CALLING_NUMPLAN
CALLING_NPA
The NPA component of the calling number.
CALLING_NXX
The NXX component of the calling number.
CALLING_LINE
The LINE component of the calling number.
CALLING_INT_NUM
The entire calling number if the number is thought to
be international.
CALLING_PARTY_CAT_CD
CALLED_NPA
The NPA component of the called number.
CALLED_NXX
The NXX component of the called number.
CALLED_LINE
The LINE component of the called number.
CALLED_INT_NUM
The entire called number if the number is thought to
be international.
CHARGE_NPA
The NPA component of the charge number.
CHARGE_NXX
The NXX component of the charge number.
CHARGE_LINE
The LINE component of the charge number.
CHARGE_INT_NUM
The entire charge number if the number is thought to
be international.
CALLED_NUMPLAN
IAM_DATE_TIME
The initial address message date/timestamp (nearest
second).
IAM_MILLISEC
The initial address message timestamp (milliseconds
component).
ANM_DATE_TIME
The answer message date/timestamp (nearest
second).
ANM_MILLISEC
The answer message timestamp (milliseconds
component).
REL_DATE_TIME
The release message date/timestamp (nearest second).
REL_MILLISEC
The release message timestamp (milliseconds
component).
EXM_DATE_TIME
The exit message date/timestamp (nearest second).
EXM_MILLISEC
The exit message timestamp (milliseconds
component).
ACM_DATE_TIME
The address completes message date/timestamp
(nearest second).
ACM_MILLISEC
The address completes message timestamp
(milliseconds component).
RLC_DATE_TIME
The release-clear message date/timestamp (nearest
second).
RLC_MILLISEC
The release-clear message timestamp (milliseconds
component).
IAM_REL_DUR
Time duration between IAM and REL messages
(seconds).
IAM_REL_CCS
Time duration between IAM and REL messages
(CCS).
ANM_REL_DUR
Time duration between ANM and REL messages
(seconds).
ANM_REL_CCS
Time duration between ANM and REL messages
(CCS).
CALLING_NATR_ADDR_CD
Acronym describing the context of the calling
number derived from the calling nature of address
indicator.
CALLING_NATR_ADDR_IND
Raw calling nature of address indicator.
CALLING_EVEN_ODD_FLG
Even/odd number of address signals for calling
number.
CALLED_NATR_ADDR_CD
Acronym describing the context of the called number
derived from the called nature of address indicator.
CALLED_NATR_ADDR_IND
Raw called nature of address indicator.
CALLED_EVEN_ODD_FLG
Even/odd number of address signals for called
number.
CHARGE_NATR_ADDR_CD
Acronym describing the context of the charge
number derived from the charge nature of address
indicator.
CHARGE_NATR_ADDR_IND
Raw charge nature of address indicator.
CHARGE_EVEN_ODD_FLG
Even/odd number of address signals for charge
number.
ORIG_LINE_CD
Represents toll class of service for the call.
CARRIER_ID_CD
Identifies the carrier selected by the caller.
CARRIER_SELECT_CD
Identifies how the caller selected a carrier.
TCIC
Trunk circuit identification code.
JURISDICTION
Numerical data indicating the geographic origination
of the call.
BACKWD_CHARGE_CD
Backward charge indicator for called party.
BACKWD_CALLED_STAT_CD
Backward called party's status indicator.
BACKWD_CALLED_CAT_CD
Backward called party's category indicator.
BACKWD_END_TO_END_CD
Backward end-to-end method indicator.
BACKWD_INTERWORK_FLG
Backward interworking indicator.
BACKWD_IAM_SEG_FLG
Backward IAM segmentation indicator.
BACKWD_ISUP_FLG
Backward ISDN user part indicator.
BACKWD_HOLDING_FLG
Backward holding indicator.
BACKWD_ISDN_ACCESS_FLG
Backward ISDN access indicator.
BACKWD_ECHO_CNTL_FLG
Backward echo control device indicator.
BACKWD_SCCP_CD
Backward SCCP method indicator.
RELEASE_CAUSE_CD
Indicates the reason for releasing a specific
connection. Note CDRs are generated for failed calls
as well as successful calls.
RELEASE_LOC_CD
Indicates where the release was initiated.
TRANSIT_NETWORK_CD
Indicates the long distance carrier or transit network
to be used to carry this call. This is used whenever
the call is an inter-LATA call or international call.
ORIG_CALLED_NUMPLAN
ORIG_CALLED_NPA
Used when call redirecting (forwarding) occurs.
Identifies the NPA component of the number of the
party that initiated the redirection.
ORIG_CALLED_NXX
Used when call redirecting (forwarding) occurs.
Identifies the NXX component of the number of the
party that initiated the redirection.
ORIG_CALLED_LINE
Used when call redirecting (forwarding) occurs.
Identifies the LINE component of the number of the
party that initiated the redirection.
ORIG_CALLED_INT_NUM
Used when call redirecting (forwarding) occurs.
Identifies the entire number of the party that initiated
the redirection if this number is thought to be
international.
ORIG_CALLED_NATR_ADDR_IND
Raw original called number nature of address
indicator.
REDIRECT_NPA
Used when call redirecting (forwarding) occurs.
Identifies the NPA component of the number to
which the called number is to be redirected.
REDIRECT_NXX
Used when call redirecting (forwarding) occurs.
Identifies the NXX component of the number to
which the called number is to be redirected.
REDIRECT_LINE
Used when call redirecting (forwarding) occurs.
Identifies the LINE component of the number to
which the called number is to be redirected.
REDIRECT_INT_NUM
Used when call redirecting (forwarding) occurs.
Identifies the number to which the called number is
to be redirected if this number is thought to be
international.
REDIRECT_NATR_ADDR_IND
Raw redirecting number nature of address indicator.
ORIG_REDIRECT_REASON_CD
Indicates the reason the original redirection occurred.
REDIRECT_REASON_CD
Indicates the reason for subsequent redirection.
REDIRECT_COUNT
Indicates the number of redirections that have
occurred.
FORWD_IN_INT_CALL_FLG
Forward incoming international call indicator.
FORWD_END_TO_END_CD
Forward end-to-end method indicator.
FORWD_INTERWORK_FLG
Forward interworking indicator.
FORWD_IAM_SEG —
FLG Forward IAM segmentation indicator.
FORWD_ISUP_FLG
Forward ISDN user part indicator.
FORWD_ISUP_PREF_CD
Forward ISDN user part preference indicator.
FORWD_ISDN_ACCESS —
FLG Forward ISDN access indicator.
FORWD_SCCP_CD
Forward SCCP method indicator.
FORWD_PORTED_NUM_FLG
Forward ported number translation indicator.
LRN_NPA
Used with Local Number Portability (LNP). Indicates
the NPA component of the local routing number.
LRN_NXX
Used with Local Number Portability (LNP). Indicates
the NXX component of the local routing number.
LRN_LINE
Used with Local Number Portability (LNP). Indicates
the LINE component of the local routing number.
LRN_INT_NUM
Used with Local Number Portability (LNP).
Identifies the local routing number if this number is
thought to be international.
GAP_NPA
Indicates the NPA component of the Generic Address
Parameter (GAP) number. When LNP is provided,
the GAP provides the actual dialed digits for a ported
number.
GAP_NXX
Indicates the NXX component of the Generic
Address Parameter (GAP) number. When LNP is
provided, the GAP provides the actual dialed digits
for a ported number.
GAP_LINE
Indicates the LINE component of the Generic
Address Parameter (GAP) number. When LNP is
provided, the GAP provides the actual dialed digits
for a ported number.
GAP_INT_NUM
Indicates the Generic Address Parameter (GAP)
number if the number is thought to be international.
When LNP is provided, the GAP provides the actual
dialed digits for a ported number.
GAP_TYPE_OF_ADDR_IND
Indicates the type of address contained in the Generic
Address Parameter (GAP).
GAP_NATR_OF_ADDR_IND
Raw Generic Address Parameter (GAP) nature of
address indicator.
OUT_TRUNK_GROUP_NUM
Outgoing trunk group number.
SERVICE_CODE_CD
Service code assigned by the North American
Numbering Plan Administration. Can be used to
identify a specific type of service.
CIP_SEQ_NUM
This is a number assigned sequentially from 0 for
each CDR pertaining to the same leg of the same call.
For example, if RCIP/CIP CDRs are configured, the
first CIP CDR has a sequence number of 0, the first
RCIP CDR has a sequence number of 1, the second
RCIP CDR has a sequence number of 2 and so on.
With CIP CDRs, but no RCIP CDRs, the CIP CDR
has a sequence number of 0 and the final CDR a
sequence number of 1. With no CIP CDRs at all, the
final CDR has a sequence number of 0.
CIP_CORRELATION_ID
This is an identifier which is the same for all CIP
CDRs which apply to the same leg of the same call
(and different from all other CIP CDRs)
CIP_START_TIME
The start time of the period covered by this call in
progress CDR (accurate to 1 second)
CIP_START_MILLISEC
The milliseconds portion of the CIP_START_TIME
CIP_END_TIME
The end time of the period covered by this call in
progress CDR (accurate to 1 second)
CIP_END_MILLISEC
The milliseconds portion of the CIP_END_TIME
CORRELATION_ID
Sequences number for a correlated set of CDRs.
Given a CDR that is a member of a correlated set,
this can be used to find the other members of the
correlated set.
CORRELATION_DUPLICATE_FLG
This flag indicates that this CDR is thought to be
identical to another CDR within the set of CDRs to
be correlated.
CORRELATABLE_FLG
This flag indicates that this CDR is thought to be
complete enough to be included in the correlation
processing.
ENRICHED_CALLING_NPA
Contains the CALLING_NPA to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLING_NXX
Contains the CALLING_NXX to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLING_LINE
Contains the CALLING_LINE to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLING_INT_NUM
Contains the calling digits to be used in the
correlation process in the event they are thought to be
an international number. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLED_NPA
Contains the CALLED_NPA to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLED_NXX
Contains the CALLED_NPX to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLED_LINE
Contains the CALLED_LINE to be used in the
correlation process. Local number portability,
number completion, etc can influence the contents of
this column.
ENRICHED_CALLED_INT_NUM
Contains the called digits to be used in the correlation
process in the event they are thought to be an
international number. Local number portability,
number completion, etc can influence the contents of
this column.
CORRELATION_CONFIDENCE
This parameter indicates the degree of confidence
associated with the correlation of this CDR with other
CDRs. This is a bit-wise parameter where each bit
has a specific meaning.
CROSS_CORRELATION_ID
The term call detail record (CDR) refers to any electronic record of the details of a call including, for example, originating number (NPA/NXX), terminating number (NPA/NXX), time, duration, etc . . . What constitutes a CDR varies by vendor and customer.
Even within a single OSS family, different applications, such as billing, fraud detection, and business intelligence may direct the formation of CDRs with varying content. Further, there are several efforts at formulating standards from CDR content, such as ANSI standard TIA/EIA-124 Revision D for CDR content for wireless applications. The applicability of the present invention will remain regardless of the nomenclature, content and format of the electronic record that may vary from vendor to vendor and system to system.
In accordance with an embodiment of the present invention, the BI system 200 is improved by the addition of a new BI application (or modification to an existing BI application), which preferably operates in non-real-time (e.g. batch) mode, but may be operated in real-time mode. The new BI application identifies users of the network having certain characteristics that identify them as a certain type of user, for example a work-at-home user. It is to be understood, that while this embodiment of the present invention is being described as being integrated with the BI system 200 , those of ordinary skill in the art will recognize that the present invention can be implemented as a stand-alone system. Further, while the present invention is described with respect to the use of CDRs, any data feed with the appropriate information may be utilized.
FIG. 3 is a flow chart of a method according to an embodiment of the present invention adapted to identify work-at-home users. In particular the method described in FIG. 3 is suitable for identifying work-at-homers that use dial-up ISPs. This can be potential valuable information for LECs that may wish to target such users with advertisements for other services such as DSL or a second line.
The method starts in step 300 . In step 302 , a set of ISP numbers is selected. This allows the requester to limit the subsequent report to a select number of ISPs. All ISPs on a network, or connected networks, can be identified using, for example, the ISP finder BI application discussed hereinabove available from Agilent Technologies, Inc. The set of ISP numbers can be limited to one or more ISPs of interest, or can be based on the NPA/NXX of the ISP or any other relevant factor. Of course, all identified ISPs can be selected.
Next, in step 304 , the set of available CDRs is filtered based on the ISP numbers in the set. The output is a set of CDRs having CALLED_NPA, CALLED_NXX, and CALLED_LINE corresponding to one of the ISP numbers in the set. In step 306 , the remaining CDRs are filtered to remove those with call origination times (using for example IAM_DATE_TIME) outside of normal business hours, such as 8:00 AM to 6:00 PM. In step 308 , the remaining CDRs are filtered to identify those with a connect time of more than 4 hours (for example, the IAM_REL_DUR value which represent the difference between the release time and the call time).
Subsequently, in step 310 , the CDRs remaining after the filters in steps 304 through 308 are analyzed to generate an exclusion list containing the calling numbers (i.e. CALLING_NPA; CALLING_NXX; and CALLING_LINE) that had connection time on the weekend. In step 312 , the remaining CDRs are compared with the exclusion list and the CDR having originating numbers on the exclusion list are filtered out to leave those CDRs representing calls during business hours of greater than 4 hours to an identified ISP where the calling party did not connect on the weekend to the ISPs. Finally in step 314 , by extracting the calling numbers from the remaining CDRs and eliminating duplicate entries a list of exclusive calling numbers is generated. This list of exclusive numbers may then be presented in a report to the requestor. The method end in step 316
TABLE 2 contains a procedure comprising a series of SQL commands that can produce a report in accordance with the example shown in FIG. 3 . The commands in TABLE 2 take all daily CDR in a BI system and filters the lists to all local ISP terminated calls that have full 10-digit calling party number information. Then, it further filters the list such as only calls with connect time greater than 4 hours are included.
TABLE 2
SET ARRAY 100
SET ECHO OFF
SET FEED OFF
SET FLU OFF
SET HEA OFF
SET LIN 32767
SET PAGES 0
SET TERM OFF
SET TRIMS ON
SET VER OFF
DEF parallelism = 8
DEF tabspacename = ‘STUDY’
DEF tabname = & 1.
DEF mmdd = &2.
DEF tmp_tab_1 = ‘jh_wah_&&mmdd._1’
DEF tmp_tab_2 = ‘jh_wah_&&mmdd._2’
DEF tmp_tab_3 = ‘jh_wah_&&mmdd._3’
DEF spool_file_1 = ‘wah_s1.txt’
DEF spool_file_2 = ‘wah_s2.txt’
DEF spool_file_3 = ‘wah_s3.txt’
DEF outfile = ‘wah_&&mmdd.txt’
ALTER SESSION ENABLE PARALLEL DML;
ALTER SESSION SET optimizer_mode = all_rows;
ALTER SESSION SET sort_area_size = 104857600;
ALTER SESSION SET sort_area_retained_size = 104857600;
DROP TABLE &&tmp_tab_1.;
spool &&spool_file_1.
CREATE TABLE &&tmp_tab_1.
PARALLEL (DEGREE &&parallelism.) NOLOGGING PCTFREE 0 PCTUSED
99 TABLESPACE &&tabspacename.
STORAGE (INITIAL 1M NEXT 1M PCTINCREASE 0 MAXEXTENTS
UNLIMITED) AS
SELECT /*+ PARALLEL (&tabname.,&&parallelism.) */
TO_CHAR(iam_date_time,‘D’) dotw,
TO_CHAR(iam_date_time,‘HH24’) hr,
‘(‘∥enriched_calling_npa∥’)’∥enriched_calling_nxx∥‘-’∥enriched_calling_line cgpn,
ia_called_state cd_st,
ia_carrier_code ocn,
ia_tgsn tgsn,
anm_rel_dur/60 mou
FROM
&tabname., tsdbi_dba.line_specific_current
WHERE
enriched_called_npa∥enriched_called_nxx∥enriched_called_line=line_number
AND
ia_call_category IN (‘LOC’,‘1S2LOC’,‘2S2LOC’,‘2S1LOC’) AND
length(enriched_calling_npa∥enriched_calling_nxx∥enriched_calling_line) = 10;
spool &&spool_file_2.
INSERT /*+ PARALLEL (&&tmp_tab_2.,&&parallelism.) */ INTO &&tmp_tab_2.
SELECT /*+ PARALLEL (&&tmp_tab_1.,&&parallelism.) */
dotw,
hr,
cgpn,
cd_st,
ocn,
tgsn,
count(mou),
sum(mou)
FROM
&&tmp_tab_1.
HAVING
avg(mou) > 3600
GROUP BY
dotw, hr, cgpn, cd_st, ocn, tgsn;
spool off
DROP TABLE &&tmp_tab_1.;
--DROP TABLE &&tmp_tab_2.;
--DROP TABLE &&tmp_tab_3.;
EXIT
FIG. 4 is a screen shot of a report produced using a method in accordance with a preferred embodiment of the present invention. The report shown in FIG. 4 is but one example of a report that could be produced in accordance with the described embodiment of the present invention. In particular the report in FIG. 4 shows the calling number, the date and time of the call, along with the minutes of use. Those of ordinary skill in the art will recognize that the report shown in FIG. 4 can be produced in a variety of manners, including the use of the CRYSTAL REPORTS software package.
Although a few variations of the preferred embodiment of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made to the described invention without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. For example, while the discussion herein has focused on the analysis of CDRs, those of ordinary skill in the art recognize that other data structures may be substituted, such as Correlated Call Records (CCRs) that combine of two or more CDRs representing the same call. Also, the terms applied to the various data structures and procedures do not represent any particular data structure or procedure. In particular, the present discussion was presented in the context of AGILENT's ACCESS7 and adopts the nomenclature thereof. However, the present invention is applicable to other systems, which may use different nomenclature to describe similar structures and to which the present invention may be equally applied. Further, the described procedures may also be modified to account for process flows other than the described process flow used by the AGILENT's ACCESS7 OSS.
|
A method of identifying work at home users of a telecommunications network based on call detail records. The phone numbers of the work at home users are identified from call detail records that exhibit characteristics of work at home users. In one embodiment this involves selecting records describing calls to phone numbers of known Internet Service Providers; excluding records describing calls less than a predetermined length of time; excluding records containing originating numbers with records describing calls to an ISP that occur on weekends; and excluding records containing originating numbers with records describing calls to an ISP that occur outside normal business hours.
| 7
|
DESCRIPTION
Background of the Invention
This invention relates to load positioners and, more particularly, to an electronically controlled load positioner suitable for use with a residential overhead garage door.
Automatic load positioners per se are well known in the prior art and in fact, automatic door operators for moving residential overhead garage doors have been in use for many years. Typically, such an overhead door rides along a track between a closed position and an open position, the door being driven by a reversible electric motor coupled thereto through either a chain and sprocket assembly or a worm drive. Various types of controls are required for such an operator. For example, it is essential that the operator have some means for determining the open and close limits of travel of the door. In the past, such a control has been achieved through the use of limit switches activated by, for example, a traveling nut on a rotating shaft. With such an arrangement, a pair of limit switches have been provided, one corresponding to each of the two extreme positions of the garage door. Such an arrangement provides a number of distinct disadvantages. For example, when installing such a system, the installer must very carefully make a series of adjustments to the positions of the limit switches so that they switch at the extreme open and close positions of the overhead garage door. These adjustments must be made with the power off. Then, the installer must turn the power on to check the adjustments. If improper, the power must be turned off to make further adjustments, and so on. An additional disadvantage of utilizing limit switches is that they are mechanical devices subject to wear and contact deterioration. It is therefore an object of the present invention to provide a door operator having an improved arrangement for sensing the door position and which may be easily adjusted with the power turned on.
Various safety standards have been developed over the years for door operators. This is especially important with residential garage door operators to reduce the risks to children. Most of these standards relate to the sensing of obstructions when the door is moving to deenergize, or even reverse, the motor when some minimum obstructive force is sensed. Prior art systems for sensing obstructive forces have included slip clutches, camming surfaces, or pivotal members in conjunction with a toggle switch, and some have proposed detecting the rise in motor current. However, none of these approaches are precise enough to meet the ever more rigid standards being set by industry and government for such operators. It is therefore an additional object of this invention to provide an improved obstruction sensing arrangement for use with an overhead door operator.
There are times when it is desirable to ignore the encountering of an obstruction by a traveling garage door. For example, when the door is within a small distance, for example two inches, of its close position, if an obstruction is sensed the motor should be deenergized but not reversed. Additionally, when the motor is first energized, all force sensing should be ignored for an initial period of time to allow the door to overcome its natural inertia to being moved. It is therefore a further object of this invention to provide an arrangement which is selective in its response to obstruction sensing.
It is a still further object of this invention to provide an overhead door operator which responds not only to the magnitude of obstructive forces but also responds to rapid changes in obstructive forces. Thus, for example, if a traveling door encounters a small child, the door should be reversed prior to exerting a harmful force on the child.
SUMMARY OF THE INVENTION
The foregoing and additional objects are attained in accordance with the principles of this invention by providing a door operator including means for generating a force signal which changes as a predictable function of the force opposing movement of the door. Means are provided for measuring the time rate of change of the force signal and deenergizing the motor when the magnitude of the time rate of change of the force signal exceeds a predetermined value.
In accordance with an aspect of this invention, means are provided for measuring the magnitude of the force signal and deenergizing the motor when the magnitude exceeds a predetermined threshold.
In accordance with another aspect of this invention, the door operator includes means for generating a position voltage which is predictably related to the position of the door. A first limit voltage is provided corresponding to the open position of the door and a second limit voltage is provided corresponding to the closed position of the door. Means are provided for continuously comparing the position voltage to the first and second limit voltages and deenergizing the door operator motor when the position voltage goes to either end of the range set by the first and second limit voltages.
In accordance with yet another aspect of this invention, the first and second limit voltages may be adjusted by an installer with power turned on.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings, wherein:
FIG. 1 illustrates a garage door equipped with an automatic door operator constructed in accordance with the principles of this invention;
FIG. 2 is a side view of the door operator, with its housing covers removed, showing an illustrative arrangement for generating the position voltage;
FIG. 3 is a top plan view of the door operator showing an illustrative arrangement for generating the force signal;
FIG. 4 is a block logic diagram illustrating the principles of operation of a door operator control system constructed in accordance with the principles of this invention; and
FIG. 5 is a detailed schematic circuit diagram of an illustrative door operator control system according to this invention.
DETAILED DESCRIPTION
Referring now to the drawings, wherein like elements in different figures thereof have the same reference character applied thereto, FIGS. 1, 2 and 3 show a motor driven door operator, designated generally by the reference numeral 10, which may be manually or remotely controlled for opening and closing an upwardly acting door 12. The door 12 is illustratively a residential garage door including several horizontally hinged sections having rollers mounted thereon for engagement with side rails for guiding movement of the door 12 between a lower substantially vertical closed position and an upper substantially horizontal open position. The operator 10 includes an elongated horizontal beam 18 defining a guide rail along which a carriage 20 is supported for movement lengthwise thereof. The beam 18 is supported at one end by a suitable mounting secured to the wall above the door 12 and at the other end by a suitable support within the housing of the operator 10, which in turn is suitably suspended from the garage ceiling or rafters. The carriage 20 is pivotally connected to the upper end of an arm 22, which arm 22 at its lower end is connected to the door 12 by means of a plate 24.
To move the carriage 20, the operator 10 includes a reversible electric motor 26 which has an output shaft 28 connected to a pulley 30. The pulley 30 engages a drive belt 32 which drives a larger dimeter pulley 34. The pulley 34 is drivingly coupled to a shaft 36 journaled for rotation in two spaced apart bearings 38 and 40. The end of the shaft 36 opposite the pulley 34 has connected thereto a toothed drive sprocket wheel 42. A drive chain 44 is in engagement with the sprocket wheel 42 and extends around an idler 46 to an idler sprocket wheel 48 at the far end of the beam 18. The ends of the chain 44 are coupled to the carriage 20. Accordingly, as the motor 26 rotates, the sprocket wheel 42 drives the chain 44 to move the carriage 20 lengthwise along the beam 18, whereby the door 12 is moved in either an opening or closing direction, depending upon the direction of rotation of the motor 26.
In accordance with the principles of this invention, the shaft 36 is externally threaded between the bearings 38 and 40. An internally threaded nut 50 rides on the threads 51 of the shaft 36. A linear potentiometer 52 is suitably mounted on a circuit board 54 and is directed substantially parallel to the shaft 36. An extension 56 of the wiper arm of the potentiometer 52 is inserted into a hole in the nut 50. The nut 50 is squared off and rides against the plate 55 so as to prevent the nut 50 from rotating. Rotation of the shaft 36 thus causes the nut 50 to move lengthwise on the shaft 36. Thus, whenever the drive sprocket wheel 42 is rotated to open or close the door 12, the nut 50 will move the wiper arm of the potentiometer 52 within a range of positions corresponding to the range of positions of the door 12.
The idler 46, around which the chain 44 passes, is mounted on a pivot arm 58, pivoted at 60. The pivot arm 58 has a slot 62 at its end opposite the idler 46. A linear potentiometer 64 is mounted on the chassis of the door operator and is directed substantially perpendicular to the pivot arm 58. An extension 66 of the wiper arm of the potentiometer 64 extends through a slot 67 of the chassis and is captured within the slot 62. When the carriage 20 is traveling either forward or backward along the beam 18, thereby moving the door 12 toward its open or closed position, and an obstruction is encountered, a force will be exerted on the chain 44. The exertion of a force on the chain 44 will tension one side of the chain 44 relative to the other and, through the idler 46, will cause the pivot arm 58 to pivot toward the side with less tension. This moves the wiper arm of the potentiometer 64. It will be noted that the wiper arm of the potentiometer 64 will move in one direction from a neutral position if the door 12 meets an obstruction while closing and will move in the other direction from the neutral position if the door 12 meets an obstruction while opening. This movement is predictably related to the force opposing movement of the door 12. If desired, a pair of springs 68, 70, may be provided to bias the pivot arm 58 toward a central, or neutral, position.
FIG. 4 is a block diagram useful for illustrating the principles of operation of a system constructed in accordance with this invention. A switch 102 is wired to the control logic 104 through a static protection circuit 106. The purpose of the circuit 106 is to stop any high voltages, which may be generated by lightning, walking across a carpet, sliding across a car seat, etc., from damaging the control logic 104. Although for simplicity a two terminal pushbutton switch 102 is illustrated, it is understood that other contact closure devices, such as a remote controlled radio receiver, may be utilized in parallel with the switch 102 to provide a circuit completion function. From the static protection circuit 106, the switch closure initiated signal goes to the delay circuit 108. The switch 102 must be closed for a specified time period, illustratively one tenth of a second, before the delay circuit 108 will provide an output signal to the control logic 104. The delay circuit 108 thus eliminates transient or spurious signals.
As described previously, the wiper arm of the position sensing potentimeter 52 moves predictably in accordance with the position of the door 12 and acts as a voltage divider to provide a DC position voltage, which an vary from zero to the full value of the power supply. The position voltage is thus predictably related to the position of the door 12. This position voltage is fed to two comparators, an open comparator 110 and a close comparator 112. Each of the two comparators 110, 112, has its own trim potentiometer 114 and 116, respectively. Each trim potentiometer 114, 116, forms a voltage divider and is set to a different voltage, which is prevented from overlapping the voltage range of the other. When the door 12 is being opened and the voltage output from the position sensing potentiometer 52 goes beyond the voltage setting of the open trim potentiometer 114, the open comparator 110 signals the control logic 104. When the door 12 is being closed and the voltage output from the position sensing potentiometer 52 goes beyond the voltage setting of the closed position potentiometer 116, the close comparator 112 signals the control logic 104. The trim potentiometers 114 and 116 thus establish the up and down limits of the door 12. It is evident from the foregoing that if the door 12 has reached the system' s down limit without reaching the floor, adjusting the close potentiometer 116 will cause the motor 26 to be reenergized and close the door further. This same form of instantaneously responsive adjustment is also possible on the open cycle via the open trim potentiometer 114.
Once the close limit is set for full closing of the door 12, the output voltage from the close trim potentiometer 116 corresponds to the door's fully closed position as sensed by the position sensing potentiometer 52. Whenever the voltage output from the position sensing potentiometer 52 comes within a preset value of the setting of the close trim potentiometer 116, the two inches from the floor comparator 118 signals the control logic 104.
As was mentioned previously, the wiper arm of the linear potentiometer 64 moves predictably in response to changes in the load on the door 12 and acts as a voltage divider to provide a DC voltage, pedictably related to the force opposing movement of the door 12, on its wiper arm that is fed to two circuits; a differential load sensing circuit 120 and a maximum load sensing circuit 122. In the differential load sensing circuit 120, the voltage output from the wiper arm of the linear potentiometer 64 is filtered and only the variations in voltage are used. When these variations exceed a preset limit, an output signal is transmitted through the OR gate 124 to the control logic 104. When the wiper arm of the load sensing potentiometer 64 is in the middle, or neutral, position the door load is zero and the voltage output from the wiper arm is half that of the power supply. When in response to a load in either the opening or closing cycle, the wiper arm moves in one direction or the other to cause either a high or low voltage to appear thereon, the maximum load sensing circuit 122 compares this voltage to its preset limits, which establish the maximum load the door opener should safely handle. The differential load sensing circuit 120 is preset to respond to load variations just in excess of the rapidly occurring variations that are a result of the jerking, binding and releasing, and other load disturbances in the normal movement of an unobstructed door. This circuit 120 does not respond either to the constant weight of the door 12 or to load variations that build gradually, as when the rollers of the door 12 must turn a corner of the side rails. Therefore, whether the door 12 weighs two pounds or two hundred pounds, the differential load sensing circuit 120 will theoretically detect even a two ounce sudden change in load that results from an obstruction. Once preset by the manufacturer, neither the maximum load sensing circuit 122 nor the differential load sensing circuit 120 needs any further adjustment by the installer of the door operator. This is an important safety feature because it is undesirable to allow the installer to make adjustments to compensate for particular obstructions, such as bent side rails. The installer must fix the door so that the controller will always operate within the factory set limits.
The control logic 104 processes the various input signals just described. Assuming that the door 12 is initially closed, upon receipt of a time delayed switch closure signal over the lead 126, the control logic 104 activates the open output 128 until the open comparator 110 signals that the door 12 has reached its preset open limit. If, during the opening cycle, another switch closure is signalled over the lead 126, the control logic 104 will terminate the open output 128. The open output 128 will remain in this state and the door 12 will not be moved until the next contact closure of the switch 102, whereupon the open output 128 will again be activated, causing the opening of the door 12 to be resumed. If the control logic 104 receives a signal from the load sensing circuits over the lead 130 during the opening cycle, the control logic 104 will deenergize the open output 128. The next contact closure of the switch 102 will cause the control logic 104 to reactivate the open output 128. The next contact closure after the door 12 reaches the open limit causes the control logic 104 to activate the close output 132.
Once the close output 132 has been activated, the closing cycle will continue until the close comparator 112 signals that the close limit has been reached. If at any time during the closing cycle either a contact closure over the lead 126 or a load sensing signal over the lead 130 occurs, the control logic 104 will immediately reverse the direction of travel of the door 12 by deactivating the close output 132 and activating the open output 128. The only exception occurs when the door 12 is less than approximately two inches from its close limit, as signaled by the comparator 118. Under these circumstances, the close output 132 will be deactivated without an energization of the open output 128.
As will be described hereinafter, included within the control logic 104 is a timer circuit which lights a lamp for a preset period of time whenever there is a switch closure signal over the lead 126. Another timer circuit deactivates the close output 132 and activates the open output 128 if the close limit is not reached within a predetermined time after initiation of a closing cycle. A third timer circuit causes load sensing signals on the lead 130 to be ignored for a short interval after either the open output 128 or the close output 132 is activated to prevent the control logic 104 from falsely triggering due to load sensing signals caused by the inertial bucking that typically accompanies the initiation of door movement.
The power section of the door operator circuit, to be described in full detail hereinafter, uses two triacs to apply power to the meter 26. A first triac 134 conducts the line voltage 136 to the open winding of the motor 26. The second triac 138 conducts the line voltage 136 to the close winding of the motor 26. Power resistors 140 and 142 limit the electrical current surges to each of the triacs 134 and 138, respectively. Each of the triacs 134 and 138 is signaled to turn on through its own high voltage isolator 144 and 146, respectively. The isolators 144 and 146 isolate the low voltage DC logic circuitry of the control logic 104 from the high voltage line current, which is AC. When either the open output 128 or the close output 132 is activated, its connected isolator 144, 146, activates the gate of the connected triac 134, 138. This causes the respective one of the triacs 134, 138, to avalanche and thereby energize either the open or the close winding of the motor 26.
Referring to FIG. 5 for a detailed circuit diagram of the system shown in, and described with respect to, FIG. 4, the garage door opener circuit takes commercially available AC power in through a line cord 202. A fuse 204 provides overcurrent protection. The motor 26 and lamp 206 common leads are wired to the hot side 208 of the line, while the neutral side 210 of the line is connected to triac 134, triac 138 and triac 212. The triacs 134, 138 and 212 each have a respective transformer secondary 214, 216 and 218 connected to their gate. Triacs 134 and 138 each have a surge protection resistor 140 and 142, respectively, connected serially therewith to prevent the triacs 134 and 138 from blowing out when first turned on into the capacitively loaded motor 26.
The logic circuitry DC power supply consists of a 120 volt to 16 volt transformer 220 whose output is full wave rectified by the diode bridge 222 and then filtered by capacitor 224. The filtered voltage is then regulated by the voltage regulator 226, which is illustratively a Motorola type MC 78L12 voltage regulator, and protected from transient surges by a combination of the zener diode 228 and the diode 230 to provide the +15 volts low voltage DC supply. The transformer 220 and the transformers 214, 216 and 218 provide the high voltage to low voltage isolation required for safety.
In the logic circuitry portion, the push button switch 102 connects the lead 232 to the lead 234 when closed. Diodes 236 and 238 function as the static protection circuit 106. Diode 236 becomes conductive if the lead 232 tries to go above the V+ line while the diode 238 conducts if the lead 232 tries to go more negative than the lead 234, which is at ground. Resistors 240 and 242 and capacitor 244 form the time delay circuit 108 which delays the turn-on of the NAND gate 248 for one tenth of a second after closure of the switch 102. This is a transient filter protection circuit which requires that the switch 102 be closed for a full tenth of a second before a positive going transition is seen at the output of the NAND gate 248. The flip-flops 250 and 252, which are D-type flip-flops, interpret this transition to determine whether the door 12 should be opening, closing or stopping, depending upon the condition of their inputs.
If the door 12 is in its opening cycle, then output 254 of flip-flop 250 will be high and output 256 will be low. Flip-flop 252 will have output 258 high and input 260, its reset input, will be low. Resistor 262, along with diodes 264, 266 and 268, form a three input "open" AND gate. All of the anodes of the diodes 264, 266 and 268 must be high in order for the open node 270 to go high. Resistor 272, along with diodes 274, 276 and 278, form a three input "close" AND gate. Again, all three diode anodes must be high for the close node 280 to go high.
With output 256 of flip-flop 250 low, diode 278 is conducting and holding the close node 280 low. With output 254 of flip-flop 250 high, diode 266 is non-conductive, therefore allowing the open node 270 to be high. With the open node 270 high, diode 282 is conducting, causing reset input 284 of flip-flop 250 to be high, inhibiting the flip-flop 250 from responding to any further clock pulses at the input 286 as a result of closures of the switch 102. In addition, input 288 of NAND gate 290 is also being held high by the open node 270, therefore its output 292 will be low, causing the data input 294 of flip-flop 252 to be low, readying the flip-flop 252 to bring its output 258 low on the next clock pulse at the input 296 due to closure of the switch 102. A low on output 258 will cause diode 264 to be conductive, thereby pulling the open node 270 low and stopping the opening of the garage door 12. Thus, the garage door 12 is in the state where it is neither opening nor closing and is just stopped somewhere between being fully open and fully closed. The low at the open node 270 causes reset input 284 of flip-flop 250 now to go low, since diode 282 is now non-conductive and that in turn causes output 292 of NAND gate 290 to go back to its high state. With the next switch closure pulse, flip-flops 250 and 252 are both clocked. However, the output 258 of flip-flop 252 immediately goes high, causing the open node 270 to go high, and resetting flip-flop 250 through diode 282. This starts the garage door 12 reopening. With reset 284 of flip-flop 250 now held high by the open node 270, again this section is disabled and the next clock pulse will cause flip-flop 252 output 258 to go low, bringing the open node 270 low.
After the door 12 reaches its full open position, the open node 270 will be held low. The output of AND gate 290 will be high, causing data input 294 of flip-flop 252 to be high. With the next switch closure pulse, flip-flop 252 remains in the same state and flip-flop 250 changes state, causing the close node 280 to go high because diode 278 is now non-conductive. Output 254 of flip-flop 250 goes low, keeping the open node 270 low through diode 266. The door 12 is now closing.
The next switch closure pulse into input 286 of flip-flop 250 causes output 254 to go high and output 256 to go low, thereby stopping the closing action and instantly starting an opening action. This is the instant reverse feature. With the open node 270 high again, diode 282 is again conductive and disables flip-flop 250 through input 284. Output 258 of flip-flop 252 is low, causing the data of flip-flop 252 to be ready to go low with the next switch closure pulse, and thereby causing the stoppage of the opening stroke through diode 264. Accordingly, with each successive switch closure pulse, the door 12 will be caused to open, stop opening, (until it reaches full open this will be repeated), close, and instantly reverse from the closing to the opening stroke.
The open and close limits for the door 12 are set through the use of the linear potentiometer 52, connected as a voltage divider, and the open and close trim potentiometers 114 and 116, respectively. The wiper arm 300 of the linear potentiometer 52 is coupled to the traveling nut 50 which rides on the threaded shaft 26 which is attached to the sprocket wheel 42 of the garage door opener chain 44. Since the wheel 42 drives the chain 44, and the position of the chain 44 determines the position of the door 12, the position of the wiper arm 300 is directly and predictably related to the position of the door 12. With each wiper arm 300 position, there is a position voltage output thereon. This position voltage is connected to input 302 of open comparator 110, input 304 of close comparator 112, and input 305 of comparator 118. The voltage divider made up of resistances 306, 116, 114 and 308 forms the settings for the close and open limits of the door 12. Zener diode 310 is a 3.3 volt zener diode and drops the voltage to the voltage divider and the linear potentiometer 52 to 3.3 volts below V+. This is because the inputs of the comparators 110, 112 and 118 will not respond to a voltage going all the way to V+.
Resistors 306 and 308 insure that the wiper of potentiometer 116 will not go to the new V+ setting and the wiper of potentiometer 114 will not go to the ground potential. Also, the travel of the linear potentiometer 52 is limited so that it will not mechanically go beyond its resistance limits. Potentiometers 116 and 114 are connected in series so that a setting of potentiometer 114 will never have a higher voltage than the lowest setting of potentiometer 116. Therefore, the close and open settings cannot overlap. With potentiometer 116 at a particular setting, a voltage is established on its wiper arm 312. The linear potentiometer 52 wiper 300 has a changing voltage thereon as the door 12 is moved, and this is applied to the inverting input 304 of comparator 112. The non-inverting input of comparator 112 has thereon a voltage which does not change, set by wiper 312 of potentiometer 116. When the voltage on wiper 300 exceeds that of wiper 312, then the output 314 of comparator 112 goes low, causing diode 276 to go into its conductive state and bring the close node 280 low, thereby stopping the closing stroke of the door 12. It can be seen in this circuit that if someone were to adjust potentiometer 116 to a slightly higher voltage, the close node 280 would go high and the garage door 12 would start to move again toward the closed position. In this manner the close limit can be set with power on so that the close limit is easily and accurately established. Similarly, the open limit is established by the setting of potentiometer 114. The voltage to the inverting input 316 of comparator 110 is compared to the linear potentiometer 52 wiper 300 voltage at input 302. When input 302 has a potential thereon that goes below the potential at input 316, then the output 318 of comparator 110 goes low, causing diode 268 to go into conduction, pulling the open node 270 low and stopping the door 12 from opening further. If potentiometer 114 were to be adjusted so that its voltage was lower than that of the linear potentiometer 52 wiper 300, output 318 would go high again, causing the open node 270 to go high and the door 12 would move to its new open position.
Comparator 118 provides the function of sensing when the door 12 is within two inches of its close limit. Input 320 of comparator 118 takes in the voltage setting of the close limit potentiometer 116 and compares it to the position of the linear potentiometer 52 wiper 300. When wiper 300 becomes more positive than wiper 312, the output 322 of comparator 118 goes high and signals various circuitry that the door 12 is two inches from its close limit. This signal is utilized by the load sensing circuitry, which will be described next. It will be noted that the two inches from the close limit is automatically established when the close limit is set.
Load sensing is accomplished by reading the voltage from the wiper arm 330 of the linear potentiometer 64. The linear potentiometer 64 is mechanically connected to the door operator, as previously described, so that its wiper arm 330 moves in a first direction when sensing an increased load while the door 12 is opening, and moves in the other direction when sensing an increased load while the door 12 is closing. The potentiometer 64 is connected as a voltage divider and its wiper arm 330 maintains a neutral voltage value when no obstructive forces are exerted on the door 12. The voltage at the wiper arm 330 is fed to capacitors 332 and 334, which together form a polarity independent capacitor. Equal resistors 336 and 338 form a half V+ voltage divider. When the wiper arm 330 force voltage output of the linear potentiometer 64 changes slowly, capacitors 332 and 334 will charge slowly, and cause a small signal output to be seen at the node 340. If the change is very rapid, a much larger signal will be seen at the node 340. A constant load on the door 12 will cause no signal change at the node 340. Thus, the function of a differential load sensor is achieved.
Resistor 342 performs the function of a maximum load sensing circuit, whereby with a particular position of the wiper arm 330 of the linear potentiometer 64 under a constant load, this will establish a steady voltage at the node 340. Thus, the capacitors 332 and 334 together form a differentiator which measures the time rate of change of the force voltage and provides a first partial force signal related thereto, the resistor 342 forms a maximum force measurer which measures the magnitude of the force voltage (its deviation from its neutral value) and provides a second partial force signal related thereto, and the node 340 functions to combine the first and second partial force signals into an obstruction signal. Resistor 343, zener diode 344 and resistor 346 form the limit comparison circuit for the load sensing comparators 348 and 350. The resistors 336, 338, 343 and 346 all have the same value.
When the obstruction signal at the 340 goes more positive than the anode of the zener diode 344, the output 352 of the comparator 348 will go from its normally low state to a high state and cause the reset input 260 of flip-flop 252 to immediately go low and stop the open through diode 264 to the open node 270. On the other hand, if the node 340 goes more negative than the cathode of zener diode 344, then the output 356 of comparator 350 goes high and through resistor 358 and subsequently diode 360, which now is in its conductive state, causes the reset input 284 of flip-flop 250 to go high, thereby resetting the flip-flop 250. This causes the output 256 to go low and the output 254 to go high, which results in stopping the closing stroke and instantly turning on the open node 270 through diode 266. Therefore, the door 12 instantly reverses from the closing to the opening stroke. Output 356 of comparator 350, when it goes high, also causes diode 362 to go into its conductive state, thereby pulling input 364 of NAND gate 366 high. If this happens when input 368 is high, input 368 being high when the output 322 from comparator 118 is also high, then output 370 of NAND gate 366 will go low, causing diode 274 to become conductive and stopping the close cycle.
When output 322 of comparator 118 is high, transistor 372, through resistor 374, is conducting and this stops the signal from output 356 of comparator 350 from getting back to the reset input 284 of flip-flop 250. Therefore, if there is a load sensing pulse at the node 340 when the two inches from the close limit sensing comparator 118 is high, then the door 12 does not stop and instantly reverse, it merely stops. When output 370 of NAND gate 366 is low, it means that output 376 of NAND gate 378 is high. Resistor 380 provides a latching feedback loop to input 364 of NAND gate 366, so that once input 364 is momentarily high while input 368 is high, the door 12 will stop and remain stopped until output 322 of comparator 118 again goes low during the opening stroke.
The load sensing circuitry has an additional portion, the ignore circuit. The function of the ignore circuit is to ignore the signals from the comparators 348 and 350 for the first half second after initiation of an opening or a closing cycle because the inertia of the door 12 causes overload conditions during this time. This function is provided by flip-flop 400, a D-type flip-flop. The flip-flop 400 is clocked through diode 402 from the opening node 270 and through diode 404 from the close node 280. When flip-flop 400 is clocked, resistor 406 and capacitor 408 form a timing circuit that times a pulse for one half second. During this half second, output 410 of flip-flop 400 goes low, causing diode 412 to go into its conductive state, and holding the reset input 260 of flip-flop 252 low so that it will not respond to any open load sensing pulses from comparator 348. In addition, output 410 of flip-flop 400 being low holds diode 414 in its conductive state, thereby inhibiting any close load pulses from the load sensing circuit. Further insurance that the ignore circuit will operate, even during instant reverse, is provided by capacitor 416 and pulldown resistor 418. When the flip-flop 250 changes state to go through instant reverse, output 254 of flip-flop 250 will go high, supplying a pulse through capacitor 416 to the set input 420 of flip-flop 400. This will cause the flip-flop 400 to initialize into its half second ignore mode.
When output 410 of flip-flop 400, the ignore timer, goes low, diode 422 becomes conductive and discharges capacitor 424 through resistor 426. These two components are in the lamp timer circuit and capacitor 424 and resistor 426 form the timing elements thereof. Their junction is fed into input 430 of comparator 432, where the voltage thereat is compared with the voltage on the input 434, which is connected to the voltage divider circuit of resistor 436 and resistor 438 for voltage reference. When the voltage at the input 430 goes more positive than the voltage at the input 434, output 440 will go low, causing current to be drawn through resistor 442, thereby charging capacitor 444 through the primary of transformer 218. Transformer 218 triggers triac 212, as will be next described.
Transistor 446 is pulsed by a pulsing circuit which causes it to short circuit capacitor 444 and the primary of transformer 218. This discharges the capacitor 444 directly into transformer 218. The discharge pulse is coupled to the secondary of transformer 218 which is connected across the gate of triac 212, thereby turning on the triac 212 and allowing current to pass through the lamp 206. Similarly, the open node 270, when it goes high, draws current through resistor 448 and charges capacitor 450 through the primary of transformer 214. Transistor 452 is pulsed by the same pulse source as transistor 446 and discharges capacitor 450 through the primary of transformer 214. The secondary of transformer 214 supplies pulses to the gate of triac 134. This provides the triac 134 with turn-on current to drive the motor 26 in its door opening direction. When the close node 280 goes high, current is drawn through resistor 460 and charges capacitor 462 through the primary of transformer 216. In this case, transistor 464 is pulsed and capacitor 462 discharges through the primary of transformer 216. The pulses generated at the secondary of transformer 216 cause triac 138 to turn on and operate the motor 26 in the door closing direction. The purpose of the transformers 214, 216 and 218 is isolation between the low voltage side of the circuitry and the high voltage side of the circuitry.
The pulses to the transistors 446, 452 and 464 are provided by comparator 470 and flip-flop 472. Comparator 470, along with resistor 474 and capacitor 476 form an oscillator, operating at, illustratively, 2000 Hertz. The output of comparator 470 on lead 478 is fed to the clock input of D-type flip-flop 472, which performs the function of a fast rise time trigger pulser. The rise time, or turn-on time, is approximately 10 nanoseconds and the amount of time that output 480 of flip-flop 472 stays high, approximately 2 microseconds, is dependent upon resistor 482 and capacitor 484. The output on lead 480 is fed to resistor 486, which drives transistor 452; resistor 488, which drives transistor 464; and diode 490, which drives transistor 446. The pulse train is continuous and the pulses occur at twice the oscillator frequency, or approximately 4000 times per second. Since the line voltage is at 60 cycles per second, there are 66 pulses for every cycle of the AC line voltage. This insures that a pulse will be seen by a triac no more than 500 microseconds after the line current rises from zero. The duration of each pulse is so short that it allows capacitors 444, 450 and 462 to charge up to nearly V+ before the next discharge.
The last portion of the operator circuitry to be discussed functions to provide a fifteen second safety reset timer. As soon as the garage door 12 begins a closing stroke, diode 500, which formerly was in its conductive state discharging capacitor 502 through resistor 504, goes into its non-conductive state. This allows capacitor 502 to now charge through resistor 506. Comparator 508 compares the voltage on capacitor 502 to the set point determined by voltage divider resistors 436 and 438. When the voltage at the input 510 of comparator 508 exceeds the set point voltage on the input 512, output 514 of comparator 508 will go high, causing diode 516 to go into its conductive state. This pulls the reset input 284 of flip-flop 250 high, causing the flip-flop 250 to reset, stop the close cycle and start the open cycle. If, however, the close node 280 goes low before the fifteen second time period has expired, the safety timer has no effect, because capacitor 502 never gets fully charged. In this way, if something was wrong with the garage door operator, or if the door 12 gets jammed, and the door 12 never reaches its fully closed position within fifteen seconds, the safety timer will cause the motor 26 to be reversed and reopen the door 12.
Accordingly, there has been described an improved automatic door operator. While this invention has been described with reference to a preferred embodiment thereof, numerous other variations, modifications and adaptations of the present invention will be apparent to those skilled in the art and such as come within the spirit and scope of the appended claims are considered to be embraced by the present invention. For example, although the present invention has been described with respect to a hard wired logic circuit, it is apparent that the present invention contemplates within its scope employment of an appropriately programmed microcomputer or other similar device. Additionally, although a reversible motor with two windings has been illustrated, this invention may also be practiced by using a DC motor whose direction of rotation is dependent upon the polarity of the applied energization, or even by a unidirectionally rotating motor having a mechanically reversible output arrangement. Also, although potentiometric sensing of load and position has been described, it is contemplated that other sensing devices may be utilized such as optical sensors for load and position sensing or strain gages for load sensing.
|
An automatic door operator system is provided with a first potentiometer having its wiper arm coupled to a pivoting member whose angular position varies in accordance with the magnitude and direction of an obstructive load applied to the door. A second potentiometer is provided having its wiper arm coupled to a movable member whose position corresponds to the position of the door. The potentiometers are connected as voltage dividers and the voltages provided at their wiper arms are utilized for controlling the movement of the door.
| 4
|
TECHNOLOGICAL FIELD
[0001] The invention relates to copying or moving content between servers, in particular, but not exclusively, to copying content between servers storing different types of communication data, including multimedia files.
BACKGROUND
[0002] Modern mobile communication devices are used for a wide range of purposes in addition to traditional telephony. For example, it is known to use instant messaging or email to send messages that include multimedia objects such as images, audio files and video clips. Such messages often include large amounts of data that a user may wish a network to store independently of the messages they were originally attached to.
[0003] The Open Mobile Alliance (OMA) is developing a Converged IP Messaging (CPM) specification that provides for the convergence of multi-media communication services. The Open Mobile Alliance publishes much of its work on its website (www.openmobilealliance.org).
[0004] FIG. 1 shows a system, indicated generally by the reference numeral 2 , comprising a client device 4 and a central system 6 . The client device 4 includes a message and media storage client 8 . The central system 6 includes a message and media storage server 10 . The client device 4 may be a CPM-enabled device and the central system 6 may be a CPM system.
[0005] The message and media storage server 10 provides management and storage functions for messages and other media and is used, for example, to store users' multimedia data. The message and media storage client 8 manages a particular user's resources at the server 10 and also manages the resources stored locally at the client device 4 .
[0006] The message and media storage server 10 may be one component or consist of two components, one storing messages and another one storing media. The same can hold for the client side, i.e., it can host a message storage client and a media storage client.
[0007] Data stored in the message and media storage server 10 can be classified in two different ways:
1. Message-like contents (such as CPM messages, CPM conversations, and CPM session histories, including their attachments); and 2. Unstructured contents, e.g. plain binary files (of any type).
[0010] In some circumstances, a user may wish to transfer an attachment of a message from an area storing message-like contents (including the said attachment) to an area containing plain binary files. This may, for example, be done when a user is no longer interested in the whole message, but would like to keep the attachment. For example, if a user receives a message including an image as an attachment, the user may wish to copy the image to a separate location and then delete the original message.
[0011] FIG. 2 is a flow chart 20 showing, in broad terms, how such an attachment may be transferred. The flow chart 20 includes a first step 22 in which the attachment is downloaded from the message and media storage server 10 to the client 4 . Next, at step 24 , the attachment is uploaded from the client 4 to the area of the server 10 that stores plain binary files.
[0012] The transfer of data via the client device 4 involves two over-the-air data transmissions. In the event that the end file is not stored at the client device 4 , these over-the-air transmissions represent an unnecessary use of network resources.
[0013] The present invention seeks to address at least some of the problems outlined above.
BRIEF SUMMARY
[0014] In one exemplary embodiment, a method of forwarding content is provided. The method may comprise: issuing a request to a first server, wherein the request requests that content at a second server be forwarded to the first server and wherein the request includes an indication of a location of the content on said second server; issuing a content access request from the first server to the second server; and forwarding said content from said second server to said first server in response to the content access request. The request issued to the first server may be issued by a user. The content may be multimedia data, such as image, audio or video data.
[0015] In another exemplary embodiment, a method of forwarding content is provided. The method may comprise: receiving a request to copy content (for example from a user, a user device, or a client) at a first server, the request to copy content requesting that content from a second server be provided to said first server, the request to copy content including an indication of a location of the content on the second server; issuing a content access request from the first server to the second server; and receiving said content at said first server in response to the content access request. The content may be multimedia data, such as image, audio or video data.
[0016] In a further exemplary embodiment, a method of forwarding content is provided. The method may comprise receiving a content access request from a first server (e.g. a content sharing server) at a second server (e.g. a message storage server), the content access request including an indication of a location of the content on the second server; and forwarding said content from said second server to said first server in response to the content access request. The content may be multimedia data, such as image, audio or video data.
[0017] In another exemplary embodiment, an apparatus is provided. The apparatus may provide a first server and a second server, wherein: the first server is adapted to issue a content access request to the second server in response to receiving a request to copy content (for example from a user, a user device, or a client), wherein the request to copy content includes an indication of a location of content stored on the second server; and the second server is adapted to provide said content to said first server in response to the content access request.
[0018] In yet another exemplary embodiment, an apparatus is provided. The apparatus may provide a first server (such as a content sharing server) adapted to: receive a request to copy content, the request to copy content requesting that content at a second server be provided to the first server, the request to copy content including an indication of a location of the content on the second server; issue a content access request to the second server; and receive said content in response to the content access request.
[0019] In a further exemplary embodiment, an apparatus is provided. The apparatus may provide a first server (such as a content sharing server). The first server may comprise: means for receiving a request to copy content (for example from a user), the request to copy content requesting that content at a second server be provided to the first server, the request to copy content including an indication of a location of the content on the second server; means for issuing a content access request to the second server; and means for receiving said content in response to the content access request.
[0020] Thus, the present invention enables a user to request that content at a second server (such as a message storage server of a CPM system) be provided to a first server (such as a content sharing server of a CPM system), without that content being passed via the user device. In many forms of the invention, the original content at the second server is retained.
[0021] The first server may store the content received from the second server. Thus, content can be copied from the second server to the first server in response to the request to copy content, without the user needing to receive the content. The content may be deleted from the second server, if desired.
[0022] The request to copy content may be an HTTP PUT request. In one particular form of the invention, the request to copy content is an HTTP PUT request with content reference. Other formats for the request to copy content are possible, including non HTTP formats. IMAP is one such alternative.
[0023] The indication of the location of the content on the second server included in said request to copy content may be provided as an IMAP uniform resource indicator.
[0024] The content access request issued by the first server to the second server may take the form of an IMAP request; for example, the content access request may include an IMAP uniform resource indicator indicating the location of the content on the second server. Alternatively, the content access request may take the form of an HTTP request, such as an HTTP GET request. Again, other formats are possible, such as requests in accordance with FTP and gopher protocols.
[0025] In some embodiments of the invention, the requested content is forwarded directly from the second server to the first server. In other forms of the invention, the requested content is forwarded from the second server to the first server via an intermediary, such as an adapter. The adapter may take the form of a separate server. Alternatively, the adapter may be provided as part of the first server. By way of example, the requested content may be forwarded from the second server to a dedicated resource of the first server and may then be further transferred within the first server. The content access request sent by the first server to the second server may be sent via the said adapter.
[0026] The location of the content on the second server may be identified by a base uniform resource locator in combination with a second uniform resource locator. In some forms of the invention, the request from the user received at the first server includes the base uniform resource locator and the second uniform resource locator. In some other forms of the invention, the request from the user received at the first server includes the second uniform resource locator and the first server provides the base uniform resource locator.
[0027] The request to copy content received at the first server may include a base uniform resource locator and a second uniform resource locator. The base uniform resource locator may refer to a resource on the first server; in such an arrangement, the content access request may include an HTTP GET request issued to the resource and the resource may issue an IMAP request to the second server. Alternatively, the base uniform resource locator may refer to a resource on the second server; in such an arrangement, the content access request may include an HTTP GET request issued by the first server to the resource on the second server. In a further alternative, the base uniform resource locator may refer to a resource on a third server; in such an arrangement, the content access request may include an HTTP GET request to the resource on the third server and the resource may issue an IMAP request to the second server.
[0028] In some embodiments of the invention, the first server is an HTTP server. Other server types are possible. The first server may be a WebDAV server. Further, other non-HTTP servers (such as an IMAP server) are possible.
[0029] In some embodiments of the invention, the second server is an IMAP server. Again, other server types are possible. For example, the second server may be an HTTP server. In some embodiments of the invention, both the first and second servers are HTTP servers.
[0030] The first server may take the form of a content sharing server. The second server may take the form of a message storage server. The first and second servers may form part of a Converged IP Messaging (CPM) system. According to some aspects of the invention, a file is created or replaced at a content sharing server using the content downloaded from said message storage server.
[0031] In another exemplary embodiment, a system, such as a converged IP messaging system, is provided. The system may comprise a content sharing server and a message storage server, wherein: the content sharing server is configured to receive a request to copy content (for example from a user) requesting that content at the message storage server be provided to the content storage server, the request to copy content including an indication of a location of the content on the message storage server; the content sharing server is configured to issue a content access request to the message storage server; and the message storage server is configured to provide the content to said content sharing server in response to the content access request. The system may include any of the aspects of the invention described above.
[0032] In another exemplary embodiment a computer program product is provided. The computer program product may be configured to: receive a request to copy content (for example from a user), the request to copy content requesting that content at a server be provided to the computer program product, the request to copy content including an indication of a location of the content on the server; issue a content access request to said server; and receive said content at said computer program product in response to the content access request. The computer program product may include a computer readable medium. The computer program product may include any of the features of the invention described above.
[0033] In another exemplary embodiment a computer program product is provided. The computer program product may be configured to: receive a request to copy content from a user, the request to copy content requesting that content be forwarded from a second server to a first server, the request to copy content including an indication of a location of the content on the second server; issue a content access request to said second server; provide said content to said first server in response to the content download request; and store said content at said first server. The computer program product may include a computer readable medium. The computer program product may include any of the features of the invention described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Embodiments of the invention are described below, by way of example only, with reference to the following numbered Figures.
[0035] FIG. 1 is a block diagram of part of a known communication system;
[0036] FIG. 2 is a flow chart demonstrating an aspect of the use of the system of FIG. 1 ;
[0037] FIG. 3 is a block diagram of part of a system in accordance with an aspect of the present invention;
[0038] FIG. 4 is a message sequence demonstrating an aspect of the use of the system of FIG. 3 ;
[0039] FIG. 5 is a message sequence demonstrating an aspect of the use of the system of FIG. 3 in accordance with an aspect of the present invention;
[0040] FIG. 6 is a message sequence demonstrating an aspect of the use of the system of FIG. 3 in accordance with an aspect of the present invention;
[0041] FIG. 7 is a message sequence demonstrating an aspect of the use of the system of FIG. 3 in accordance with an aspect of the present invention; and
[0042] FIG. 8 is a message sequence demonstrating an aspect of the use of the system of FIG. 3 in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
[0043] As discussed above, data stored in the message and media storage server 10 can be classified as either message-like contents or unstructured content (e.g. plain binary files). The two types of data may be accessed in a different manner. For example, Internet Message Access Protocol (IMAP) is one possible protocol for managing message-like contents. HTTP and Web-based Distributed Authoring and Versioning (WebDAV), which is an extension of HTTP, are two possible protocols for managing the plain binary files.
[0044] Since the types of the stored objects are different and the management protocols are different, it is a logical consequence to split the message and media storage server 10 into two parts. Such an arrangement is shown in FIG. 3 .
[0045] FIG. 3 shows the message and media storage server 10 referred to above. The message and media storage server 10 includes a message storage server 32 and a content sharing server 34 . The message storage server 32 contains the message-like contents discussed above (including any attachments to the messages): the content sharing server 34 contains the plain binary files discussed above. In some embodiments of the invention, data stored at the message storage server 32 is accessed using the IMAP protocol and that server may be referred to as an IMAP server. Similarly, in some embodiments of the invention, data stored at the content sharing server 34 is accessed using the HTTP protocol and that server may be referred to as an HTTP server.
[0046] FIG. 4 shows a message sequence, indicated generally by the reference numeral 40 , showing how the algorithm 20 described above with reference to FIG. 2 can be used to transfer data between the message storage server 32 and the content sharing server 34 . The message sequence 40 shows the data being transferred from the client 4 to the content sharing server 34 using an HTTP PUT request, with the content being included in the request body.
[0047] The message sequence 40 begins with the client 4 issuing an IMAP download request 42 to the message storage server 32 . In response, the message storage server 32 provides the requested content in message 44 . The client 4 then sends the content to the content sharing server 34 as an HTTP PUT request 46 . In response, the content sharing server issues an OK message 48 to the client 4 . The IMAP download request 42 and the HTTP PUT request 46 may be issued by the message and media storage client 8 of the client 4 .
[0048] The HTTP PUT request 46 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-Type: text/plain
Hello World!
[0049] Executing the HTTP PUT request 46 results in a file being created or replaced at the location given by the URL:
http://myMediaStorage.operator.net/home/ivo/MyHelloWorld.txt
[0051] The content of the file created (or replaced) at that location is the text “Hello World!”. In this example, the content of the file obtained from the message storage server (the text “Hello World!”) in the message 44 is included in the HTTP PUT request 46 . It should be noted that the actual text is included in the body of the PUT request, in accordance with the normal use of the HTTP PUT request.
[0052] The message sequence 40 involves a first data transfer from the message storage server 32 to the client 4 and a second data transfer from the client 4 to the content sharing server 34 . This wastes network resources and incurs unnecessary costs.
[0053] As discussed above, in an exemplary embodiment of the invention, the message storage server 32 is an IMAP server and the content sharing server 34 is an HTTP server. Thus, in the message sequence 40 , content is obtained from the message storage server 32 using an IMAP request, and content is sent to the content sharing server 34 using an HTTP request.
[0054] FIGS. 5 to 8 show message sequences 50 , 60 , 70 and 80 respectively, in accordance with aspects of the present invention. Each of the message sequences 50 , 60 , 70 and 80 omits the IMAP download request 42 of the message sequence 40 . Instead, in each case, an HTTP PUT request with content reference is sent from the client 4 to the content sharing server 34 .
[0055] An HTTP PUT request with content reference differs from an ordinary HTTP PUT request in that, instead of the body of the request containing the actual content being transferred, the body of the request only contains a reference containing the location at which the content is stored. Further details regarding such requests can be found at http://www.ietf.org/rfc/rfc2017.txt. The HTTP PUT request with content reference is sometimes referred to in this specification as a request to copy content, since it requests that content at one server be copied to another server.
[0056] Each of the message sequences 50 , 60 , 70 and 80 makes use of the HTTP PUT request with content reference in a different way, as discussed in detail below.
[0057] As shown in FIG. 5 , the message sequence 50 begins with the client 4 issuing an HTTP PUT request with content reference 52 to the content sharing server 34 .
[0058] In response to the request 52 , the content sharing server 34 sends an IMAP download request 54 to the message storage server 32 . The IMAP download request 54 is similar to the request 42 of the message sequence 40 , except that the request 54 is sent from the content sharing server 34 (the eventual destination of the requested content) and not the client 4 . In response to the request 54 , the message storage server 32 provides the requested content in message 56 . The message 56 is similar to the message 44 , again, with the exception of the destination of the message.
[0059] In response to the message 56 , the content sharing server issues an OK message 58 to the client 4 .
[0060] Thus, as in the message sequence 40 , the message storage server 32 receives an IMAP request and the content sharing server 34 receives an HTTP request.
[0061] The HTTP PUT request with content reference 52 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-type: message/external-body; access-type=URL;
URL=“imap://MyMessageStorageServer.operator.net/ivo.sedlacek@
operator.net/MyFolder/MyMail/MyAttachment”
[0062] Executing the request 52 results in a file being created or replaced at the location given by the URL:
http://myMediaStorage.operator.net/home/ivo/MyHelloWorld.txt
using the attachment stored at:
[0000]
imap://MyMessageStorageServer.operator.net/ivo.sedlacek@operator
.net/MyFolder/MyMail/MyAttachment
[0064] Upon receipt of the request 52 , the content sharing server 34 uses an integrated IMAP client to fetch the content identified by the IMAP uniform resource indicator (URI) (imap://MyMessageStorageServer.operator.net/ivo.sedlacek@operator.net/MyFolder/MyMail/MyAttachment) from the message storage server 32 and store it in the specified location of the content sharing server (steps 54 and 56 as discussed above). In order to do so, the content sharing server 34 must include an integrated IMAP client. In other words, the content sharing server needs to know how to handle IMAP URIs.
[0065] FIG. 6 shows a message sequence 60 in accordance with an aspect of the present invention. The message sequence 60 begins with the client 4 issuing an HTTP PUT request with content reference 62 to the content sharing server 34 .
[0066] In response to the request 62 , the content sharing server 34 sends an HTTP GET request 64 to the message storage server 32 . The GET request 64 initiates a download of the relevant content from the message storage server 32 and is therefore similar to the IMAP download request 54 described above with reference to FIG. 5 . In response to the request 64 , the message storage server 32 provides the requested content in message 66 . The message 66 is similar to the message 56 described above.
[0067] In response to the message 66 , the content sharing server issues an OK message 68 to the client 4 .
[0068] The HTTP PUT request with content reference 62 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-type: message/external-body;access-
type=URL;URL=“http://MyMessageStorageServer.operator.net:1234
5/CPMRedirector?TakeFrom=imap%3A%2F%2FMyMessageStorageServer.
operator.net%2Fivo.sedlacek@operator.net%2FMyFolder%2FMyMail%
2FMyAttachment”
[0069] Executing the request 62 results in a file being created or replaced at the location given by the URL:
http://myMediaStorage.operator.net/home/ivo/MyHelloWorld.txt
using the attachment stored at:
[0000]
imap://MyMessageStorageServer.operator.net/ivo.sedlacek@operator
.net/MyFolder/MyMail/MyAttachment
[0071] The HTTP GET request 64 differs from the IMAP request 54 described above in that it is an HTTP request and not an IMAP request. An IMAP request is not possible, since, in this example, it is assumed that the content sharing server 34 is not able to issue an IMAP request, for example because the content sharing server 34 does not contain an integrated IMAP client. The HTTP GET request 64 specifies the base URI of the message storage server 34 as follows:
[0000]
http://MyMessageStorageServer.operator.net:12345/CPMRedirector?
TakeFrom=
[0072] The location of the requested content is provided in the TakeFrom parameter of the HTTP GET request 64 thus:
[0000]
imap://MyMessageStorageServer.operator.net/ivo.sedlacek@operator
.net/MyFolder/MyMail/MyAttachment
[0073] Provided the message storage server 32 is able to understand HTTP requests, the message sequence 60 can be used, since the message storage server is able to use the TakeFrom parameter of the HTTP GET request 64 to access the content requested by the content sharing server.
[0074] FIG. 7 shows a message sequence 70 in accordance with an aspect of the present invention. The message sequence 70 begins with the client 4 issuing an HTTP PUT request with content reference 72 to the content sharing server 34 . In response to the request 72 , the content sharing server 34 sends an HTTP GET request 73 to a different location on the content sharing server 34 .
[0075] This different location hosts a resource (such as a dedicated process) on the content sharing server 34 that is able to issue IMAP requests upon receiving HTTP requests and HTTP responses upon receiving IMAP responses.
[0076] The HTTP GET request 73 initiates a download of the relevant content from the message storage server 32 using an IMAP download request 74 . The request 74 is largely the same as the IMAP download request 54 described above with reference to FIG. 5 . In response to the request 74 , the message storage server 32 provides the requested content in message 76 . The message 76 is similar to the messages 56 and 66 described above (although it should be noted that the messages 56 and 76 are in response to an IMAP request, whereas the message 66 is in response to an HTTP request, and is therefore implemented differently).
[0077] In response to the message 76 , the content sharing server issues an OK message 77 to the originator of the request 73 . The content sharing server 34 then sends an OK message 78 to the client 4 .
[0078] The HTTP PUT request with content reference 72 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-type: message/external-body;access-type=URL;
URL=“http://myMediaStorage.operator.net:9876/IMAPFetcher?Take
From=imap%3A%2F%2FMyMessageStorageServer.operator.net%2Fivo.s
edlacek@operator.net%2FMyFolder%2FMyMail%2FMyAttachment”
[0079] The message sequence 70 differs from the message sequence 60 in that, in response to the HTTP PUT request with content reference 72 , an HTTP GET request is sent to a dedicated resource on the content sharing server, which itself sends an IMAP download request to the message storage server 32 . Thus, the message storage server 32 receives an IMAP request, without the original requesting part of the content sharing server needing to be able to issue an IMAP request. Thus, the dedicated resource of the content sharing server acts as a kind of adapter that receives an HTTP request and issues an IMAP request (and also receives an IMAP response and forwards an HTTP response). Thus, the message sequence 70 can be used in scenarios where it is not possible to issue the original request as an IMAP request and the message storage server is not able to process an HTTP request.
[0080] The message sequence 70 differs from the message sequence 50 in the use of the dedicated resource on the content sharing server.
[0081] FIG. 8 shows a message sequence 80 in accordance with an aspect of the present invention. The message sequence 80 begins with the client 4 issuing an HTTP PUT request with content reference 82 to the content sharing server 34 .
[0082] In response to the request 82 , the content sharing server 34 sends an HTTP GET request 84 to a third server 36 . The third server 36 may be referred to as an adapter. The third server/adapter 36 initiates a download of the relevant content from the message storage server 32 using an IMAP download request 86 . The request 86 is largely the same as the IMAP download requests 54 and 74 described above with reference to FIGS. 5 and 7 respectively. In response to the request 86 , the message storage server 32 provides the requested content in message 88 . The message 88 is similar to the messages 56 , 66 and 76 described above (although the messages 56 , 76 and 88 are in response to an IMAP request, whereas the message 66 is in response to an HTTP request, and is therefore implemented differently).
[0083] In response to the message 88 , the third server issues an OK message 90 , together with the requested content to the content sharing server 34 . Finally, the content sharing server 34 sends an OK message (message 92 ) to the client 4 .
[0084] The message sequence 80 differs from the message sequence 70 in that, whereas the HTTP GET request 73 is sent from the content sharing server 34 to another location on the same server (which location is able to issue IMAP requests), the HTTP GET request 84 is sent from the content sharing server 34 to the third server 36 . Thus, the third server 36 performs the function of the dedicated resource described above.
[0085] The HTTP PUT request with content reference 82 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-type: message/external-body;access-
type=URL;URL=“http://MyImapResolver.operator.net:12345/Resolv
eImapToHttp?TakeFrom=imap%3A%2F%2FMyMessageStorageServer.oper
ator.net%2Fivo.sedlacek@operator.net%2FMyFolder%2FMyMail%2FMy
Attachment”
[0086] In the message sequence 80 , the HTTP PUT request with content reference message 82 includes a base URI (providing the location of the third server) as follows:
[0000] http://MyImapResolver.operator.net:12345/ResolveImapToHttp?TakeFrom=
[0087] The provision of a base URI in the client enables the HTTP GET message 84 to be sent to the third server 36 . This arrangement is not essential.
[0088] The HTTP PUT request with content reference message 82 may be sent without including the base URI of the third server 36 . In such an arrangement, the content sharing server 34 may be pre-configured with the base URI of the third server 36 . (This contrasts with the embodiments described above, in which the client 4 may be pre-configured with the relevant base URI.)
[0089] Such an HTTP PUT request with content reference 82 may take the following form:
[0000]
PUT /home/ivo/MyHelloWorld.txt HTTP/1.1
Host: myMediaStorage.operator.net
Content-type: message/external-body; access-type=URL;
URL=“imap://MyMessageStorageServer.operator.net/ivo.sedlacek@
operator.net/MyFolder/MyMail/MyAttachment”
[0090] As discussed above, the content sharing server 34 is pre-configured to send the HTTP GET request 84 to the third server 36 , the URI of which is stored at the content sharing server 34 . The remainder of the message sequence 80 can proceed exactly as described above.
[0091] The HTTP PUT requests with content references 62 and 72 of the message sequences 60 and 70 respectively can be modified in similar ways.
[0092] For example, the HTTP PUT request with content reference 62 may omit the base URI of the message storage server 32 , with the content sharing server 34 being pre-configured to send the HTTP GET request 64 to the relevant resource on the message storage server 32 . Similarly, the HTTP PUT request with content reference 72 may omit the base URI of the resource on the content sharing server, with the content sharing server 34 being pre-configured to send the HTTP GET request 73 to the relevant resource on the content sharing server 34 .
[0093] In the various embodiments of the invention described above, the HTTP PUT requests with content reference 52 , 62 , 72 and 82 are described as being issued by the client 4 . Of course, in practice, those HTTP PUT requests may be issued by the message and media storage client 8 of the client 4 .
[0094] Many of the embodiments described above make use of the IMAP protocol to obtain data from the message storage server. This is not essential. For example, other protocols, such as FTP and gopher, could be used to obtain data instead of IMAP.
[0095] In the embodiments of the invention described above, the message storage server is described as being an IMAP server. This is not essential. For example, the principles of the invention can be used to copy files between two HTTP servers.
[0096] The content sharing server 34 is generally referred to above as an HTTP server. This is not essential. For example, the content sharing server 34 may also be a WebDAV server.
[0097] The embodiments of the invention described above are illustrative rather than restrictive. It will be apparent to those skilled in the art that the above devices and methods may incorporate a number of modifications without departing from the general scope of the invention. It is intended to include all such modifications within the scope of the invention insofar as they fall within the scope of the appended claims.
|
Arrangements for forwarding content from a message storage server to a content sharing server of a Converged IP Messaging (CPM) system are described. An HTTP PUT request is issued by a user/client to the content sharing server, with the request identifying the location of the content on the message storage server. In response to the HTTP PUT request, the content sharing server issues a request, such as an IMAP download request, to the message storage server (either directly or via an intermediary). In response, the message storage server provides the content, without that content being sent to the user device.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of international patent application no. PCT/EP01/00155, filed Jan. 9, 2001, designating the United States of America, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. 100 02 509.9, filed Jan. 21, 2000.
FIELD OF THE INVENTION
[0002] The invention concerns substituted glutarimides having the general formula I
[0003] their production and their use in medicaments.
BACKGROUND OF THE INVENTION
[0004] Autoimmune diseases arise as a result of a reactivity of the immune system against structures or components occurring naturally in the body. As part of this process, the normally existing tolerance towards the body's own tissue lapses. In addition to antibodies, T-lymphocytes and monocytes/macrophages in particular play a significant role in the pathogenesis of the various autoimmune diseases. Activated monocytes and/or macrophages secrete a number of different proinflammatory mediators that are directly or indirectly responsible for destroying the tissue affected by the autoimmune disease. The activation of monocytes/macrophages occurs either in the interaction with T-lymphocytes or via bacterial products such as lipopolysaccharide (LPS).
[0005] IL-12 is a heterodimeric molecule consisting of a covalently bonded p35 and p40 chain. The molecule is formed by antigen-presenting cells (monocytes/macrophages, dendritic cells, B-lymphocytes). The formation of IL-12 by monocytes/macrophages is triggered either by various microbial products such as LPS, lipopeptides, bacterial DNA or in the interaction with activated T-lymphocytes (Trinchieri, 1995, Ann. Rev. Immunol. 13: 251). IL-12 has a central immunoregulatory significance and is responsible for the development of proinflammatory TH1 reactivities. The presence of a TH1 immune reaction against self-antigens leads to the occurrence of serious diseases.
[0006] The significance of inflammatory cytokines such as IL-12 for the development and course of inflammations and autoimmune diseases has been clearly documented by numerous animal experimental and preliminary clinical trials. The pathophysiological importance of IL-12 has been demonstrated in various animal models for diseases such as rheumatoid arthritis, multiple sclerosis, diabetes mellitus and inflammatory diseases of the intestines, skin and mucous membranes (Trembleau et al., 1995, Immunol. Today 16: 383; Muller et al., 1995, J. Immunol. 155: 4661; Neurath et al., 1995, J. Exp. Med. 182: 1281; Segal et al., 1998, J. Exp. Med. 187: 537; Powrie et al., 1995, Immunity 3: 171; Rudolphi et al., 1996, Eur. J. Immunol. 26: 1156; Bregenholt et al., 1998, Eur. J. Immunol. 28: 379). Application of IL-12 could trigger the relevant disease and neutralisation of endogenous IL-12 led to the course of the disease being moderated, or even the cure of the animals. The use of antibodies against IL-12 in humans is imminent.
[0007] It can be said in summary that an excess of IL-12 conditions the pathophysiology of a number of inflammatory diseases. Attempts to normalize the IL-12 level therefore have great therapeutic potential.
[0008] IL-12 is also involved in regulating the survival of cells. Uncontrolled cell growth is regulated by apoptosis (programmed cell death) amongst other things. Using T-lymphocytes it has been shown that IL-12 has an anti-apoptotic action and promotes the survival of T-cells (Clerici et al., 1994, Proc. Natl. Acad. Sci. USA 91: 11811; Estaquier et al., 1995, J. Exp. Med. 182: 1759). A local overproduction of IL-12 can therefore contribute to the survival of tumour cells.
[0009] Inhibitors of IL-12 formation therefore possess great therapeutic potential.
[0010] One potential inhibitor of IL-12 formation is the known active agent thalidomide (Journal of Immunology 159 (10), 5157-5161 (1997)).
[0011] U.S. Pat. No. 5,114,937 describes renin-inhibiting peptide derivatives, the carboxamide groups in which are replaced by their isosteres. The compounds are suitable for the treatment of renin-associated hypertension, congestive heart failure, hyperaldosteronism, glaucoma and diseases caused by the retroviruses HTLV-I, -II and -III.
[0012] DE 198 43 793 describes substituted benzamides with immunomodulatory properties in which the ring-containing structural parts of the molecule are linked together by an amide bond. The disadvantage of the amide bond is its susceptibility to hydrolysis with an accompanying loss of action for the compound.
[0013] The object of the invention was therefore to develop new immunomodulators that are suitable for the treatment and/or prophylaxis of diseases caused by formation of the proinflammatory cytokine IL-12 and that at the same time display an improved hydrolytic stability.
DETAILED DESCRIPTION OF THE INVENTION
[0014] It has now been discovered that substituted glutarimides satisfy the above requirements.
[0015] The invention accordingly provides substituted glutarimides having the formula I
[0016] in which X denotes a group having the formula CH 2 —NH or S—CH 2 ,
[0017] R 1 stands for a carboxyl group; an ester group having the formula COOR 5 in which R 5 denotes an alkyl group (straight-chain or branched) with 1 to 6 carbon atoms or a benzyl radical; or an amide group having the formula CONR 6 R 7 , in which R 6 and R 7 are the same or different and represent hydrogen, an alkyl group (straight-chain or branched) with 1 to 6 Carbon atems (optionally substituted with the radical COOR 5 and/or a phenyl group), a phenyl radical or taken together with the N atom represent a hydrazide group, a pyrrolidine, piperidine or morpholine ring or stand for an amino group substituted with the radical CH(═O) or COR 5 , in which R 5 is as defined above, and
[0018] R 2 stands for hydrogen, an amino or nitro group,
[0019] and enantiomers, mixtures of enantiomers, racemates, diastereomers or mixtures of diastereomers thereof in the form of their bases or salts with physiologically compatible acids.
[0020] The following substituted glutarimides are particularly preferred:
[0021] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] benzoic acid,
[0022] 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl] benzoic acid,
[0023] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl]-N,N-diethylbenzamide,
[0024] (3S)-[2-morpholine-4-carbonyl)benzylamino]piperidine-2,6-dione,
[0025] {2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] benzoylamino} methyl acetate,
[0026] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] benzamide,
[0027] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl]-N-ethyl benzamide,
[0028] (3S)-[2-pyrrolidine-1-carbonyl)benzylamino] piperidine-2,6-dione,
[0029] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] benzoic acid hydrazide,
[0030] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl]-N-phenyl benzamide,
[0031] 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl]-N-phenyl benzamide,
[0032] 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl]-N,N-diethyl benzamide,
[0033] 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl] benzamide,
[0034] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] methyl benzoate,
[0035] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] benzyl benzoate,
[0036] 2-(2,6-dioxopiperidin-3-yl methyl sulfanyl) methyl benzoate,
[0037] N-{2-[2,6-dioxopiperidin-3-ylamino)methyl] phenyl} acetamide,
[0038] N-{2-[2,6-dioxopiperidin-3-ylamino)methyl] phenyl} formamide,
[0039] 3-(2,6-dioxopiperidin-3-yl methyl sulfanyl)-6-nitro methylbenzoate, and
[0040] 2-amino-5-(2,6-dioxopiperidin-3-yl methyl sulfanyl) methyl benzoate.
[0041] The present invention also provides methods for the production of compounds according to the invention having the general formula I.
[0042] Compounds having the general formula I can be obtained by cyclizing glutaric acid derivatives having the general formula II,
[0043] in which X, R 1 and R 2 have the same meaning as defined above for formula I, A stands for OH, B for NH 2 or NHOH, or vice versa, in the presence of activating reagents such as carbonyl diimidazole. If X in the compound having the formula I denotes a CH 2 —NH group, cyclization is preferably performed with compounds having the formula II, in which the NH function is present in protected form, for example with a benzyl oxycarbonyl group, which is then removed at a temperature of between 20 and 40° C., e.g. with a solution of hydrogen bromide in acetic acid.
[0044] Heating a compound of formula II in which A and B both stand for OH in acetic anhydride, first produces a cyclization to the cyclic anhydride, from which the compound having formula I is obtained by heating with urea or another nitrogen source.
[0045] Compounds having the general formula I can also be produced from lactams having the general formula III,
[0046] in which R 1 , R 2 and X have the same meanings as defined above for formula I, by oxidizing compound III to an imide, preferably with m-chloroperbenzoic acid or ruthenium(IV) oxide/sodium periodate.
[0047] Compounds having the formula I, in which X stands for the CH 2 —NH group, can also be obtained by alkylating α-aminoglutarimides having the general formula IV,
[0048] with compounds having the general formula V,
[0049] in which R 1 and R 2 have the same meanings as above and Y stands for a chlorine, bromine or iodine atom or a toluene-4-sulfonate radical.
[0050] Compounds in which X stands for the CH 2 —NH group can also be obtained by reductive amination from compounds having the general formulae VI and IV, in which R 1 and R 2 have the same meanings as above.
[0051] Sodium borohydride, sodium triacetoxyborohydride, sodium cyanoborohydride, the borane-pyridine complex or catalytically excited hydrogen is preferably used as the reducing agent.
[0052] Compounds having the formula I where X is CH 2 —NH can also be obtained by alkylating a compound having the general formula VII,
[0053] in which R 1 and R 2 have the same meanings as above, with α-bromoglutarimide having the general formula VIII
[0054] Compounds having the general formula I, in which X stands for an S—CH 2 group, can be obtained by adding a mercaptan having the general formula X
[0055] to 3-methylene glutarimide having the general formula IX
[0056] The reaction is preferably performed in solvents such as acetonitrile or toluene with addition of tertiary amines such as triethylamine or diisopropyl ethylamine at temperatures of 80 to 110° C.
[0057] Compounds having the formula I, in which R 2 stands for an amino group, can generally be obtained by reduction of compounds having the formula I where R 2 ═NO 2 . The reduction is performed, for example, by catalytically excited hydrogen in acid-containing organic solvents such as ethyl acetate, whereby palladium catalysts are preferably used. Alternatively, the reduction can be performed with metals such as tin or iron in acid solution.
[0058] The compounds according to the invention possess immunomodulatory activity which is demonstrated by an inhibition of the production of IL-12 by LPS-activated monocytes. In comparison to compounds that have already been proposed, they also demonstrate an improved hydrolytic stability. They are suitable for the treatment and/or prophylaxis of inflammation and autoimmune diseases and also of haematological/oncological diseases.
[0059] Accordingly, the present invention also includes methods and pharmaceutical compositions for the treatment of these diseases. The method according to the invention comprises administering to a mammal, such as a human, in need thereof, an effective amount of a suitable pharmaceutical composition comprising a substituted glutarimide of the invention.
[0060] The above groups of diseases include, amongst others, inflammations of the skin (e.g. atopic dermatitis, psoriasis, eczema), inflammations of the respiratory tracts (e.g. bronchitis, pneumonia, bronchial asthma, ARDS (adult respiratory distress syndrome), sarcoidosis, silicosis/fibrosis), inflammations of the gastrointestinal tract (e.g. gastroduodenal ulcers, Crohn's disease, ulcerative colitis), and diseases such as hepatitis, pancreatitis, appendicitis, peritonitis, nephritis, aphthosis, conjunctivitis, keratitis, uveitis, and rhinitis.
[0061] The autoimmune diseases include, for example, arthritic diseases (e.g. rheumatoid arthritis, HLA-B27-associated diseases), Behcet's disease, and multiple sclerosis, juvenile diabetes or lupus erythematosus.
[0062] Further indications are sepsis, bacterial meningitis, cachexia, transplant rejection reactions, graft-versus-host reactions as well as reperfusion syndrome and atherosclerosis along with angiopathies (such as macula degeneration, diabetic retinopathies).
[0063] The symptoms that can be inhibited by a reduction in IL-12 also include haematological diseases such as multiple myeloma and leukaemias, along with other oncological diseases such as glioblastoma, prostate cancer and mammary cancer.
[0064] Medicaments according to the invention contain, in addition to at least one compound having the general formula I, carriers, fillers, solvents, diluents, dyestuffs and/or binders. The choice of auxiliaries and the quantities to be used depend on whether the medicament is to be administered by oral, rectal, ophthalmic (intravitreal, intracameral), nasal, topical (including buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous, intradermal, intratracheal and epidural) means.
[0065] Preparations in the form of tablets, chewable tablets, sugar-coated tablets, capsules granules, drops, liquids or syrups are suitable for oral administration, while solutions, suspensions, easily reconstituted dry preparations and sprays are suitable for administration by parenteral or topical means or by inhalation. Cutaneous administration forms are salves, gels, creams and pastes. Ophthalmic administration forms include drops, salves and gels. Compounds according to the invention contained in a reservoir in dissolved form, a carrier film or a plaster, optionally with the addition of skin-penetrating agents, are examples of suitable percutaneous administration forms. The compounds according to the invention can be released on a delayed basis from oral or percutaneous forms of preparation.
[0066] The amount of active agent to be administered to patients varies according to the weight of the patient, the type of administration, the indication and the severity of the disease. 1 to 150 mg/kg of at least one compound according to the invention having the formula I are conventionally administered.
EXAMPLES
[0067] The following examples serve to describe the present invention in greater detail, and should not be construed to limit the invention in any way.
[0068] Silica gel 60 (0.040-0.063 mm) from E. Merck, Darmstadt, was used as stationary phase for the chromatographic separations. The mixing ratios of the eluents are always given as percentages by volume.
[0069] The substances were characterised by their melting point and/or the 1 H-NMR spectrum. The spectra were recorded at 300 MHz using a Gemini 300 device from Varian. The chemical shifts are given in ppm (δ-scale). Tetramethyl silane (TMS) was used as internal standard.
Example 1
3-(2-chlorobenzylamino) Piperidine-2,6-dione; Hydrochloride
[0070] Step 1:
[0071] 3-bromopiperidine-2,6-dione
[0072] 4.5 ml bromine were added to 10.2 g glutarimide suspended in 20 ml chloroform and the mixture was stirred in a closed vessel for 90 minutes at a bath temperature of 110° C. After cooling, the vessel was opened and stirring was continued until no more hydrogen bromide escaped. The reaction mixture was evaporated in vacuo, the residue dissolved in ethanol and evaporated again. 17.1 g (99% of theoretical) of the title compound remained in the form of practically white crystals, which melted at 76 to 83° C.
[0073] Step 2:
[0074] 3-(2-chlorobenzylamino) Piperidine-2,6-dione; Hydrochloride
[0075] A solution of 0.39 g of the product from step 1 and 0.71 g 2-chlorobenzylamine in 8 ml N,N-dimethylformamide was stirred for 36 hours at 20° C. After evaporation in vacuo the oily residue was dissolved in 25 ml methanol and the solution stirred for two hours with 1 g Amberlyst A-21. It was filtered, 2 g silica gel were added to the filtrate and it was evaporated until dry. The adsorbed substance was placed in a chromatography column and the product was eluted with a mixture of ethyl acetate/cyclohexane (1/2->1/1) containing 1% triethylamine. The residue remaining after evaporation of the product fractions was dissolved in 10 ml methanol and 25 ml each of diethyl ether saturated with hydrogen chloride and diethyl ether were added to the solution. The precipitated hydrochloride was separated off and recrystallised from methanol/diethyl ether. 0.24 g (41% of theoretical) of the title compound were obtained in the form of crystals, which melted at 217° C. with decomposition.
[0076] [0076] 1 H-NMR (DMSO-d 6 ): 2.15-2.34 (1H, m); 2.40-2.56 (1H, m); 2.60-2.80 (2H, m); 4.35 (1H, t, J=13.5 Hz); 4.45 (2H, d, J=13.8 Hz); 7.40-7.94 (4H, m).
Example 2
[0077] Using the procedure described in Example 1, step 2 and the corresponding benzylamines, the following compounds were obtained in the same way:
[0078] 2.1: 3-(2-trifluoromethyl Benzylamino) Piperidine-2,6-dione; Hydrochloride
[0079] Melting point: >250° C. (decomposition)
[0080] 2.2: 3-(2,4-dimethoxybenzylamino) Piperidine-2,6-dione; Hydrochloride
[0081] Melting point: 214° C. (decomposition)
[0082] 2.3: 3-(2,6-difluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0083] Melting point: 208-215° C. (decomposition)
[0084] 2.4: 3-(2,5-difluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0085] Melting point: 208° C. (decomposition)
[0086] 2.5: 3-(3,5-difluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0087] Melting point: 230-236° C. (decomposition)
[0088] 2.6: 3-[(naphth-1-ylmethyl)amino] piperidine-2,6-dione; Hydrochloride
[0089] Melting point: 188° C. (decomposition)
[0090] 2.7: 3-(2,3-difluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0091] Melting point: 206-212° C. (decomposition)
[0092] 2.8: 3-(4-dimethylaminobenzylamino) Piperdine-2,6-dione; Base
[0093] 2.9: 3-(4-nitrobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0094] 2.10: 3-(3-trifluoromethylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0095] 2.11: 3-(3-trifluoromethoxybenzylamino) Piperdine-2,6-dione; Hydrochloride
[0096] Melting point: 199-201° C.
[0097] 2.12: 3-[(naphth-2-ylmethyl)amino] piperidine-2,6-dione, Base
[0098] Melting point: 120-125° C. (decomposition)
[0099] 2.13: 3-(2-chloro-4-fluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0100] Melting point: 241-242° C.
[0101] 2.14: 3-(3-nitrobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0102] Melting point: from 240° C. with decomposition
[0103] 2.15: 3-(2-chloro-6-methylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0104] Melting point: 238-240° C.
[0105] 2.16: 3-(2-methylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0106] Melting point: 235-240° C.
[0107] 2.17: 3-(3,5-dichlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0108] Melting point: 234-238° C.
[0109] 2.18: 3-[3-fluoro-5-(trifluoromethyl) Benzylamino] piperidine-2,6-dione; Hydrochloride
[0110] Melting point: 241-243° C.
[0111] 2.19: 3-(3-fluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0112] Melting point: 231-235° C.
[0113] 2.20: 3-(3-methylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0114] Melting point: 240-242° C.
[0115] 2.21: 3-(4-trifluoromethylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0116] Melting point: 252-255° C.
[0117] 2.22: 3-[4-fluoro-2-(trifluoro Methyl) Benzylamino] Piperidine-2,6-dione; Hydrochloride
[0118] Melting point: from 241° C. with decomposition
[0119] 2.23: 3-(4-fluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0120] Melting point: 241-242° C.
[0121] 2.24: 3-(4-tert-butylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0122] Melting point: from 239° C. with decomposition
[0123] 2.25: 3-(3,5-dimethylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0124] Melting point: from 226° C. with decomposition
[0125] 2.26: 3-(3-chlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0126] Melting point: 237-238° C.
[0127] 2.27: 3-(4-methoxybenzylamino) Piperdine-2,6-dione; Hydrochloride
[0128] Melting point: from 227° C. with decomposition
[0129] 2.28: 3-(2,4-dichlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0130] Melting point: 240-242° C.
[0131] 2.29: 3-(2-fluorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0132] Melting point: 245-247° C.
[0133] 2.30: 3-(2-bromobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0134] Melting point: 244-246° C.
[0135] [0135] 2 . 31 : 3 -[2-fluoro-5-(trifluoromethyl) Benzylamino] Piperidine-2,6-dione; Hydrochloride
[0136] Melting point: from 251° C. with decomposition
[0137] 2.32: 3-(2,3-dichlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0138] Melting point: 246-248° C.
[0139] 2.33: 3-(3,4-dichlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0140] Melting point: 252-254° C.
[0141] 2.34: 3-[3,5-bis(trifluoromethyl) Benzylamino] Piperidine-2,6-dione; Hydrochloride
[0142] Melting point: 263-265° C.
[0143] 2.35: 3-(3-bromobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0144] Melting point: 229-232° C.
[0145] 2.36: 3-(4-trifluoromethoxybenzylamino) Piperdine-2,6-dione; Hydrochloride
[0146] Melting point: 253-255° C.
[0147] 2.37: 3-(4-chlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0148] Melting point: 262-265° C.
[0149] 2.38: 3-(4-methylbenzylamino) Piperdine-2,6-dione; Hydrochloride
[0150] Melting point: 256° C. with decomposition
[0151] 2.39: 3-(2-ethoxybenzylamino) Piperdine-2,6-dione; Hydrochloride
[0152] Melting point: 208-212° C.
[0153] [0153] 2 . 40 : 3 -(2,5-dichlorobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0154] Melting point: 242-246° C.
[0155] 2.41: 3-(3-methoxybenzylamino) Piperdine-2,6-dione; Hydrochloride
[0156] Melting point: 217-219° C.
[0157] All compounds listed under 2.1 to 2.41 are in the form of the racemate.
Example 3
3-(3-aminobenzylamino) Piperdine-2,6-dione; Hydrochloride
[0158] 0.56 g of the product from example 2.14 in a mixture consisting of 17 ml ethyl acetate and 0.85 ml 6N hydrochloric acid were hydrogenated at 20° C. under a pressure of 4 bar over 0.17 g palladium on activated carbon (10% Pd). After consumption of the theoretical amount of hydrogen, the mixture was filtered off from the catalyst and the filtrate evaporated in vacuo. After recrystallisation of the residue from methanol, 0.25 g (50% of theoretical) of the racemic title compound were obtained in the form of slightly colored crystals, which melted at 236-239° C.
[0159] [0159] 1 H-NMR (DMSO-d 6 ): 2.05-2.20 (m, 1H); 2.28-2.39 (m, 1H); 2.55-2.74 (m, 2H); 3.97-4.12 (q, 2H); 4.18-4.28 (m, 1H); 6.58-6.70 (m, 3H); 7.02-7.11 (m, 1H).
Example 4
[0160] Using the procedure described in Example 1, step 2 and the corresponding arylalkylamines, the following compounds were obtained in the same way:
[0161] 4.1: 3-phenethylaminopiperidine-2,6-dione; Hydrochloride
[0162] Melting point: from 220° C. with decomposition
[0163] 4.2: 3-[2-(2-chlorophenyl) Ethylaminopiperidine-2,6-dione; Hydrochloride
[0164] Melting point: 230° C. (decomposition)
[0165] 4.3: 3-(4-phenylbutylamino) Piperdine-2,6-dione; Hydrochloride
[0166] Melting point: from 231° C. with decomposition
[0167] 4.4: 3-(N-benzyl-N-methylamino) Piperdine-2,6-dione; Base
[0168] Melting point: 95-115° C.
[0169] 4.5: 3-(methylnaphth-1-yl Methylamino) Piperdine-2,6-dione; Base
[0170] Melting point: 157-162° C.
[0171] All compounds listed under 4.1 to 4.5 are in racemic form.
[0172] 4.6: (2S)-[(3S) or (3R)-(2,6-dioxopiperidin-3-ylamino)] Methyl Phenylacetate; Hydrochloride
[0173] Melting point: 200-207° C.
[0174] 4.7: (2R)-[(3S) or (3R)-(2,6-dioxopiperidin-3-ylamino)] Methyl Phenylacetate; Hydrochloride
[0175] Melting point: 171-177° C. (decomposition)
[0176] 4.8: (2S)-[(3R,S)-(2,6-dioxopiperidin-3-ylamino)] -3-methyl Phenylpropionate; Hydrochloride
[0177] (Mixture of Diastereomers)
[0178] Melting point: 146-150° C. (decomposition)
Example 5
[0179] 3-benzylaminopiperidine-2,6-dione
[0180] A) A solution of 0.50 g 3-aminopiperidine-2,6-dione (K. Fickentscher, Arch. Pharm. 1974, 307, 840-844), 1.5 ml triethylamine and 0.4 ml benzyl bromide was stirred for 20 h at 20° C. It was then evaporated, the residue taken up in 50 ml aqueous potassium carbonate solution (10% K 2 CO 3 ) and the solution extracted twice with 40 ml ethyl acetate each. The organic phases were washed with 50 ml each of distilled water and saturated sodium chloride solution, dried over sodium sulfate and evaporated in vacuo. The residue was purified by flash chromatography on silica gel with a mixture of ethyl acetate/ cyclohexane (2/1) containing 1% triethylamine as eluent, whereby 0.21 g (26% of theoretical) of the title compound was obtained as viscous oil.
[0181] The title compound could also be obtained in the form of the hydrobromide as pure S enantiomer in the following way:
[0182] B) Step 1:
[0183] (2S)-(N-benzyl-N-benzyloxycarbonylamino)-4-carbamoyl Butanoic Acid
[0184] 0.6 ml benzyl chloroformate were added dropwise to 0.95 g (2S)-benzylamino-4-carbamoyl butanoic acid (E. Davidov et al., Isr. J. Chem. 1969, 7, 487-489) dissolved in 4 ml 2 M aqueous sodium hydroxide and 8 ml 1 M sodium hydrogen carbonate solution, over 2.5 h at 20° C. whilst being stirred. The mixture was then extracted twice with 20 ml diethyl ether each. The aqueous phase was acidified with conc. hydrochloric acid to pH 2-3 and extracted twice with 30 ml ethyl acetate each. The extracts were washed with distilled water, dried over sodium sulfate and evaporated in vacuo. After adding diethyl ether to the oily residue, 0.55 g (37% of theoretical) of the title compound were obtained in the form of colorless crystals, which melted at 98-99° C.
[0185] Step 2:
[0186] (3S)-(N-butyl-N-benzyloxycarbonylamino) Piperdine-2,6-dione
[0187] A solution of 0.162 g N,N-carbonyl diimidazole in 3 ml dry tetrahydrofuran was dripped into a solution of 0.37 g of the product from step 1 in 2.5 ml dry tetrahydrofuran. It was refluxed for 3.5 h then stirred for a further 3 h at 20° C. The oil remaining after evaporation of the solvent in vacuo was dissolved in ethyl acetate and the solution washed successively with 20 ml each of 1 M aqueous sodium hydrogen carbonate solution, saturated sodium chloride solution and distilled water. It was then dried over sodium sulfate and evaporated in vacuo. 0.23 g (65% of theoretical) of the title compound remained in the form of crystals, which melted at 51-52° C.
[0188] Step 3:
[0189] (3S)-benzylaminopiperidine-2,6-dione; Hydrobromide
[0190] The solution of 0.15 g of the product from step 2 in 3 ml of a solution of hydrogen bromide in acetic acid (33% HBr) was stirred for 1 h at 20° C. The reaction mixture was then poured onto 50 ml diethyl ether. The precipitate that was formed was separated off, washed with diethyl ether and dried in vacuo. 0.08 g (63% of theoretical) of the title compound remained in the form of crystals, which melted at 228-230° C. with decomposition.
[0191] 1H-NMR (DMSO-d 6 ): 2.01-2.43 (m, 2H); 2.60-2.80 (m, 2H); 4.20-4.45 (m, 3H); 7.40-7.60 (m, 5H).
Example 6
[0192] 6.1 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzoic Acid, Hydrobromide
[0193] Step 1:
[0194] 2-[(1S)-(3-carbamoyl-1-carboxypropylamino)methyl] Benzoic Acid
[0195] A suspension of 1.65 g 2-formylbenzoic acid in 5 ml ethanol and 5 ml 2 M sodium hydroxide solution was added to a solution of 1.46 g L-glutamine in 5 ml of a 2 M aqueous sodium hydroxide solution. After stirring for 1 h at 20° C., the mixture was cooled to 0° C. and 0.25 g sodium borohydride were added in portions over 15 min with vigorous stirring. After 90 min a further 0.33 g 2-formyl benzoic acid and 0.05 g sodium borohydride were added. After stirring for 16 h at 20° C., the reaction mixture was acidified with conc. hydrochloric acid to pH 2 and cooled to 0° C. The precipitate formed was separated off, washed with acetone and dried in vacuo. 0.87 g (31% of theoretical) of the title compound remained in the form of crystals, which melted at 132-133° C.
[0196] Step 2:
[0197] 2-{(1S)-[N-benzyloxycarbonyl-N-(3-carbamoyl-1-carboxypropyl)amino] Methyl} Benzoic Acid
[0198] Using the procedure described in Example 5 B, step 1, the title compound was obtained in the same way from the product from step 1 in the form of crystals, which melted with decomposition at 103-104° C.
[0199] Step 3:
[0200] 2-{(3S)-[N-benzyloxycarbonyl-N-(2,6-dioxopiperidin-3-yl)amino] Methyl} Benzoic Acid
[0201] Using the procedure described in Example 5 B, step 2, the title compound was obtained in the same way from the product from step 2 in the form of crystals, which melted at 71-73° C.
[0202] Step 4:
[0203] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzoic Acid, Hydrobromide
[0204] Using the procedure described in Example 5B, step 3, the title compound was obtained in the same way from the product from step 3 in the form of colorless crystals, which melted at 158-161° C.
[0205] [0205] 1 H-NMR (DMSO-d 6 ): 2.00-2.25 (m, 1H); 2.35-2.95 (m, 1H); 2.60-2.80 (m, 2H); 4.35-4.50 (m, 1H); 4.50-4.70 (m, 2H); 7.50-7.75 (m, 3H); 8.00-8.10 (m, 1H).
[0206] 6.2 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzoic Acid; Hydrobromide
[0207] Replacing L- by D-glutamine in Example 6.1, step 1, and using the procedure described in Example 6.1, the title compound was obtained in the same way in the form of crystals, which melted at 148-152° C.
Example 7
2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] -N,N-diethylbenzamide; Hydrobromide
[0208] Step 1:
[0209] (3S)-[N-(2-diethylcarbamoylbenzyl)-N-benzyloxycarbonyl] Aminopiperidine-2,6-dione
[0210] A solution of 1.00 g of the product from Example 6.1, step 3, 0.27 g N-methyl morpholine and 0.46 g 2-chloro-4,6-dimethoxy-1,3,5-triazine in 7 ml dry tetrahydrofuran was stirred for 1 h at 20° C. After adding 0.19 g diethylamine, stirring was continued for a further 7 h. The solution was then diluted with chloroform to a volume of 50 ml and washed successively with 25 ml 0.05 N hydrochloric acid, 25 ml 1 M aqueous sodium hydrogen carbonate solution and saturated sodium chloride solution. The organic phase was dried over sodium sulfate and evaporated in vacuo. After purifying the residue by flash chromatography on silica gel with ethyl acetate/cyclohexane (9/1) as eluent, 0.36 g (32% of theoretical) of the title compound were obtained in the form of crystals, which melted at 65-66° C.
[0211] Step 2:
[0212] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] -N,N-diethylbenzamide; Hydrobromide
[0213] 0.30 g of the product from step 1 were reacted as described in Example 5B, step 3 with 3 ml of a solution of hydrogen bromide in acetic acid (33% HBr). After working up and purification by recrystallisation from methanol/diethyl ether, 0.175 g (66% of theoretical) of the title compound were obtained in the form of crystals, which melted at 119-120° C.
[0214] [0214] 1 H-NMR (DMSO-d 6 ): 1.06 (t, J=7.5 Hz, 3H); 1.21 (t, J=6.9 Hz, 3H); 2.04-2.24 (m, 1H); 2.28-2.46 (m, 2H); 2.58-2.80 (m, 2H); 3.19 (dd, 2H); 3.51 (dd, 2H); 4.24 (s, 2H); 4.25-4.40 (m, 1H); 7.44 (d, 1H); 7.48-7.66 (m, 2H); 7.72 (d, 1H).
Example 8
[0215] By replacing diethylamine in Example 7, step 1, by other amines, ammonia or hydrazine and using the additional procedure described in Example 7, the following were obtained in the same way:
[0216] 8.1: (3S)-[2-morpholine-4-carbonyl)benzylamino] Piperidine-2,6-dione; Hydrobromide
[0217] Melting point: 133-135° C.
[0218] 8.2: {2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzoylamino} Methyl Acetate; Hydrobromide
[0219] Melting point: 121-123° C.
[0220] 8.3: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzamide; Hydrobromide
[0221] Melting point: 155-156° C. (decomposition)
[0222] 8.4: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] -N-ethyl Benzamide; Hydrobromide
[0223] Melting point: 144-146° C.
[0224] 8.5: (3S)-[2-pyrrolidine-1-carbonyl)benzylamino] Piperidin-2,6-dione; Hydrobromide
[0225] Melting point: 136-138° C.
[0226] 8.6: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzoic Acid Hydrazide; Hydrobromide
[0227] Melting point: 241-242° C.
[0228] 8.7: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] -N-phenylbenzamide; Hydrobromide
[0229] Melting point: 136-138° C.
[0230] 8.8: (2R)-{(3S)-2-[(2,6-dioxopiperidin-3-ylamino)methyl] Benzoylamino} Methyl Phenylacetate; Hydrobromide
[0231] Melting point: 149-151° C.
[0232] 8.9: (2S)-{(3S)-2-[(2,6-dioxopiperidin-3-ylamino)methyl] Benzoylamino} Methyl Phenylacetate; Hydrobromide
[0233] Melting point: 181-182° C.
[0234] 8.10: 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl]-N-phenyl Benzamide; Hydrobromide
[0235] Melting point: 168-171° C.,
[0236] 8.11: 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl] -N,N-diethyl Benzamide; Hydrobromide
[0237] Melting point: 128-132° C.
[0238] 8.12: 2-[(3R)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzamide; Hydrobromide
[0239] Melting point: 232-233° C.
Example 9
[0240] 9.1: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Methyl Benzoate; Hydrobromide
[0241] Step 1:
[0242] 2-{(3S)-[N-benzyloxycarbonyl-N-(2,6-dioxopiperidin-3-yl)amino]-methyl} Methyl Benzoate
[0243] A mixture consisting of 0.60 g of the product from Example 6.1, step 3, and 0.25 g N,N′-carbonyl diimidazole in 5 ml dry tetrahydrofuran was stirred for 1.5 h at 20° C. 64 μl methanol were then added and stirring was continued for a further 40 h at 20° C. After evaporating off the solvent in vacuo the residue was taken up in 80 ml chloroform and the solution washed with 1 M sodium hydrogen carbonate solution and distilled water. It was dried over sodium sulfate and evaporated in vacuo. After purification of the residue by column chromatography on silica gel with chloroform/acetone (94/6) as eluent, 0.32 g (51% of theoretical) of the title compound were obtained as a viscous oil.
[0244] Step 2:
[0245] 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Methyl Benzoate; Hydrobromide
[0246] By removing the benzyloxycarbonyl protective group in the product from step 1 using the procedure described in Example 5B, step 3, the title compound was obtained in the same way in the form of crystals, which melted at 187° C.
[0247] 1H-NMR (DMSO-d 6 ): 2.07-2.30 (m, 1H); 2.30-2.48 (m, 1H); 2.60-2.85 (m, 2H); 3.90 (s, 3H); 4.40-4.70 (m, 3H); 7.58-7.78 (m, 3H); 8.05 (d, J=8 Hz, 1H).
[0248] 9.2: 2-[(3S)-(2,6-dioxopiperidin-3-ylamino)methyl] Benzyl Benzoate; Hydrobromide
[0249] By replacing methanol with benzyl alcohol in Example 9.1 and using the procedure described therein, the title compound was obtained in the same way in the form of white crystals, which melted at 175-177° C.
Example 10
3-phenylaminomethyl Piperidine-2,6-dione
[0250] 30 ml absolute triethylamine and 2.75 ml freshly distilled aniline were added to a solution of 1.25 g 3-methylene piperidine-2,6-dione (M. J. Wanner and G.-J. Koomen, Tetrahedron Lett. 1992, 33, 1513-1516) in 100 ml acetonitrile and the mixture was stirred for 16 h at 80° C.
[0251] After cooling, 10 g silica gel were added and the mixture was evaporated in vacuo. The residue was purified by flash chromatography on silica gel with tert-butyl methyl ether/cyclohexane (2/1) as eluent. 1.87 g (86% of theoretical) of the title compound were obtained in the form of crystals, which melted at 137° C.
[0252] [0252] 1 H-NMR (CDCl 3 ): 1.84-1.99 (m, 1H); 2.08-2.17 (m, 1H); 2.49-2.64 (m, 1H); 2.73-2.83 (m, 2H); 3.41-3.50 (m, 1H); 3.60-3.70 (m, 1H); 6.64-6.80 (m, 3H); 7.17-7.29 (m, 2H).
Example 11
[0253] By replacing aniline in Example 10 by other amines and using the procedure therein described, whereby optionally the mixture of toluene/diisopropyl ethylamine was also used instead of the solvent system acetonitrile/triethylamine at a reaction temperature of 110° C., the following compounds could be obtained in the same way:
[0254] 11.1: 3-[(4-bromophenylamino)methyl] Piperidine-2,6-dione
[0255] Melting point: 149-150° C.
[0256] 11.2: 3-[(3-trifluoromethyl Phenylamino)methyl] Piperidine-2,6-dione
[0257] Melting point: 135-138° C.
[0258] 11.3: 3-(naphth-1-ylaminomethyl) Piperidine-2,6-dione
[0259] Melting point: 145-148° C.
[0260] 11.4: 3-(biphenyl-4-ylaminomethyl) Piperidine-2,6-dione
[0261] Melting point: 135-138° C.
[0262] 11.5: 3-[(3-methoxyphenylamino)methyl] Piperidine-2,6-dione
[0263] Viscous
[0264] 11.6: 3-[(4-trityl Phenylamino)methyl] Piperidine-2,6-dione
[0265] Melting point: 221-225° C.
[0266] 11.7: 3-[(2,6-dioxopiperidin-3-ylmethyl)amino] Ethyl Benzoate
[0267] Viscous
[0268] 11.8: 3-(benzylaminomethyl) Piperidine-2,6-dione
[0269] Viscous
[0270] 11.9: 3-[(3-acetyl Phenylamino)methyl] Piperidine-2,6-dione
[0271] Melting point: 129-132° C.
[0272] 11.10: 3-[(N-methyl-N-phenylamino)methyl] Piperidine-2,6-dione
[0273] Melting point: 132-134° C.
[0274] 11.11: 3-{[(naphth-1-ylmethyl)amino]methyl} Piperidine-2,6-dione
[0275] Viscous
[0276] 11.12: 3-[(2-methoxyphenylamino)methyl] Piperidine-2,6-dione
[0277] Viscous
[0278] 11.13: 3-[(4-methoxyphenylamino)methyl] Piperidine-2,6-dione
[0279] Melting point: 131-134° C.
[0280] 11.14: (2S)-[(2,6-dioxopiperidin-3-ylmethyl)amino] -3-methyl Phenylpropionate
[0281] Viscous
[0282] 11.15: 2-[(2,6-dioxopiperidin-3-ylmethyl)amino] Benzamide
[0283] Melting point: 203-206° C.
[0284] 11.16: 3-[(4-acetylphenylamino)methyl] Piperidine-2,6-dione
[0285] Melting point: 160° C.
[0286] 11.17: 3-[(3-benzoyl phenylamino)methyl] Piperidine-2,6-dione
[0287] Melting point: 152-158° C.
[0288] 11.18: 4-[(2,6-dioxopiperidin-3-ylmethyl)amino] Methyl Benzoate
[0289] Melting point: 142-144° C.
Example 12
3-[(2-hydroxymethyl Phenylamino)methyl] Piperidine-2,6-dione
[0290] Step 1:
[0291] 3-{[2-tert-butyl Dimethyl Silanyloxymethyl)phenylamino] Methyl} Piperidine-2,6-dione
[0292] By replacing aniline in Example 10 by 2-(tert-butyl dimethyl silanyloxymethyl) phenylamine and using the procedure therein described, the title compound was obtained in the form of white crystals, which melted at 85-87° C.
[0293] Step 2:
[0294] 3-[(2-hydroxymethyl Phenylamino)methyl] Piperidine-2,6-dione
[0295] 5 ml of a 1 M solution of tetrabutyl ammonium fluoride trihydrate in tetrahydrofuran were added to a solution of 0.20 g of the product from step 1 in 5 ml tetrahydrofuran. It was stirred for 3 h at 20° C., evaporated in vacuo and the residue was purified by flash chromatography on silica gel with ethyl acetate as eluent. 0.12 g (85% of theoretical) of the title compound were obtained in the form of a yellowish oil.
Example 13
[0296] By replacing aniline in Example 10 by thiophenols or mercaptans and using the procedure therein described, the following were obtained in the same way:
[0297] 13.1: 3-phenylsulfanylmethyl Piperidine-2,6-dione
[0298] Melting point: 98° C.
[0299] 13.2: 3-phenethylsulfanylmethyl Piperidine-2,6-dione
[0300] Melting point: 78° C.
[0301] 13.3: 2-(2,6-dioxopiperidin-3-ylmethyl)sulfanyl) Methyl Benzoate
[0302] Melting point: 142-144° C.
[0303] 13.4: 3-benzylsulfanylmethyl Piperidine-2,6-dione
[0304] Melting point: 105-107° C.
[0305] 13.5: 3-(3-aminophenylsulfanylmethyl) Piperidine-2,6-dione
[0306] Melting point: 133-135° C.
[0307] 13.6: 5-(2,6-dioxopiperidin-3-ylmethylsulfanyl)-6-nitro Methylbenzoate
[0308] Melting point: 147-150° C.
Example 14
2-amino-5-(2,6-dioxopiperidin-3-ylmethylsulfanyl) Methyl Benzoate
[0309] The title compound was obtained in the same way by catalytic hydrogenation of the product from Example 13.6 over palladium on activated carbon (10% Pd) under the conditions described in Example 3.
[0310] Melting point: 164-167° C.
Example 15
3-phenylsulfanylmethyl-1-piperidin-1-ylmethyl Piperidine-2,6-dione
[0311] 0.52 ml aqueous formaldehyde solution (35%) and 0.43 ml piperidine were added to a solution of 1.20 g of the product from Example 13.1 in 30 ml ethanol. After being refluxed for 1 hour, the mixture was evaporated in vacuo. The residue was taken up in ethyl acetate and n-hexane was added to the solution until precipitation. The crystals were separated off and dried in vacuo. 1.23 g (74% of theoretical) of the title compound were obtained, which displayed a melting point of 63-66° C.
[0312] [0312] 1 H-NMR (DMSO-d 6 ): 1.37-1.47 (m, 6H), 1.72-1.88 (m, 1H), 2.08-2.16 (m, 1H), 2.21-2.33 (m, 4H), 2.49-2.57 (m, 1H), 2.70-2.82 (m, 1H), 3.07-3.18 (m, 1H), 3.28-3.33 (m, 1H), 3.47-3.56 (m, 1H), 4.56-4.69 (m, 2H), 7.17-7.25 (m, 1H), 7.28-7.39 (m, 4H).
Example 16
N-{2-[2,6-dioxopiperidin-3-ylamino)methyl] Phenyl} Acetamide; Hydrobromide
[0313] Step 1:
[0314] 2[(2-acetyl Aminobenzyl) Benzyloxycarbonylamino]-4-carbamoyl Butanoic Acid
[0315] 1.20 g N-(2-formyl phenyl) acetamide, dissolved in 10 ml methanol and 3.7 ml 1 N sodium hydroxide solution, were added to a solution of 0.98 g L-glutamine in 3.4 ml 2N sodium hydroxide solution, stirred for 30 minutes at 20° C. and cooled to 0° C. 0.31 g sodium borohydride were then added in portions with stirring over 30 minutes. Stirring was continued for 16 hours at 0 to 5° C. and 14.2 ml of a 1 N aqueous sodium hydrogen carbonate solution were then added. A solution of 1.4 ml benzyl oxycarbonyl chloride in 1.1 ml tetrahydrofuran and 2.5 ml 4N sodium hydroxide solution were then simultaneously added dropwise over one hour. Stirring was continued for 2 hours at 20° C. The neutral reaction solution was extracted three times with diethyl ether and the aqueous phase then adjusted to pH 1 to 2 with 1 N hydrochloric acid. It was then extracted three times with 20 ml ethyl acetate. The combined organic phases were washed with 20 ml saturated sodium chloride solution, dried over sodium sulfate and evaporated in vacuo. 0.93 g of the unpurified title compound were obtained, which were then reacted further.
[0316] Step 2:
[0317] (2-acetylaminobenzyl)-(2,6-dioxopiperidin-3-yl) Benzyl Carbamate
[0318] A solution of 0.36 g carbonyl diimidazole in 3 ml absolute tetrahydrofuran was added to a solution of 0.90 g of the product from step 1 in 6 ml anhydrous tetrahydrofuran. The mixture was refluxed for 4 hours. After evaporation of the solvent in vacuo, the residue was taken up in 50 ml distilled water and extracted three times with 50 ml ethyl acetate. The extracts were first washed three times with 50 ml water, then with saturated sodium chloride solution, dried over sodium sulfate and evaporated in vacuo. 0.25 g (11% of theoretical, relative to the L-glutamine used in step 1) of the title compound were obtained by flash chromatography on silica gel with ethyl acetate/cyclohexane (2/1).
[0319] Step 3:
[0320] N-{2-[(2,6-dioxopiperidin-3-ylamino)methyl] Phenyl} Acetamide; Hydrobromide
[0321] 1 ml of a solution of hydrogen bromide in glacial acetic acid (33% HBr) was added to a suspension of 0.20 g of the product from step 2 in 1 ml glacial acetic acid. The mixture was stirred for 1 hour at 20° C. and then poured into 100 ml diethyl ether. After cooling to 0 to 5° C. the solid that had formed was separated off, washed with diethyl ether and dried in vacuo. After reprecipitation from methanol/diethyl ether, 0.09 g (50% of theoretical) of the title compound were obtained.
[0322] Melting point: 152-156° C.
[0323] [0323] 1 H-NMR (DMSO-d 6 ): 2.05-2.22 (m, 1H); 2.13 (s, 3H); 2.35-2.74 (m, 1H); 2.69-2.74 (m, 2H); 4.26 (s, 2H); 4.43 (d, 1H); 7.33-7.60 (m, 4H); 9.88 (s, 1H); 11.41 (s, 1H).
Example 17
N-{2-[(2,6-dioxopiperidin-3-ylamino)methyl] Phenyl} Formamide; Hydrobromide
[0324] By replacing the acetamide derivative used in Example 16, step 1, with N-(2-formyl phenyl) formamide and using the procedure described in steps 1 to 3, the title compound was obtained in the same way.
[0325] Melting point: 169-174° C.
Example 18
3-(2,6-dioxopiperidin-3-yl Methyl Sulfanyl)-6-nitro Methylbenzoate
[0326] The title compound was produced using the procedure described in Example 10, by replacing the aniline with the corresponding mercaptan (formula X with R 1 ═COOCH 3 in the 3 position and R 2 ═NO 2 in the 4 position).
[0327] Melting point: 147-150° C.
Example 19
2-amino-5-(2,6-dioxopiperidin-3-yl Methyl Sulfanyl) Methyl Benzoate
[0328] The title compound was obtained in the same way by catalytic hydrogenation of the product from Example 18 over palladium on activated carbon (10% Pd) under the conditions described in Example 3.
[0329] Melting point: 164-167° C.
[0330] Stimulation of Human Monocytes with Lipopolysaccharide for Secretion of IL-12
[0331] Human monocytes were isolated from peripheral blood mononuclear cells (PBMC) obtained by means of a Ficoll density-gradient centrifugation of heparinized whole blood. To this end, the PBMC were incubated with a monoclonal antibody directed against the monocyte-specific surface molecule CD14 and to which superparamagnetic microbeads (Miltenyi Biotech, Bergisch Gladbach) are coupled. In order for the marked monocytes to be positively selected from the mixture of cells in the PBMC, the total cell suspension was transferred to a column with a ferromagnetic carrier matrix and the column placed in a magnetic field. This caused the cells loaded with microbeads to be bonded to the carrier matrix, whilst unmarked cells passed through the column and were discarded. After removing the matrix from the magnetic field, the antibody-loaded cells were eluted by rinsing the now demagnetised column with buffer. The purity of this CD14-positive monocyte population thus obtained was around 95 to 98%. These monocytes were incubated in a density of 10 6 cells/ml culture medium (RPMI, supplemented with 10% fetal calf serum) with the test substances dissolved in DMSO for one hour at 37° C. and 5% CO 2 . 20 μg/ml LPS from E. coli were then added. After 24 hours, cell-free culture supernatants were taken and tested for their IL-12 content.
[0332] The concentration of IL-12 in the cell culture supernatants was determined by means of sandwich ELISA using two anti-IL-12 monoclonal antibodies (Biosource Europe, Fleurus, Belgium). A reference standard curve with human IL-12 was included. The detection limit of the IL-12 ELISA was 10 pg/ml.
TABLE 1 Influence of the test substances on IL-12 production by LPS-activated monocytes. Inhibition of IL-12 production Example no. Maximum (%) IC50 (μg/ml) 6.1 85 1.0 6.2 75 1.0 9.1 90 0.1 9.2 82 1.5 8.3 90 0.15 8.12 84 1.0 7 90 1.5 8.11 90 0.2 8.1 90 1.8 8.5 80 2.0 8.4 80 0.9 8.7 55 0.7 8.10 50 — 8.6 90 0.04 8.2 70 1.8 13.3 50 6.0 16 95 3.0 17 98 0.02 18 57 3.0 19 66 5.0
[0333] The results set out in Table 1 show that the substituted glutarimides have an immunomodulatory action. They exert a potent inhibitory effect on the synthesis of IL-12 by LPS-activated monocytes.
[0334] The foregoing description and examples have been set forth merely to illustrate invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations falling within the scope of the appended claims and equivalents thereof.
|
Substituted glutarimides of formula I
and their method of making. Also disclosed are pharmaceutical compositions comprising the glutarimidie, particularly as immunomodulators and as inhibitors of angiopathies, or haematological or oncological diseases, as well as a method for treating various diseases using the glutarimides.
| 2
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 60/308,303 filed Jul. 27, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity. In further detail, the present invention relates to a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity, characterized in that it comprises a granulation product of sustained-release fine particles and one or two or more fillers selected from the group consisting of sugars or sugar alcohols granulated with binder for quick-disintegrating tablets in the buccal cavity, and in that the ratio of ungranulated sustained-release fine particles in the entire composition is 0 to 15%.
BACKGROUND OF THE INVENTION
[0003] The “sustained-release fine particles” of the present invention means fine particles that contain a drug, have been submitted to various types of sustained-release treatments, and have a mean particle diameter of approximately 0.1 μm to approximately 350 μm. The various types of sustained-release treatments means treatment to give the quality of “sustained release” that is well known pharmaceutically. Treatment that has given gradual drug releasability, treatment that has given gastrosolubility, treatment that has given enterosolubility, treatment that has given timed releasability, treatment that has given releasability that is a combination of these, and the like, can be given as examples. Moreover, those that have been given enterosolubility are called “enteric sustained-release fine particles.”
[0004] Various types of disintegrating tablets in buccal cavity were previously developed so that they could be easily taken, even without water, by persons with weak swallowing ability, including the elderly, children, and the like. Moreover, the demand for the use of an assortment of drugs in recent years has led to the need for providing the function of sustained releasability to quick-disintegrating tablets in the buccal cavity.
[0005] First-generation quick-disintegrating tablets in the buccal cavity, for instance, “Zydis™” marketed by R. P. Scherer, and the like, are known to be pharmaceutical preparations manufactured by lyophilization. These first-generation quick-disintegrating tablets in the buccal cavity are basically manufactured by lyophilization, or special drying, using a solution or suspension of the drug. Thus, the process of manufacture in a liquid state was essential, and there was no discussion of providing the function of sustained releasability.
[0006] Various second-generation quick-disintegrating tablets in the buccal cavity are known, including those that use the function of disintegrants (Japanese Kokai Patent No. Hei 10-182436, International Early Disclosure Pamphlet WO98/02185, and the like), those characterized in that a saccharide of high moldability is spray coated and/or granulated as binder on a saccharide of low moldability and which can be humidified and dried when tablet strength is further necessary (International Early Disclosure Pamphlet WO 95/20380 (corresponding U.S. Pat. No. 5,576,014, Japanese Patent No. 312141), and the like, and these are manufactured by tableting. Consideration has been given to quick-disintegrating tablets in the buccal cavity containing fine particles that have been sustained-release treated, for instance, coated by a polymer, in order to solve the apparent contradictory problem of providing the function of sustained releasability to these second-generation quick-disintegrating tablets in the buccal cavity. However, even though attempts have been made to simply mix fine particles that have been sustained-release treated with a filler for quick-disintegrating tablets in the buccal cavity and tablet this mixture, segregation occurs due to a difference in apparent specific gravity and a difference in fluidity between the filler and the sustained-release fine particles during the tableting process. The term “segregation” used here is the state where the sustained-release fine particles are not uniformly dispersed in the filler and segregation occurs when they are not uniformly dispersed. It is possible to confirm segregation by determining uniformity of content of drugs that comprise tablets once tablets have been made. For instance, it can be said that if the coefficient of variation (CV %) of the amount of drug, which is shown below, is 0 to 3.5%, segregation will not occur and if the coefficient of variation exceeds 3.5%, segregation will occur. Various problems are produced with this segregation as the cause. For instance, there are the problems of (1) tableting pressure being propagated directly to the sustained-release fine particles due to contact between the punch face and the sustained-release fine particles during tableting, or direct contact between sustained-release fine particles themselves, resulting in destruction of the sustained-release fine particles and acceleration of dissolution after they have been made into tablets, (2) the degree of destruction of the sustained-release fine particles varying with the degree of segregation and therefore, controlled dissolution, which is the design goal of sustained-release fine particle preparation, not being realized with good reproducibility after tablets are made, (3) there being fluctuations in the number of sustained-release fine particles contained in one tablet and it being impossible to guarantee uniformity of drug content, and the like.
[0007] An invention relating to a method of manufacturing spherical fine particles that are useful for manufacturing controlled-release pharmaceutical preparations that are easy to take by a special tumbling granulation method is disclosed in International Early Disclosure Pamphlet WO00/24379. This pamphlet gives a manufacturing method involving special tumbling granulation of these spherical fine particles and shows that dissolution is controlled by coating spherical fine particles and that these spherical fine particles can be used in quick-disintegrating tablets in the buccal cavity. However, our research has confirmed that the above-mentioned various problems occur and the purpose cannot be accomplished if quick-disintegrating tables in the buccal cavity simply contain spherical fine particles that have been sustained-release treated. Moreover, there is no disclosure or indication of specific means for dealing successfully with these problems in said specification.
[0008] Thus, although as yet unknown, there is a demand for introduction of quick-disintegrating tablets in the buccal cavity comprising sustained-release fine particles with which acceleration of the drug dissolution after being made into a tablet that is the result of destruction of sustained-release fine particles under tableting pressure when tablets are made is inhibited, and controlled dissolution, which is the design goal of sustained-release fine particle preparation, is realized with good reproducibility even after tablets are made, and with which uniformity of drug content is guaranteed.
BRIEF SUMMARY OF THE INVENTION
[0009] Under these circumstances, the inventors focused on studies of quick-disintegrating tablets in the buccal cavity comprising sustained-release fine particles and researched methods of preventing segregation of sustained-release fine particles and filler used in quick-disintegrating tablets in the buccal cavity, which is the source of various problems. As a result of repeating a variety of experiments, they successfully completed the present invention upon discovering that segregation of sustained-release fine particles and filler can be prevented by preparing a granulation product comprising sustained-release fine particles, several of which have aggregated together during this granulation process, using a granulation process whereby all or part of the surface of individual sustained-release fine particles is covered with filler. The “granulation” here means to make granules or powder the size and shape of which are virtually uniform. As a result of further detailed studies, it was discovered that segregation of sustained-release fine particles and filler is prevented when the ratio of ungranulated sustained-release fine particles in the entire composition that is eventually obtained is 0 to 15%. It had been thought that usually segregation readily occurs as a result of an increase in the difference in apparent specific gravity between the fine particles and filler and deterioration of fluidity of the fine particles, and the like, when several particles aggregate in this way. However, it was a complete surprise that it is possible not only to guarantee uniformity of content when making tablets, but to also simultaneously neutralize pressure during tableting by avoiding direct contact between the punch face and sustained-release fine particles, or the sustained-release fine particles themselves, and realize good reproducibility of controlled dissolution, which is the goal.
[0010] That is, the present invention relates to
[0011] 1. a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity, characterized in that it comprises the product of granulation of sustained-release fine particles containing a drug and one or two or more fillers selected from the group consisting of sugars or sugar alcohols with a binder for quick-disintegrating tablets in the buccal cavity, and in that the ratio of ungranulated sustained-release fine particles in the entire composition is 0 to 15%,
[0012] 2. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 1 , wherein the binder for quick-disintegrating tablets in the buccal cavity is one or two or more selected from the group consisting of saccharides of high moldability, water-soluble polymer substances, and saccharides with a low melting point,
[0013] 3. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 2 , wherein the sugar or sugar alcohol is one or two or more selected from the group consisting of saccharides with low moldability, saccharides with a high melting point, and saccharides with a low melting point,
[0014] 4. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 3 , wherein the mixture ratio of sustained-release fine particles, filler, and binder for quick-disintegrating tablets in the buccal cavity is 1 to 50%, 20 to 98%, and 1 to 30%, respectively,
[0015] 5. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 4 , wherein the mean particle diameter of the sustained-release fine particles is approximately 0.1 μm to approximately 350 μm,
[0016] 6. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 5 , wherein the sustained-release fine particles consist of at least crystal cellulose particles, drug, and polymer substance,
[0017] 7. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 6 , wherein the drug is tamsulosin hydrochloride,
[0018] 8. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 7 , wherein the sustained-release fine particles are enteric sustained-release fine particles,
[0019] 9. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 8 , wherein the polymer substance is hydroxypropylmethyl cellulose, ethyl cellulose, Eudragit L30D55, and Eudragit NE30D,
[0020] 10. the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 9 , wherein the binder for quick-disintegrating tablets in the buccal cavity is one or two or more selected from the group consisting of maltose, trehalose, sorbitol, and maltitol,
[0021] 11. quick-disintegrating tablets in the buccal cavity consisting of the composition comprising sustained-release fine particles of above-mentioned 10 ,
[0022] 12. the quick-disintegrating tablets in the buccal cavity of above-mentioned 11 , characterized in that the coefficient of variation (CV %) of the amount of drug, which is an indicator of uniformity of content, is 3.5% or less,
[0023] 13. a method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity, characterized in that it comprises the product of granulation of sustained-release fine particles containing a drug and one or two or more fillers selected from the group consisting of sugars or sugar alcohols with a binder for quick-disintegrating tablets in the buccal cavity, and in that the ratio of ungranulated sustained-release fine particles in the entire composition is 0 to 15%,
[0024] 14. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 13 , wherein the binder for quick-disintegrating tablets in the buccal cavity is one or two or more selected from the group consisting of saccharides of high moldability, water-soluble polymer substances, and saccharides with a low melting point,
[0025] 15. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 14 , wherein the sugar or sugar alcohol is one or two or more selected from the group consisting of saccharides with low moldability, saccharides with a high melting point, and saccharides with a low melting point,
[0026] 16. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 15 , wherein the mixture ratio of sustained-release fine particles, filler, and binder for quick-disintegrating tablets in the buccal cavity is 1 to 50%, 20 to 98%, and 1 to 30%, respectively,
[0027] 17. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 16 , wherein the mean particle diameter of the sustained-release fine particles is approximately 0.1 μm to approximately 350 μm,
[0028] 18. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 17 , wherein the sustained-release fine particles consist of at least crystal cellulose particles, drug, and polymer substance,
[0029] 19. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 18 , wherein the drug is tamsulosin hydrochloride,
[0030] 20. the method of manufacturing composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 19 , wherein the sustained-release fine particles are enteric sustained-release fine particles,
[0031] 21. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 20 , wherein the polymer substance is hydroxypropylmethyl cellulose, ethyl cellulose, Eudragit L30D55, and Eudragit NE30D,
[0032] 22. the method of manufacturing a composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of above-mentioned 21 , wherein the binder for quick-disintegrating tablets in the buccal cavity is one or two or more selected from the group consisting of maltose, trehalose, sorbitol, and maltitol,
[0033] 23. a method of manufacturing quick-disintegrating tablets in the buccal cavity consisting of the composition comprising sustained-release fine particles of above-mentioned 22 , and
[0034] 24. the method of manufacturing quick-disintegrating tablets in the buccal cavity of above-mentioned 23 , characterized in that the coefficient of variation (CV %) of the amount of drug, which is an indicator of uniformity of content, is 3.5% or less.
[0035] The “binder for quick-disintegrating tablets in the buccal cavity” of the present invention means of binders that are generally used, a binder that is particularly useful in the preparation of quick-disintegrating tablets in the buccal cavity, and a variety is selected in relationship with the “filler” of the present invention. The details are described below, including its embodiments.
[0036] The “ungranulated sustained-release fine particles” in the present invention means sustained-release fine particles that do not comprise granulation product when sustained-release fine particles are granulated together with filler using a binder for quick-disintegrating tablets in the buccal cavity. Moreover, the ratio of “ungranulated sustained-release fine particles” is calculated by the following formulas using the values from determination of particle diameter distribution of the sustained-release fine particles and quantitative ratio by particle diameter of the composition comprising sustained-release fine particles by the following methods:
Ratio of ungranulated sustained-release fine particles (%)= G 1 +Σ( G i+1 −( P i −G i ))
[0037] Here, the estimation of Σ is obtained by calculation from i=1 and estimating the value up to the point before (G i+1 −(P i −G i )) becomes negative.
[0038] P 1 : sustained-release fine particle ratio on sieve with smallest opening size within the particle diameter distribution of the sustained-release fine particles (with the exception of that where it is 0%).
[0039] P 2 : sustained-release fine particle ratio on sieve with second smallest opening size within particle diameter distribution of the sustained-release fine particles (with the exception of that where it is 0%). The third, fourth and so on are referred to as P 3 , P 4 , and so on, and they are as a whole represented as P 1 .
[0040] G 1 : value of quantitative ratio by particle diameter distribution of composition on sieve with the same opening size as P 1 .
[0041] G 2 :value of quantitative ratio by particle diameter distribution of composition on sieve with same opening size as P 2 ; the third, fourth, and so on are referred to as G 3 , G 4 , and so on, and they are as a whole represented as G 1 .
[0042] The “the ratio of ungranulated sustained-release fine particles in the total composition is brought to 15% or less” in the present invention in other words means that the ratio of sustained-release fine particles that are not granulated is low, that is, the majority of sustained-release fine particles are contained in each granulation product. Moreover, it also means that segregation of sustained-release fine particles and filler is inhibited.
[0043] “Granulation product” in the present invention means a granulation product consisting of sustained-release fine particles, filler, and binder for quick-disintegrating tablets in the buccal cavity, and granulation product that does not comprise sustained-release fine particles is defined in particular as “granulation product that does not comprise sustained-release fine particles.” That is, the specific form of the composition of the present invention is a mixture comprising “granulation product,” “ungranulated sustained-release fine particles,” and “granulation product that does not comprise sustained-release fine particles.”
[0044] Moreover, the quick-disintegrating tablets in the buccal cavity in the present invention indicates tablets with which disintegration time in the buccal cavity is 0 to 2 minutes, preferably 0 to 1 minute, and can be those disclosed in International Early Disclosure Pamphlet WO98/02185, International Early Disclosure Pamphlet WO95/20380, Kokai Patent No. Hei 10-182436, U.S. patent application Ser. No. 10/142,081 (corresponding International Patent Application No. PCT/JP02/04481), and the like.
[0045] Moreover, the “acceleration of dissolution of sustained-release fine particles is inhibited” and “controlled dissolution, which is the goal [of sustained-release fine particles], is realized” in the present invention means that there is not a difference between the dissolution rate of the sustained-release fine particles and the dissolution rate of the quick-disintegrating tablets in the buccal cavity. Specifically, when dissolution tests of sustained-release fine particles and quick-disintegrating tablets in the buccal cavity comprising the sustained-release fine particles are performed and drug dissolution of the sustained-release fine particles is compared, the difference between the dissolution rate of sustained-release fine particles and the dissolution rate of quick-disintegrating tablets in the buccal cavity is 0 to 15% at each dissolution time where drug dissolution of sustained-release fine particles is approximately 30%, approximately 50%, and approximately 80%. If the sustained-release fine particles are enteric sustained-release fine particles, the above-mentioned evaluation cannot be performed under conditions of a pH of 1.2, the difference between the dissolution rate of the enteric sustained-release fine particles and the dissolution rate of quick-disintegrating tablets in the buccal cavity two hours after starting the dissolution experiment is 0 to 10%.
[0046] Moreover, “good reproducibility” means that the same results are obtained, for instance, even with quick-disintegrating tablets in the buccal cavity prepared on a different occasion, when the difference between dissolution of quick-disintegrating tablets in the buccal cavity and dissolution of sustained-release fine particles comprising these tablets is compared as described above.
[0047] Moreover, the “coefficient of variation (CV %) of the amount of drug” in the present invention is an indicator of uniformity of content. Tests of uniformity of content described below are conducted and the CV % is calculated by the following formula:
CV %=(standard deviation of each content)/(mean content)×100
[0048] A “CV % of 0 to 3.5%” can be regarded as no segregation with few fluctuations in drug content of the tablets that have been prepared, and it can be said that “uniformity of drug content is guaranteed.” Moreover, a “CV % exceeding 3.5%” can be regarded as segregation with large fluctuations in drug content, and it can be said that “uniformity of content is poor.” Incidentally, a “CV % of 0 to 3.5%” is the appropriate range of the coefficient of variation in the present invention, the number that appears to be necessary for quality assurance and indicates that a composition with a constant drug content is obtained.
[0049] The composition comprising sustained-release fine particles of the present invention and manufacturing method thereof of the present invention will now be described in detail.
[0050] There are no particular restrictions to the drug used in the present invention as long as it is an active component requiring sustained releasability that is effective in terms of treatment or that is effective in terms of prevention. Examples of this drug are hypnotic sedatives, sleep-inducing agents, anti-anxiety drugs, anti-epilepsy drugs, antidepressants, anti-Parkinson's drugs, psychoneurotic drugs, central nervous system drugs, local anesthetics, skeletal muscle relaxants, autonomic nerve drugs, antipyretic analgesic anti-inflammatory agents, antispasmodics, anti-vertigo drugs, cardiotonics, drugs for arrhythmia, diuretics, hypotensives, vasoconstrictors, vasodilators, drugs for the circulatory system, drugs for hyperlipidemia, drugs to promote respiration, antitussives, expectorants, antitussive expectorants, bronchodilators, antidiarrheal agents, drugs for controlling intestinal function, drugs for peptic ulcer, stomachics, antacids, laxatives, cholagogues, gastrointestinal drugs, adrenocortical hormones, hormones, urogenital drugs, vitamins, hemostatics, drugs for liver disease, drugs used for gout, drugs used for diabetes, antihistamines, antibiotics, antibacterials, drugs used against malignant tumors, chemotherapeutic drugs, multisymptom cold medications, nutrition-enhancing health drugs, osteoporosis drugs, and the like. Examples of these drugs are anti-inflammatory, antipyretic antispasmodics or analgesics, such as indomethacin, diclofenac, diclofenac sodium, codeine, ibuprofen, phenylbutazone, oxyfenbutazone, mepirizole, aspirin, idensamide, acetaminophen, aminopyrine, phenacetin, butyl scopolamine bromide, morphine, etomidoline, pentazocine, fenoprofen calcium, naproxen, celecoxib, vardecoxib, tramadole, and the like, anti-rheumatic drugs, such as etodolac, and the like, anti-tuberculosis drugs, such as isoniazide, ethambutol chloride, and the like, drugs for the circulatory system, such as isosorbid nitrate, nitroglycerin, nifedipine, bardnidipine hydrochloride, nicardipine hydrochloride, dipyridamile, amrinone, indenolol hydrochloride, hydralazine hydrochloride, methyl dopa, furosemide, spironolactone, guanetidine nitrate, resperine, amosulalol hydrochloride, lisinoopril, methoprolol, pilocarbpine, tasosartan, and the like, psychoneurotic drugs, such as chlorpromazine hydrochloride, amitriptyline hydrochloride, nemonapride, haloperidole, moperone hydrochloride, perphenazine, diazepam, lorazepam, chlordiazepoxide, adinazolam, alprazolam, methylphenidate, milnasivran, peroxetin, risperidone, sodium valproate, and the like, antiemetics, such as methoclopramide, ramosetron hydrochloride, granisetron hydrochloride, ondansetron hydrochloride, azasetron hydrochloride, and the like, antihistamines, such as chlorpheniramine maleate, diphenhydramine hydrochloride, and the like, vitamins, such as thiamine nitrate, tocopherol hydrochloride, sicotiamine, pyridoxal phosphate, cobamamide, ascorbic acid, nicotinamide, and the like, antigout drugs, such as allopurinol, colchicine, probenamide, and the like, anti-Parkinson's drugs, such as levo dopa, selegiline, and the like, hypnotic sedatives, such as amobarbital, bromwarelyl urea, midazolam, chloral hydrate, and the like, anti-malignant tumor drugs, such as fluorouracil, carmofur, aclarubicin hydrochloride, cyclophosphamide, thiotepa, and the like, anti-allergy drugs, such as pseudoephedrine, terfenadine, and the like, antidepressants, such as phenyl propanolamine, ephedrins, and the like, drugs used to treat diabetes, such acethexamide, insulin, torbutamide, desmopressine, glibizide, and the like, diuretics, such as hydrochlorthiazide, polythiazide, triaterene, and the like, bronchodilators, such as aminophyllin, formoterol fumarate, theophylline, and the like, antitussives, such as codeine phosphate, noscapine, dimemorphan phosphate, dextromethorphan, and the like, antiarrythmia drugs, such as quinidine nitrate, digitoxin, propafenone hydrochloride, procainamide, and the like, surface anesthetics, such as aminoethyl benzoate, lidocaine, dibucaine hydrochloride, and the like, antiepilepsy drugs, such as phenytoin, etosuccimide, primidone, and the like, synthetic corticosteroids, such as hydrocortisone, prednisone, triamcinolone, betamethasone, and the like, drugs for the digestive tract, such as famotidine, ranitidine hydrochloride, dimethisone, sucralfate, sulpiride, tepronone, praunotol, 5-aminosalicylic acid, sulfasalazine, omeprazole, lannoprazole, and the like, drugs for the central nervous system, such as indeloxazine, idebenone, thiapride hydrochloride, bifermerane hydrochloride, calcium homopanthothenate, and the like, agents for treatment of hyperlipidemia, such as pravastatin sodium, sinvastatin, lovastatin, prevastatin, atorvastatin, and the like, antibiotics, such as ampicillin phthalizyl hydrochloride, cefotetan, josamycin, and the like, BPH therapeutic agents, such as tamsulosin hydrochloride, doxazocin mesilate, terazosine hydrochloride, and the like, anti-asthma drugs, such as pranrucast, zafirlukast, albuterol, ambrozole, budesonide, leverbuterol, and the like, prostaglandin I derivative agents for improving peripheral circulation, such as beraprost sodium, and the like, antithrombotics, hypotensives, agents for treatment of heart failure, agents for treatment of various complications of diabetes, agents for treatment of peptic ulcer, agents for treatment of skin ulcers, agents for treatment of hyperlipidemia, anti-asthma agents, and the like. The drug can be used in free form or as any salt that is pharmaceutically acceptable.
[0051] Moreover, the present invention can comprise drugs that do not require sustained-releasability. Furthermore, one or a combination of two or more drugs can be used. There are no special restrictions to the amount of this drug as long as it is the amount that is usually effective for treatment, but it is preferably 50 w/w % or less, preferably 20 w/w % or less, in terms of tablet weight. For instance, when it exceeds 50 w/w % in terms of tablet weight, the ratio of fine particles to filler is high and granulation by the filler will be insufficient.
[0052] These drugs are sustained-release treated and contained in the sustained-release fine particles as fine particles with which release of the drug is controlled by the conventional methods described below. There are no special restrictions to the particle diameter of the sustained-release fine particles as long as it is within a range with which there is not a gritty feeling in the buccal cavity. Usually approximately 0.1 μm to approximately 350 μm is preferred, approximately 5 μm to approximately 250 μm is more preferred, and approximately 50 μm to approximately 250 μm is further preferred as the mean particle diameter. If it is smaller than 0.1 μm, it will be difficult to provide sustained releasability with the current pharmaceutical technology, while if it is larger than 350 μm, it will have a very uncomfortable feeling, such as a gritty feeling, in the buccal cavity.
[0053] Moreover, the sustained-release fine particles of the present invention can be prepared by conventional methods. For instance, sustained-release fine particles can be made by the agitation granulation method or tumbling fluidized granulation method after adding polymer solution to drug and microcrystalline cellulose, as disclosed in Japanese Patent No. Hei 7-72129 (corresponding U.S. Pat. No. 4,772,475) and International Early Disclosure Pamphlet WO00/24379, or sustained-release fine particles can be made by layering and coating drug over commercial microcrystalline cellulose particles (avicel particles, Asahi Kasei, brand name Celphere 102, and the like) as the core by conventional coating methods, such as fluidized bed coating, tumbling fluidized coating, and the like, and then further coating with polymer substance to form a controlled-release film (Avicel Jiho, No. 40, P. 16-33, Asahi Kasei Corp.). Moreover, it is also possible to use a conventional crystalline filler of approximately 1 μm˜approximately 150 μm, specifically crystalline lactose, granular sugar, sodium chloride, corn starch, silicon dioxide (silica gel), and the like, taking into consideration the size of the sustained-release fine particles (approximately 0.1 to approximately 350 μm). Pre-coating with water-soluble polymer substance, water-insoluble polymer substance, and the like, can also be used in order to round the edges of the filler, which becomes the core, in this case. In addition, it is also possible to make sustained-release fine particles by spray drying a solution or suspension of drug and polymer substance using appropriate equipment, such as a spray dryer, and the like. Examples of solvents used to prepare these sustained-release fine particles are water, organic solvent, and the like. Examples of organic solvents are alcohols, specifically, methanol, ethanol, propanol, isopropanol, and the like, halogenated alkanes, specifically dichloromethane, chloroform, chloroethane, trichloroethane, carbon tetrachloride, and the like, ketones, specifically acetone, methyl ethyl ketone, and the like, nitrites, specifically acetonitrile, and the like, and hydrocarbons, specifically n-hexane, cyclohexane, and the like. One or a mixture at an appropriate ratio of two or more of these organic solvents can be used, and they can also be used as a mixture with water at an appropriate percentage.
[0054] The polymer substance used to prepare the sustained-release fine particles can be selected as needed in accordance with the purpose of use. Examples are water-insoluble polymers, gastrosoluble polymers, enterosoluble polymers, wax-like substances, and the like. Examples of water-insoluble polymers are water-insoluble cellulose ether, such as ethyl cellulose, Aquacoat (brand name, Asahi Kasei), and the like, water-insoluble acrylic acid copolymers, such as ethyl acrylate-methyl methacrylate-trimethyl ammonium chloride ethyl methacrylate copolymer (for instance, brand name of Eudragit RS, Röhm), methyl methacrylate-ethyl acrylate copolymer dispersion (for instance, brand name: Eudragit NE30D, Röhm), and the like, and the like. Examples of gastrosoluble polymers are gastrosoluble polyvinyl derivatives, such as polyvinyl acetal diethyl aminoacetate, and the like, gastrosoluble acrylic acid copolymers such as methyl methacrylate-butyl methacrylate-dimethylaminoethyl methacrylate copolymer (for instance, brand name Eudragit E, Röhm), and the like, and the like. Examples of enterosoluble polymers are enterosoluble cellulose derivatives, such as hydroxypropylmethyl cellulose acetate succinate, hydroxypropyl methyl cellulose phthalate, hydroxymethyl ethyl cellulose phthalate, carboxymethyl ethyl cellulose, and the like, enterosoluble acrylic acid copolymers, such as methacrylic acid-methyl methacrylate copolymer (for instance, brand name: Eudragit L100, Eudragit S, both by Röhm), methacrylic acid-ethyl acrylate copolymer (for instance, brand name of Eudragit L100-55, Eudragit L30D55, Röhm), and the like, and the like. Examples of wax-like substances are solid oils and fats, such as hydrogenated castor oil, hydrogenated coconut oil, tallow, and the like, higher fatty acids, such as stearic acid, lauric acid, myristic acid, palmitic acid, and the like, and higher alcohols, such as cetyl alcohol, stearyl alcohol, and the like. Of these, methacrylic acid-ethyl acrylate copolymer is preferred for providing enterosolubility and pH-independent water-insoluble polymer, particularly ethyl cellulose, is preferred for providing sustained release whereby a drug is released gradually. One or an appropriate combination of two or more of these polymer substances can be used for the goal of controlled dissolution.
[0055] Furthermore, plasticizer can also be added as needed. Examples of this plasticizer are triacetin, triethyl citrate, dibutyl sebacate, acetylated monoglyceride, ethyl acrylate-methyl methacrylate copolymer dispersion (for instance brand name: Eudragit NE30D, Röhm), and the like, and triacetin and ethyl acrylate-methyl methacrylate copolymer dispersion are preferred.
[0056] Moreover, water-soluble polymers, saccharides, salts, and the like, can be mixed with the above-mentioned polymer substances, such as water-insoluble polymers, gastrosoluble polymers, enterosoluble polymers, and the like, or wax-like substances, and the like. Examples of these substances are hydroxypropylcellulose, hydroxypropylmethyl cellulose, polyvinyl pyrrolidone, polyvinyl alcohol, and the like, as water-soluble polymer substances. Examples of saccharides are maltose, maltitol, and the like, and examples of salts are sodium chloride, and the like. The amount of polymer and saccharide used here can be adjusted as needed in order to control the dissolution speed of the drug. Moreover, one or a combination of two or more of these polymers and saccharides can be used. Incidentally, the water-soluble polymer substances, saccharides, and salts used here are added in order to easily control dissolution of drug from the sustained-release fine particles, and they should be differentiated from those that are used in preparation of the composition of the present invention.
[0057] There are no special restrictions to the “filler” used in the present invention as long as it is a pharmaceutically acceptable sugar or sugar alcohol. Examples of sugar or sugar alcohol are saccharides of low moldability disclosed in International Early Disclosure Pamphlet WO95/20380. Specific examples are xylitol, erythritol, glucose, mannitol, sucrose, and lactose. Of these, mannitol, lactose, and erythritol are preferred. In addition, one or a combination of two or more of these saccharides can be used. The “saccharide of low moldability” here means one that, for instance, shows a tablet hardness of less than 2 kp when 150 mg saccharide are tableted under a tableting pressure of 10 to 50 kg/cm 2 using a punch with a diameter of 8 mm (refer to WO95/20380 (corresponding U.S. Pat. No. 5,576,014, Japanese Patent No. 3122141). Moreover, sugars with a high melting point and sugars with a low melting point in U.S. patent application Ser. No. 10/142,081 (corresponding International Patent Application No. PCT/JP02/04481) can also be selected.
[0058] There are no special restrictions to the saccharide with a low melting point used in the present invention as long as it is pharmaceutically acceptable and it is a saccharide with a low melting point listed in U.S. patent application Ser. No. 10/142,081 (corresponding International Patent Application No. PCT/JP02/04481) and it has a relatively lower melting point than the drugs and saccharides with a high melting point used in the present invention, but a saccharide with a melting point of approximately 80 to approximately 180° C. is preferred and a saccharide [with a melting point] of approximately 90 to 150° C. is further preferred. Examples of this saccharide are glucose (monohydrate, melting point of 83° C.), xylitol (melting point of 93° C.), trehalose (dihydrate, melting point of 97° C.), sorbitol (hydrate, melting point of a little less than 100° C.), maltose (melting point of 102° C.), sorbitol (melting point of 110° C.), erythritol (melting point of 122° C.), glucose (melting point of 146° C.), maltitol (melting point of 150° C.), mannitol (melting point of 166° C.), sucrose (melting point of approximately 170° C.), and the like. One or two or more saccharides selected from the group consisting of these can be used. Of these saccharides, one or two or more saccharides selected from glucose, xylitol, trehalose, sorbitol, maltose, erythritol, maltitol, and their hydrates are preferred. Trehalose, maltose, erythritol, or maltitol, particularly trehalose and/or erythritol, are ideal because these saccharides themselves are only slightly moisture-absorbing and therefore are easy to handle. One or a combination of two ore more of these saccharides can be used. These saccharides also can be used as a hydrate. When the hydrate and anhydride of the saccharide have different melting points, the heating temperature should be set accordingly as needed.
[0059] The “saccharide with a high melting point” used in the present invention is a saccharide with a high melting point listed in U.S. patent application Ser. No. 10/142,081 (corresponding Patent Application No. PCT/JP02/04481). It is a saccharide whose melting point temperature difference from the saccharide with a low melting point used in the present invention is 10° C. or higher, further preferably, a saccharide with a melting point temperature difference of 20° C. or higher. Taking into consideration the difference between the temperature at which the heating device is set and the temperature of the tablet, which is the object to be heated, it is preferred that saccharides with a greater difference between their melting points be selected. Specifically, xylitol (melting point of 93° C.), trehalose (dihydrate, melting point of 97° C.), sorbitol (hydrate, melting point of a little less than 100° C.), maltose (melting point of 102° C.), sorbitol (melting point of 110° C.), erythritol (melting point of 122° C.), glucose (melting point of 146° C.), maltitol (melting point of 150° C.), mannitol (melting point of 166° C.), sucrose (melting point of approximately 170° C.), lactose (melting point of 202° C.), and the like, are given. One or two or more saccharides selected from the group consisting of these can be used. Illustration of saccharides with a high melting point virtually duplicates the saccharides with a low melting point, but because a “a saccharide with a high melting point” is selected in terms of a relative relationship with the saccharide with a low melting point, the same saccharides are not selected. The “saccharides with a high melting point” and “saccharides with a low melting point” of the present invention are selected as needed taking into consideration the chemical properties of the drug that will be used, that is, stability of the drug with respect to temperature. When the relationship between the “saccharide with a high melting point” and the “saccharide with a low melting point” is described in specific terms, xylitol, trehalose, sorbitol, erythritol, glucose, maltitol, mannitol, sucrose, lactose, and their hydrates can be used as the “saccharide with a high melting point” when glucose (monohydrate, melting point of 83° C.) is used as the “saccharide with a low melting point” that is used in the present invention. Moreover, sorbitol, erythritol, glucose, maltitol, mannitol, sucrose, lactose, and their hydrates can be used as the “saccharide with a high melting point” when xylitol (melting point of 93° C.) or trehalose (dihydrate, 97° C.) is used as the “saccharide with a low melting point” that is used in the present invention. Glucose, maltitol, mannitol, sucrose or lactose can be used as “the saccharide with a high melting point” when erythritol (melting point of 122° C.) is used as the “saccharide with a low melting point” that is used in the present invention. Furthermore, mannitol, sucrose or lactose can be used as the “saccharide with a high melting point” when maltitol (melting point of 150° C.) is used as the “saccharide with a low melting point” in the present invention. In addition, lactose can be used as the “saccharide with a high melting point” when sucrose (melting point of approximately 170° C.) is used as the “saccharide with a low melting point” in the present invention. The “saccharide with a high melting point” is selected as described, as necessary in accordance with the type of saccharide used in the present invention. When selecting the saccharides so that there is a greater difference between their melting points, the “saccharide with a high melting point” is preferably one or two or more saccharides selected from the group consisting of glucose, maltitol, mannitol, sucrose and lactose, and further preferably mannitol, sucrose, and lactose. These are used in the appropriate amounts of one or a mixture of two or more as needed.
[0060] The saccharides of high moldability listed in International Early Disclosure Pamphlet WO95/20380, the saccharides with a low melting point listed in U.S. patent application Ser. No. 10/142,081 (corresponding International Patent Application PCT/JP02/04481), or water-soluble polymer substances are selected as the “binder for quick-disintegrating tablets in the buccal cavity” used in the present invention. For instance, maltose (preferably malt syrup powder (maltose content of 83% or higher)), trehalose, sorbitol, or maltitol are given as saccharides of high moldability, and maltose and trehalose are preferred. The “saccharide of high moldability” here means one that shows a tablet hardness of 2 kp or more when 150 mg saccharide are tableted under a tableting pressure of 10 to 50 kg/cm 2 using a punch with a diameter of 8 mm (refer to WO 95/20380 (corresponding U.S. Pat. No. 5,576,014, Japanese Patent No. 3122141). The above-mentioned saccharides with a low melting point are given as saccharides with a low melting point. Moreover, hydroxypropyl cellulose, hydroxypropylmethyl cellulose, polyvinyl pyrrolidone, copolyvidone, polyvinyl alcohol, and the like, are given as water-soluble polymer substances. One or a combination of two or more “binder for quick-disintegrating tablets in the buccal cavity” can be used. Hydroxypropyl cellulose, hydroxypropylmethyl cellulose, or copolyvidone with low hygroscopicity are preferred taking into consideration the environment during storage as a starting material and a pharmaceutical preparation, and copolyvidone is ideal.
[0061] In addition, the “binder for quick-disintegrating tablets in the buccal cavity” of the present invention can be one or two or more selected from the group consisting of “saccharides of high moldability,” “saccharides with a low melting point,” and “water-soluble polymer substances.”
[0062] I. “Filler”: saccharide of low moldability, “binder for quick-disintegrating tablets in the buccal cavity”: saccharide of high moldability, or water-soluble polymer substance,
[0063] II. “Filler”: saccharide with a high melting point, “binder for quick-disintegrating tablets in the buccal cavity”: saccharide with a low melting point,
[0064] III. “Filler”: saccharide with a high melting point, “binder for quick-disintegrating tablets in the buccal cavity”: saccharide with a low melting point, and water-soluble polymer substance, and
[0065] IV. “Filler”: saccharide with a high melting point and saccharide with a low melting point, “binder for quick-disintegrating tablets in the buccal cavity”: water-soluble polymer substance or saccharide of high moldability are given as specific embodiments of the present invention relating to selection of the above-mentioned “filler” and “binder for quick-disintegrating tablets in the buccal cavity.” As a specific illustration of IV, it is preferred that erythritol is selected as the “saccharide with a low melting point,” lactose and/or mannitol are selected as the “saccharide with a high melting point,” and maltitol is further selected as the binder for quick-disintegrating tablets in the buccal cavity (“saccharide of high moldability”), or that erythritol is selected as the “saccharide with a low melting point,” lactose and/or mannitol are selected as the “saccharide with a high melting point,” and copolyvidone is further selected as the binder for quick-disintegrating tablets in the buccal cavity (“water-soluble polymer”).
[0066] The amount of “filler” used in the present invention is adjusted as needed in accordance with the dose of the drug and/or the size of the tablets. This amount added is adjusted as needed by increasing the amount of “filler” used in the present invention when the dose of drug is small and by reducing the amount of “filler” used in the present invention when the dose of drug is large, and the like, to obtain tablets of the desired size. It is usually preferably 20 to 1,000 mg, further preferably 50 to 500 mg, even more preferably 100 to 400 mg, per tablet. There is a chance that thorough granulation cannot be realized if the amount of filler added is less than 20 mg. Moreover, the amount of filler to the amount of saliva in the buccal cavity will be too great when [the amount of filler added] is more than 1,000 mg, and an uncomfortable feeling will be produced when it is in the mouth.
[0067] The amount of “binder for quick-disintegrating tablets in the buccal cavity” that is used in the present invention is usually preferably 0.5 to 50 w/w %, further preferably 1 to 30 w/w %, even more preferably 1 to 20 w/w %, per weight of “filler” used in the present invention. If it is less than 0.5 w/w % per the weight of “filler,” there is a chance that function as a binder will not be realized in full. Moreover, if there is more than 50 w/w % per the weight of “filler,” there is a possibility that many problems, including delayed disintegration, and the like, will occur and good properties will not be obtained when used as a quick-disintegrating tablet in the buccal cavity. Although the mixture ratio of “sustained-release fine particles,” “filler,” and “binder for quick-disintegrating tablets in the buccal cavity” should not be definitively set forth by their percentages, when an illustration is given, their respective mixture ratio is preferably 1 to 50%, 20 to 98%, and 1 to 30%, more preferably 1 to 20%, 60 to 98%, and 1 to 20%.
[0068] In addition to the “filler” and “binder for quick-disintegrating tablets in the buccal cavity” that are used in the present invention, it is possible to add a variety of additives that are pharmaceutically acceptable and are used as additives. These additives can be mixed with the filler when the sustained-release fine particles are granulated, or they can be used as a mixture with the composition of the present invention when tablets are made. Examples of these additives are disintegrants, sour flavorings, foaming agents, artificial sweeteners, fragrances, lubricants, coloring agents, stabilizers, and the like. One or a combination of two or more of these additives can be used. Moreover, there are no particular restrictions to the amount added as long as it is the amount normally pharmaceutically used by persons in the field and it is within a range with which the results of the present invention are not compromised.
[0069] Examples of disintegrants are starches, such as corn starch, and the like, carmellose calcium, partially alpha-converted starch, crospovidon, lower-substituted hydroxypropyl cellulose, and the like. Examples of sour flavoring are citric acid, tartaric acid, malic acid, and the like. Examples of foaming agents are sodium bicarbonate, and the like. Examples of artificial sweeteners are saccharine sodium, glycyrrhizinate dipotassium, aspartame, stevia, sormatin, and the like. Examples of fragrances are lemon, lemon-lime, orange, menthol, and the like. Examples of lubricants are magnesium stearate, calcium stearate, sucrose fatty acid ester, polyethylene glycol, talc, stearic acid, and the like. Examples of coloring agents are food coloring, such as yellow food dye No. 5, red food dye No. 2, blue food dye No. 2, and the like; food lake coloring; iron oxide red, and the like. Stabilizers are selected by drug after performing various tests. One or a combination of two or more of these additives can be added in an appropriate amount as needed.
[0070] The processes of the method of manufacturing the composition comprising sustained-release fine particles of the present invention, particularly the manufacturing conditions, and the like, will now be described in detail:
[0071] The method of manufacturing the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of the present invention will now be described using (a) the process of manufacturing sustained-release fine particles comprising the amount of drug that is effective in terms of treatment or prevention and with which the speed of dissolution of this drug is controlled and (b) the process whereby “sustained-release fine particles” and “filler” are granulated with “binder for quick-disintegrating tablets in the buccal cavity.”
[0000] Process (a): Process of Manufacture of Sustained-Release Fine Particles
[0072] The sustained-release fine particles are made by conventional methods, as previously mentioned. There are no particular restrictions to this method and it can be selected as needed as long as it is one with which the goal of controlled dissolution is obtained. For instance, drug is layered and coated on commercial crystalline cellulose particles, crystalline lactose, granular sugar, sodium chloride, silicon dioxide, and the like, using a binder such as hydroxypropylmethyl cellulose, and the like, and then a polymer substance, such as water-insoluble polymer substance, gastrosoluble polymer substance, enterosoluble polymer substance, wax-like substance, and the like, is further coated on this to make sustained-release fine particles. It is also possible to layer and coat a polymer substance, such as water-insoluble polymer substance, gastrosoluble polymer substance, enterosoluble polymer substance, wax-like substance, and the like, together with drug on commercial crystalline cellulose particles, crystalline lactose, granular sugar, sodium chloride, silicon dioxide, and the like to make sustained-release fine particles. Sustained-release fine particles are also made by the agitation granulation method or tumbling fluidized granulation method after adding a solution of polymer substance to drug and microcrystalline cellulose. The above-mentioned coating can be further performed on these sustained-release fine particles, and they can be given enterosoluble function by coating with enterosoluble polymer base as necessary. A fluidized bed granulator, and the like, for instance, is selected for coating. Temperature, and further, the spraying liquid volume, spraying air volume, and the like, are set so that the product temperature is approximately 40° C. to approximately 60° C. in the case of coating using water and at approximately 30° C. to approximately 60° C. when an organic solvent is used. The concentration of drug, percentage and amount of polymer substance, and the like, used for the coating can be adjusted as needed in accordance with the desired speed of dissolution.
[0000] Process (b): Granulation Process
[0073] There are no special restrictions to the granulation method of the present invention as long as it is one with which the sustained-release fine particles have been granulated with “filler” and “binder for quick-disintegrating tablets in the buccal cavity”. For example, fluidized bed granulation, agitation granulation, tumbling granulation, and the like, can be selected as this granulation method. Of these, the fluidized bed granulation method is preferred in terms of productivity. The method whereby a solution of the “binder for quick-disintegrating tablets in the buccal cavity” that is used in the present invention dissolved and/or suspended in a pharmaceutically acceptable solvent is sprayed onto a mixture of sustained-release fine particles and “filler” to make granules and prepare the “composition” can be selected for the fluidized bed granulation method. The sustained-release fine particles should be covered with “filler” at this time. The manufacture conditions are preferably, for instance, a product temperature of approximately 25° C. to approximately 40° C. and a water content of approximately 0.2 to approximately 5%. Moreover, granulation by intermittent spraying is preferred. “Intermittent spraying” means interrupted spraying and is the method of spraying for granulation whereby, for instance, cycles of spraying for 10 seconds following by drying for 30 seconds, and the like, are repeated. Moreover, this cycle can be set as needed for manufacture. In addition, the spray time-dry time can be selected appropriately. It is also possible to granulate after adding the above-mentioned additives as needed.
[0074] The “filler” can be a commercial product used as is. When mean particle diameter of the “filler” is larger than the mean particle diameter of the sustained-release fine particles, it is preferred that the “filler” be pulverized using an appropriate pulverizing device, such as hammer mill, sample mill, pin mill, and the like, in order to facilitate granulation with the sustained-release particles. It is preferred that the “binder for quick-disintegrating tablets in the buccal cavity” be dissolved in water to obtain a solution when it is a saccharide of high moldability. This liquid concentration should be, for instance, 10 to 40 w/w %, more preferably 20 to 30 w/w %, in order to maximize binding ability of the binder for quick-disintegrating tablets in the buccal cavity. If liquid concentration is lower than 10 w/w %, the liquid volume will be too great and the procedure will take more time, while if the liquid concentration is higher than 40 w/w %, the procedure will be completed in a shorter amount of time and it will therefore be difficult to maintain the spraying time-drying time cycle.
[0075] Moreover, the composition comprising sustained-release fine particles of the present invention can be used in the quick-disintegrating tablets in the buccal cavity, and this method comprises (c): the process of making tablets by tableting the composition obtained in process (b) and (d): the process of humidifying and drying the tablets obtained in process (c) as necessary. Furthermore, when the above-mentioned saccharide with a high melting point and saccharide with a low melting point have been selected for the composition, it is possible to select the method consisting of process (d′): the process of heating the tablets obtained by process (c), and (e): the process of cooling after process (d′). Process (d) can also be performed after processes (d′) and (e).
[0000] Process (c): Tableting Process
[0076] “Tableting” is performed by conventional methods. There are no particular restrictions as long as it is a method by which the shape of a tablet is obtained under at least the minimum pressure necessary to retain the shape of a tablet. This “tableting” can be performed using, for instance, an ordinary tableting machine, such as a single tableting machine or a rotary tableting machine, and the like, after adding the necessary additives, beginning with lubricant such as magnesium stearate, and the like, to the above-mentioned “composition.” Moreover, the above-mentioned “composition” can also be made into tablets using an external-lubricating tableting machine. Tableting pressure of usually approximately 25 to approximately 800 kg/punch is preferred, approximately 50 to approximately 500 kg/punch is further preferred, approximately 50 to approximately 300 kg/punch is most preferred.
[0000] Process (d): Humidifying and Drying Process
[0077] When the saccharide that is the “binder for quick-disintegrating tablets in the buccal cavity” used in the granulation process becomes amorphous and there is a reduction in strength of the tablet obtained by the tableting process due to absorption of moisture, that is, when the “binder for quick-disintegrating tablets in the buccal cavity” used in the present invention is a saccharide of high moldability and maltose, sorbitol, or trehalose is used, it is preferred that the following process of humidifying and drying be used: “Humidifying” is performed in combination with the drying process, which is the process that follows the humidifying process. There are no special restrictions to the method as long as it is one with which the saccharide of the “binder for quick-disintegrating tablets of the buccal cavity” used in the present invention crystallizes from amorphous substance. The conditions of this “humidifying” are determined from the apparent critical relative humidity of the mixture comprising sustained-release fine particle containing drug, “binder for quick-disintegrating tablets in the buccal cavity” used in the present invention, and “filler.” Humidifying is usually performed to at least the critical relative humidity of this mixture. For instance, approximately 30 to approximately 100 RH % is preferred and approximately 50 to approximately 90 RH % is further preferred as the humidity. Approximately 15 to approximately 50° C. is preferred and approximately 20 to approximately 40° C. is further preferred as the temperature at this time. One to 48 hours is preferred and 12 to 24 hours is further preferred as the humidifying time.
[0078] There are no particular restrictions to the “drying” as long as it is a method by which the moisture that has been absorbed by humidifying is eliminated. Usually approximately 10 to approximately 100° C. is preferred, approximately 20 to approximately 60° C. is further preferred, and approximately 25 to approximately 40° C. is most preferred as the “drying” conditions. Thirty minutes to 10 hours is preferred and 1 to 4 hours is further preferred as the drying time.
[0000] Process (d′): Heating Process
[0079] The “heating” in the present invention is performed by conventional methods, and there are no special restrictions as long as it is a method whereby the molded article obtained by process (c) can be brought to a temperature that is at least the melting point of the above-mentioned “saccharide with a low melting point.” Said “heating” process can be performed, for instance, using a ventilation oven. Temperature conditions are selected as needed depending on the type of “saccharide with a low melting point”, and there are no particular restrictions as long as it is the melting point of the “saccharide with a low melting point” used in the present invention or higher and the melting point of the “saccharide with a high melting point” or lower. When the “saccharide with a low melting point” used in the present invention is used, it is approximately 80 to approximately 180° C., preferably approximately 90 to approximately 150° C. Time conditions are selected as needed depending on the type of saccharide that is used, the desired tablet strength, disintegration performance in the buccal cavity, and the like, but it is usually 0.5 to 120 minutes, preferably 1 to 60 minutes, further preferably 2 to 30 minutes.
[0000] Process (e): Cooling Process
[0080] The “cooling” in the present invention is performed by conventional methods, and there are no particular restrictions as long as it is a method whereby the saccharide with a low melting point that is used in the present invention is solidified after melting. Said “cooling” can be performed by, for instance, being set aside at room temperature or being stored in a low-temperature atmosphere, such as a refrigerator, and the like.
[0081] Next, an example of the method of manufacturing the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of the present invention is given below: First, drug is layered and coated on commercial crystalline cellulose particles (for instance, Celphere 102) using an appropriate binder (for instance, hydroxypropylmethyl cellulose) with a fluidized bed granulator, and the like. Sustained-release fine particles are obtained by further coating a mixture of water-insoluble polymer substance (for instance, ethyl cellulose) and water-soluble polymer (for instance, hydroxypropylmethyl cellulose) as needed using a fluidized bed granulator, and the like, in order to obtain the desired dissolution. Then these fine particles and sugar (for instance, mannitol) are intermittently granulated (for instance, cycle of spraying for 10 seconds and then drying for 30 seconds) with the binder for quick-disintegrating tablets in the buccal cavity (for instance, maltose) using a fluidized bed granulator, and the like, to obtain the composition comprising sustained-release fine particles for quick-disintegrating tablets in the buccal cavity of the present invention.
[0082] Quick-disintegrating tablets in the buccal cavity comprising sustained-release fine particles can be prepared by adding additives as necessary, for example, an appropriate lubricant such as magnesium stearate, and the like, to the composition comprising sustained-release fine particles used for quick-disintegrating tablets in the buccal cavity of the present invention and making tablets using a tableting machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] FIG. 1 is the results of dissolution experiments with Japan Pharmacopoeia 1st Fluid for Disintegration Tests of the tablets and sustained-release fine particles of Example 1.
[0084] FIG. 2 is the results of dissolution experiments with Japan Pharmacopoeia 2nd Fluid for Disintegration Tests of the tablets and sustained-release fine particles of Example 1.
[0085] FIG. 3 is the results of dissolution experiments with Japan Pharmacopoeia 1st Fluid for Disintegration Tests of the tablets and sustained-release fine particles of Comparative Examples 1 and 2.
DETAILED DESCRIPTION OF THE INVENTION
[0086] The present invention will be further described below with examples, but interpretation of the present invention is not limited to these examples.
[0000] Methods of Evaluating Composition Comprising Sustained-Release Fine Particles
[0087] [Determination of Particle Diameter Distribution of Sustained-Release Fine Particles and Composition Comprising Sustained-Release Fine Particles]
[0088] Particle diameter was determined with a sieve-type particle diameter distribution gauge (Seishin Enterprise Co., Ltd. Robot Sifter) using sieves with openings of 30, 42, 60, 80, 100, 150, 200, and 250 mesh.
[0089] [Determination of Quantitative Ratio by Particle Diameter of Composition Comprising Sustained-Release Fine Particles]
[0090] Composition remaining on sieves with each of the above-mentioned opening sizes is recovered and the quantitative amount of each fraction is determined. Assuming that the total quantitative amount is 100%, the ratio accounted for by the quantitative amount on each sieve is calculated and serves as the quantitative ratio by particle diameter. Moreover, the quantitative distribution by particle diameter was obtained by arranging the quantitative ratio by particle diameter in the order of the opening size of each sieve. Incidentally, any method can be used to determine the quantitative amount as long as the drug that is contained is thoroughly recovered from the composition, and determination is performed by the determination method suitable for each drug.
[0091] [Ratio of Ungranulated Sustained-Release Fine Particles]
[0092] The particle diameter distribution of sustained-release fine particles and the quantitative distribution by particle diameter of the composition comprising sustained-release fine particles is determined and calculated by the following formula:
Ratio of ungranulated sustained release fine particles (%)= G 1 +Σ( G i+1 −( P i −G i ))
[0093] Here, the estimation of Σ is obtained by calculation from i=1 and estimating the value up to the point before (G i+1 −(P i −G i )) becomes negative.
[0094] P 1 : sustained-release fine particle ratio on sieve with smallest opening size within the particle diameter distribution of the sustained-release fine particles (with the exception of that where it is 0%). That is, it is 15.0% on 150 mesh in the following examples.
[0095] P 2 : sustained-release fine particle ratio on sieve with second smallest opening size within particle diameter distribution of sustained-release fine particles (with the exception of that where it is 0%). That is, it is 70.6% on 100 mesh in the following examples. The third, fourth and so on is referred to as P 3 , P 4 and they are as a whole represented as P i .
[0096] G 1 : value of quantitative ratio by particle diameter distribution of composition on sieve with the same opening size as P 1 . That is, it is 2.5% on 150 mesh in the following examples.
[0097] G 2 : value of quantitative ratio by particle diameter distribution of composition on sieve with same opening size as P 2 . That is, it is 14.3% on 100 mesh in the following examples. The third, fourth, and so on are referred to as G 3 , G 4 , and so on, and they are as a whole represented as G i .
[0098] For instance, if the determination results are as follows:
Particle diameter Quantitative distribution distribution of sustained- by particle diameter of release fine particles Example 1 composition 30 Mesh on (%) 0 19.0 42 Mesh on (%) 0 22.4 60 Mesh on (%) 0 23.5 80 Mesh on (%) 14.4 18.2 100 Mesh on (%) 70.6 14.3 150 Mesh on (%) 15.0 2.5 200 Mesh on (%) 0 0 200 Mesh pass (%) 0 0 the ratio (%) of ungranulated sustained-release fine particles
[0099]
=
G
1
+
Σ
(
G
i
+
1
-
(
P
i
-
G
i
)
)
=
G
1
+
(
G
2
-
(
P
1
-
G
1
)
)
+
(
G
3
-
(
P
2
-
G
2
)
)
+
…
=
2.5
+
(
14.3
-
(
15
-
2.5
)
)
+
(
18.2
-
(
70.6
-
14.3
)
)
+
(
23.5
-
(
14.4
-
18.2
)
)
=
2.5
+
(
+
1.8
)
+
(
-
38.1
)
[0100] If the figures in parentheses are negative, it means that the sustained-release fine particles have a particle diameter that is at least 1 rank larger because of granulation. Therefore, there is no further estimation performed and
= 2.5 + ( + 1.8 ) = 4.3
Methods for Evaluating Quick-Disintegrating Tablets in the Buccal Cavity
[0101] [Hardness tests] Determinations were performed using a Schleuniger tablet hardness meter (Schleuniger Co., Ltd.). The tests were performed with 5 tablets and the mean is shown. Tablet hardness is represented by the force needed to crush the tablet (units kp). A larger number indicates a stronger tablet.
[0102] [Friability] Determinations were performed using a friability tester (model PTFR-A, Pharma Test Co.) The friability is found using 6 g tablets. It is represented by the percentage weight loss of a tablet after being turned 100 times at a turning speed of 25 rpm. A smaller value indicates a stronger tablet surface.
[0103] [Disintegration in buccal cavity tests] Healthy adult males placed the tablet of the present invention in their buccal cavity without any water in the buccal cavity and the time until the tablet was completely disintegrated and dissolved by saliva only was determined.
[0104] [Content uniformity tests] The drug content of each of 10 tablets was quantitatively determined and is represented as the coefficient of variation (CV %) of the amount of drug from the above-mentioned formula.
[0105] [Dissolution tests] Tests were conducted by Dissolution Test Method No. 2 in accordance with Revised Version 12 of the Japanese Pharmacopoeia.
EXAMPLE 1
[0106] Eighty grams tamsulosin hydrochloride and 80 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 304 g purified water and 2,736 g methanol. Four-thousand grams Celphere 102 (brand name, Asahi Kasei, mean particle diameter of approximately 127 μm, particle diameter of approximately 50 to approximately 150 μm) were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with this solution by the side spraying method (spraying liquid volume 100 g/min, spraying air pressure 4 kg/cm 2 , product temperature 40° C., inlet temperature 80° C.) to obtain tamsulosin hydrochloride particles. Separately, 533 g ethyl cellulose (Nissin Chemistry Co.) and 187 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 698 g purified water and 22,582 g methanol. Four thousand grams tamsulosin hydrochloride particles were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with this solution by side spraying (spraying liquid volume of 40 g/min, spraying air pressure of 4 kg/cm 2 , product temperature of 50° C., inlet temperature of 60° C.) to obtain sustained-release fine particles. Four-thousand grams of these sustained-release fine particles were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with a mixture of 2,000 g Aquacoat (brand name, Asahi Kasei), 4,000 g Eudragit L30D55 (brand name, Röhm), 667 g Eudragit NE30D (brand name, Röhm), and 6,667 g purified water (spraying liquid volume of 40 g/min, spraying air pressure of 4 kg/cm 2 , product temperature of 40° C., inlet temperature of 60° C.) to obtain enteric sustained-release fine particles.
[0107] Then 368 g of these enteric sustained-release fine particles, 2,560 g mannitol (Towa Kasei Co., Ltd.), and 640 g lactose (Domomilk) were granulated (spraying liquid volume 200 g/min, spraying air pressure of 1.5 kg/cm 2 , product temperature of 29° C., inlet temperature of 80° C., spraying cycle of 10 seconds spraying to 30 seconds drying) with an aqueous 40% w/w solution containing 400 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, FLO-5) to obtain the composition of the present invention.
[0108] After further mixing 32 g calcium stearate with the composition that was obtained, 200 mg tablets containing 0.2 mg tamsulosin hydrochloride per tablet were made under a tableting pressure of 100 kg/punch and an initial hardness of 1.0 kp using a rotary tableting machine. Next, these tablets were kept for 18 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 5.9 kp (n=5), friability of 0.8% (100 rounds) and disintegration time in the buccal cavity of 20 seconds (n=3). Moreover, as a result of evaluating uniformity of content, CV %=2.1%, proving that there is good uniformity of content.
COMPARATIVE EXAMPLE 1
[0109] First, 319.3 g mannitol (Towa Kasei Co., Ltd) and 79.7 g lactose (Domomilk) were granulated (spraying liquid volume 10 g/min, spraying air pressure 1.5 kg/cm 2 , product temperature 30° C., inlet temperature 60° C., spraying cycle: continuous spraying) with an aqueous 20% w/w solution containing 50 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt). After mixing 45.2 g of the enteric sustained-release fine particles prepared in Example 1 and 5 g calcium stearate with the product that was obtained, 200 mg tablets containing 0.2 mg tamsulosin hydrochloride per tablet were made under a tableting pressure of 93 kg/punch and an initial hardness of 1.0 kp using a rotary tableting machine. Next, these tablets were kept for 18 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained had a hardness of 4.1 kp (n=5) and a disintegration time in the buccal cavity of 15 seconds (n=3). Moreover, the results of evaluating uniformity of content were CV %=5.6%, with the tablets having inferior uniformity of content.
COMPARATIVE EXAMPLE 2
[0110] First, 45.2 g enteric sustained-release fine particles prepared in Example 1, 319.3 g mannitol (Towa Kasei Co., Ltd.), and 79.7 g lactose (Domomilk) were granulated (spraying liquid volume 10 g/min, spraying air pressure 1.5 kg/cm 2 , product temperature 30° C., inlet temperature 60° C., spraying cycle: continuous spraying) with an aqueous 20% w/w solution containing 50 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt). After mixing 5 g calcium stearate with the product that was obtained, 200 mg tablets containing 0.2 mg tamsulosin hydrochloride per tablet were made under a tableting pressure of 96 kg/punch and an initial hardness of 1.0 kp using a rotary tableting machine. Next, these tablets were kept for 18 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained had a hardness of 3.7 kp (n=5) and a disintegration time in the buccal cavity of 15 seconds (n=3). Moreover, the results of evaluating uniformity of content were CV %=4.0%, with the tablets having inferior uniformity of content.
[0000] Experiment 1 (Quantitative Amount by Particle Diameter Distribution)
[0111] The particle diameter distribution of the sustained-release fine particles obtained in Example 1 and the particle diameter distribution as well as quantitative distribution by particle diameter of the composition prepared in Examples 1 and 2 (Table 1) as well as the product prepared in Comparative Examples 1 and 2 (Table 2) are shown together.
TABLE 1 Particle diameter distribution of sustained release fine particles and particle diameter distribution and quantitative distribution by particle diameter of compositions of Examples 1 and 2 Particle Quantitative Quantitative diameter Particle distribution by Particle distribution distribution diameter particle diameter by particle of sustained- distribution diameter of distribution diameter of release fine of Example 1 Example 1 of Example 2 Example 2 particles composition composition composition composition Mean particle 165 393 — 204 — diameter (μm) 30 Mesh on (%) 0 26.9 19.0 1.5 1.1 42 Mesh on (%) 0 29.7 22.4 5.1 6.2 60 Mesh on (%) 0 23.8 23.5 23.1 27.2 80 Mesh on (%) 14.4 9.8 18.2 31.5 43.4 100 Mesh on (%) 70.6 2.8 14.3 15.2 17.6 150 Mesh on (%) 15.0 3.1 2.5 16.1 4.3 200 Mesh on (%) 0 1.5 0 5.1 0 200 Mesh pass (%) 0 2.5 0 2.5 0 Ratio of ungranulated — — 4.3 — 11.2 product (%)
[0112]
TABLE 2
Particle diameter distribution of sustained-release fine particles and
particle diameter distribution as well as quantitative distribution by particle diameter of
products in Comparative Examples 1 and 2
Particle
Quantitative
Particle
Quantitative
Particle
diameter
distribution by
diameter
distribution
diameter
distribution
particle
distribution
by particle
distribution
of
diameter of
of
diameter of
of sustained-
Comparative
Comparative
Comparative
Comparative
release fine
Example 1
Example 1
Example 2
Example 2
particles
product
product
product
product
Mean particle diameter
165
179
—
196
—
(μm)
30 Mesh on (%)
0
4.7
0
3.1
2.1
42 Mesh on (%)
0
8.0
0
11.3
10.3
60 Mesh on (%)
0
13.8
0
17.8
19.3
80 Mesh on (%)
14.4
23.6
14.2
23.4
42.2
100 Mesh on (%)
70.6
18.9
70.9
12.8
21.2
150 Mesh on (%)
15.0
17.8
14.4
13.8
4.9
200 Mesh on (%)
0
8.4
0
8.8
0
200 Mesh pass (%)
0
4.9
0
9.0
0
Ratio of ungranulated
—
—
99.2
—
16.0
product (%)
[0113] The majority of sustained-release fine particles are within 80 to 100 mesh and the results of quantitative ratio by particle diameter distribution in Examples 1 and 2 confirm that most of the sustained-release fine particles are coated with filler by granulation and distribution of composition comprising sustained-release fine particles shifts in the direction of a large particle diameter. On the other hand, with respect to distribution of the product in Comparative Example 2, it is confirmed that apparent particle diameter is large, but the quantitative ratio by particle diameter does not necessarily coincide with distribution of the product. In particular, the quantitative ratio for 80 to 100 mesh, under which the ungranulated sustained-release particles fall, is 20% or higher and it was observed there are many sustained-release particles that are not granulated.
[0114] Separately, many sustained-release fine particles that were not granulated were observed in the 80-150 mesh part of the product of Comparative Example 2 as a result of microscopic observation of composition and product. On the other hand, almost no ungranulated sustained-release fine particles were observed with the composition of Example 1. Thus, finding that support the above-mentioned data were obtained even by microscopic observation. Consequently, these results confirm that the sustained-release fine particles were thoroughly granulated by filler in the compositions of Examples 1 and 2. Moreover, the coefficient of variation when the ratio of ungranulated product was 4.3% (Example 1) and 11.2% (Example 2) was 2.2 (CV %) and 2.1 (CV %), respectively, while the coefficient of variation when the ratio of ungranulated product was 99.2% (Comparative Example 1) and 16.0% (Comparative Example 2) was 5.6 (CV %) and 4.0 (CV %), respectively. Therefore, if the ratio of ungranulated product is 16% or higher, the results indicate that the coefficient of variation (CV %), which is an indicator of uniformity of content, is large and exceeds the allowable value of 3.5%.
[0000] Experiment 2 (Dissolution Experiment)
[0115] Dissolution experiments were performed on the tablets obtained in Example 1 and Comparative Examples 1 and 2 and the results were compared with the dissolution speed of sustained-release fine particles only. The experimental conditions were 100 rpm by the paddle method, and 500 ml each of Japanese Pharmacopoeia Disintegration Test Method 1 st fluid (pH 1.2) and 2 nd fluid (pH 6.8) were used as the experimental fluids.
[0116] As a result of the experiment, in the Example there was almost no difference (difference in values after two hours of 0.7%) between the dissolution rate of the sustained-release fine particles and tablets up to two hours after starting the dissolution experiment with the test fluid having a pH of 1.2, and even with the test fluid having a pH of 6.8, the difference between the dissolution rate of the sustained-release fine particles and tablet was always less than 15% at 2.9%, 5.8%, and 5.1% at each dissolution time where the dissolution rate of sustained-release fine particles was 30%, 50%, and 80%, respectively, confirming that dissolution when tablets are made is not accelerated ( FIGS. 1 and 2 ). On the other hand, acceleration of the dissolution speed when tablets were made was seen when compared to the sustained-release fine particles in the Comparative Examples ( FIG. 3 , difference between values after two hours of 15.9% and 12.8%). It was concluded that this was because in contrast to the fact that sustained-release fine particles were not confirmed on the tablet surface in Example 1, sustained-release fine particles were observed on the tablet surface in Comparative Examples 1 and 2 and therefore, the sustained-release fine particles had been destroyed as a result of contact between the punch surface and sustained-release fine particles.
[0117] Consequently, it was confirmed that by means of the present invention, sustained-release fine particles are thoroughly granulated by filler and acceleration of dissolution at the time tablets are made can be avoided.
EXAMPLE 2
[0118] First, 2,609 g mannitol (Towa Kasei Co., Ltd.) and 653 g lactose (Domomilk) were pulverized with a pin mill pulverizing device (Hosokawa Micron). This pulverized product and 307 g enteric sustained-release fine particles prepared in Example 1 were granulated (spraying liquid volume 100 g/min, spraying air pressure 1.5 kg/cm 2 , product temperature 28° C., inlet temperature 80° C., spraying cycles 20 seconds spraying-30 seconds drying) with an aqueous 20% w/w solution containing 400 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, FLO-5) to obtain the composition of the present invention. After mixing 32 g calcium stearate with this composition that was obtained, 120 mg tablets containing 0.1 mg tamsulosin hydrochloride per tablet were made under a tableting pressure of 100 kg/punch and initial hardness of 1.0 kp using a rotary tableting machine. Next, these tablets were stored for 18 hours while heating and humidifying at 25° C./70% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained had a hardness of 5.2 kp (n=5), friability of 0.6% (100 rounds), and a disintegration time in the buccal cavity of 20 seconds (n=3). Moreover, the results of evaluating uniformity of content were CV %=2.2%, confirming that the tablets have good uniformity of content. Furthermore, as a result of performing dissolution tests on the sustained-release fine particles and the tablets that were obtained, it was confirmed that the difference in the dissolution rate between the sustained-release fine particles and tablet was 4.7% up to two hours after starting the dissolution test with the test fluid having a pH of 1.2, and even with the test fluid having a pH of 6.8, the difference in the dissolution rate between the sustained-release fine particles and tablet was always less than 15% at 2.3%, 2.4%, and 1.4% at each dissolution time where the dissolution rate of sustained release fine particles was 30%, 50%, and 80%, respectively, indicating that dissolution at the time of tableting is not accelerated.
[0119] Tablets were separately made with the same composition and by the same manufacturing method as previously described. The tablets that were obtained had a hardness of 5.6 kp (n=5), friability of 0.6% (100 rounds), and dissolution time in the buccal cavity of 25 seconds (n=3). Moreover, the results of evaluating uniformity of content showed CV %=2.5%. As with the above-mentioned findings, the results of dissolution tests did not reveal the difference between the dissolution rates of the sustained-release fine particles and the tablet. Thus, by means of the present invention, a composition comprising sustained-release fine particles is prepared and therefore, uniformity of content is guaranteed as a result of preventing segregation between the sustained-release fine particles and filler. In addition, it was confirmed that reproducibility is obtained.
EXAMPLE 3
[0120] Three-hundred grams acetaminophen (Yoshitomi Fine Chemicals Co., Ltd.) and 60 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 720 g methanol and 720 g dichloromethane. Three-hundred grams Celphere 102 (brand name, Asahi Kasei, mean particle diameter of approximately 127 μm, particle diameter of approximately 50 to approximately 150 μm) were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with the solution by the side spraying method (spraying liquid volume 14 g/min, spraying air pressure 3 kg/cm 2 , product temperature 32° C., inlet temperature 45° C.) to obtain acetaminophen particles. Separately, 48 g ethyl cellulose (Nissin Chemistry Co.) and 12 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 57 g purified water and 1,083 g methanol. Three-hundred grams acetaminophen particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 8 g/min, spraying air pressure of 3 kg/cm 2 , product temperature of 38° C., inlet temperature of 67° C.) to obtain sustained-release fine particles. Sixty-six grams of these sustained-release fine particles and 314.25 g mannitol (Towa Kasei Co., Ltd) that had been pulverized by a pin mill pulverizing device (Hosokawa Micron) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 1.1 kg/cm 2 , product temperature of 30° C., inlet temperature of 38° C., spraying cycle of 30 seconds spraying-30 seconds drying) with an aqueous 30% w/w solution containing 67.5 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated sustained-release fine particles was 0.0%. After further mixing 2.25 g magnesium stearate with the composition that was obtained, 450 mg tablets containing 25 mg acetaminophen per tablet were made under a tableting pressure of 25 kg/punch and an initial hardness of 2.0 kp using a rotary tableting machine. Next, these tablets were kept for 24 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 3.5 kp (n=5) and disintegration time in the buccal cavity of 12 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=1.2%, confirming that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 2.8 hours after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 5 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 9 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 4.9% at 2.8 hours, 4.6% at 5 hours, and 2.5% at 9 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 4
[0121] Six-hundred grams acetaminophen (Yoshitomi Fine Chemical Co., Ltd.) and 120 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 1,440 g methanol and 1,440 g dichloromethane. Three-hundred grams sodium chloride (Shin Nihon Salt Co., Ltd., EF-70 classification, mean particle diameter of approximately 67 μm, particle diameter of approximately 75 μm or smaller) were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by the side spraying method (spraying liquid volume 10 g/min, spraying air pressure 3 kg/cm 2 , product temperature 33° C., inlet temperature 55° C.) to obtain acetaminophen particles.
[0122] Separately, 72 g ethyl cellulose (Nissin Chemistry Co.) and 8 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 76 g purified water and 1,444 g methanol. Four-hundred grams acetaminophen particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 10 g/min, spraying air pressure of 3 kg/cm 2 , product temperature of 39° C., inlet temperature of 70° C.) to obtain sustained-release fine particles.
[0123] Then 76.5 g of these sustained-release fine particles and 393.4 g mannitol (Towa Kasei Co., Ltd) that had been pulverized by a pin mill pulverizing device (Hosokawa Micron) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 1.0 kg/cm 2 , product temperature of 29° C., inlet temperature of 35° C., spraying cycle of 20 seconds spraying-40 seconds drying) with an aqueous 20% w/w solution containing 52.5 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated sustained-release fine particles was 10.8%.
[0124] After further mixing 2.6 g magnesium stearate with the composition that was obtained, 350 mg tablets containing 25 mg acetaminophen per tablet were made under a tableting pressure of 50 kg/punch and an initial hardness of 1.9 kp using a rotary tableting machine. Next, these tablets were kept for 24 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 4.8 kp (n=5), friability of 1.23% (100 rounds), and disintegration time in the buccal cavity of 13 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=2.4%, confirming that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 2.8 hours after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 5 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 9.5 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 5.5% at 2.8 hours, 3.5% sustained-release fine particles [sic] at 5 hours, and 3.1% at 9.5 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 5
[0125] First, 1,200 g acetaminophen and 120 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 2,640 g methanol and 2,640 g dichloromethane. Three-hundred grams sodium chloride (Shin Nihon Salt Co., Ltd., EF-70 classification, mean particle diameter of approximately 67 μm, particle diameter of 75 μm or smaller) were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by the side spraying method (spraying liquid volume 16 g/min, spraying air pressure 3 kg/cm 2 , product temperature 30° C., inlet temperature 75° C.) to obtain acetaminophen particles.
[0126] Separately, 45.9 g ethyl cellulose (Nissin Chemistry Co.) and 5.1 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 48.5 g purified water and 920.5 g methanol. Three-hundred forty grams acetaminophen particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 8 g/min, spraying air pressure of 2.5 kg/cm 2 , product temperature of 39° C., inlet temperature of 75° C.) to obtain sustained-release fine particles. Then 116.4 g of these sustained-release fine particles and 542.7 g mannitol (Towa Kasei Co., Ltd) that had been pulverized by a pin mill pulverizing device (Hosokawa Micron) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 1.1 kg/cm 2 , product temperature of 28° C., inlet temperature of 35° C., spraying cycle of 20 seconds spraying-40 seconds drying) with an aqueous 30% w/w solution containing 117 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated sustained-release fine particles was 1.6%.
[0127] After further mixing 3.9 g magnesium stearate with the composition that was obtained, 520 mg tablets containing 50 mg acetaminophen per tablet were made under a tableting pressure of 200 kg/punch and an initial hardness of 1.9 kp using a rotary tableting machine. Next, these tablets were kept for 24 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 6.4 kp (n=5), friability of 1.13% (100 rounds), and disintegration time in the buccal cavity of 21 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=3.3%, confirming that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 2.5 hours after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 5 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 9.5 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 8.8% at 2.5 hours, 6.3% at 5 hours, and 3.3% at 9.5 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 6
[0128] Forty grams ethyl cellulose (Nissin Chemistry Co.) were dissolved in a mixture of 380 g methanol and 380 g dichloromethane. Four-hundred grams sodium chloride (Shin Nihon Salt Co., Ltd., EF-70 classification, mean particle diameter of approximately 67 μm, particle diameter of 75 μm or smaller) were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by the side spraying method (spraying liquid volume 6 g/min, spraying air pressure 2 kg/cm 2 , product temperature 28° C., inlet temperature 60° C.) to obtain core particles. Then 1,200 g acetaminophen (Yoshitomi Fine Chemicals Co., Ltd.) and 120 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Kagaku Co., Ltd.) were dissolved in a mixture of 2,640 g methanol and 2,640 g dichloromethane. Three-hundred grams of the above-mentioned core particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by the side spraying method (spraying liquid volume 15 g/min, spraying air pressure 3 kg/cm 2 , product temperature 30° C., inlet temperature 70° C.) to obtain acetaminophen particles.
[0129] Separately, 47.2 g ethyl cellulose (Nissin Chemistry Co.) and 5.3 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 49.9 g purified water and 947.6 g methanol. Three-hundred fifty grams acetaminophen particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 8 g/min, spraying air pressure of 2.5 kg/cm 2 , product temperature of 37° C., inlet temperature of 75° C.) to obtain sustained-release fine particles. Then 116.4 g of these sustained-release fine particles and 542.7 g mannitol (Towa Kasei Co., Ltd) that had been pulverized by a pin mill pulverizing device (Hosokawa Micron Co., Ltd.) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 1.1 kg/cm 2 , product temperature of 30° C., inlet temperature of 40° C., spraying cycle of 20 seconds spraying-40 seconds drying) with an aqueous 30% w/w solution containing 117 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated sustained-release fine particles was 3.9%.
[0130] After further mixing 3.9 g magnesium stearate with the composition that was obtained, 520 mg tablets containing 50 mg acetaminophen per tablet were made under a tableting pressure of 140 kg/punch and an initial hardness of 2.6 kp using a rotary tableting machine. Next, these tablets were kept for 24 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 5.9 kp (n=5), friability of 1.64% (100 rounds), and disintegration time in the buccal cavity of 26 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=2.0%, confirming that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 2.3 hours after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 5.5 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 13.5 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 0.6% at 2.3 hours, 1.2% at 5.5 hours, and 3.2% at 13.5 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 7
[0131] Eighty grams tamsulosin hydrochloride and 80 g hydroxypropyl[methyl] cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 304 g purified water and 2,736 g methanol. Four-thousand grams Celphere 102 (brand name, Asahi Kasei, mean particle diameter of approximately 127 μm, particle diameter of approximately 50 to approximately 150 μm) were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with this solution by the side spraying method (spraying liquid volume 100 g/min, spraying air pressure 4 kg/cm 2 , product temperature 40° C., inlet temperature 80° C.) to obtain tamsulosin hydrochloride particles.
[0132] Separately, 43.7 g ethyl cellulose (Nissin Chemistry Co.) and 12.3 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 43.9 g purified water and 833.4 g methanol. Four-hundred grams tamsulosin hydrochloride particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 6 g/min, spraying air pressure of 4 kg/cm 2 , product temperature of 40° C., inlet temperature of 63° C.) to obtain sustained-release fine particles.
[0133] Next, 300 g of these sustained-release fine particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with a mixture of 90 g Aquacoat (brand name, Asahi Kasei), 180 g Eudragit L30D55 (brand name, Röhm), 30 g Eudragit NE30D (brand name, Röhm), and 300 g purified water (spraying liquid volume of 6 g/min, spraying air pressure of 3 kg/cm 2 , product temperature of 40° C., inlet temperature of 75.5° C.) to obtain enteric sustained-release fine particles. Then 92.5 g of these enteric sustained-release fine particles, 568.2 g mannitol (Towa Kasei Co., Ltd.) and 142.1 g lactose (Domomilk) that had been pulverized with a pin mill pulverizing device (Hosokawa Co., Ltd.), and 72 g erythritol (Nikken Chemicals Co., Ltd.) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 0.5 kg/cm 2 , product temperature of 40° C., inlet temperature of 70° C., spraying cycle of 15 seconds spraying-30 seconds drying) with an aqueous 5% w/w solution containing 18 g copolyvidone (BASF Co., brand name Kollidon VA64) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated fine particles was 3.0%.
[0134] After further mixing 7.2 g calcium stearate with the composition that was obtained, 300 mg tablets containing 0.4 mg tamsulosin hydrochloride per tablet were made under an initial hardness of 0.6 kp using a rotary tableting machine. Next, these tablets were heated for 13 minutes at 120° C. using a program oven (model No. MOV-112P, Sanyo Corporation) and then cooled at room temperature for 30 minutes. The tablets that were obtained showed a hardness of 6.8 kp (n=5), friability of 0.28% (100 rounds) and disintegration time in the buccal cavity of 27 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=1.6%, proving that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 1 hour after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 2 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 6 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 1.1% at 1 hour, 2.8% at 5 [sic] hours, and 9.4% at 6 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 8
[0135] First, 1,200 g nicardipine hydrochloride and 1,200 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 4,800 g methanol and 4,800 g dichloromethane. Three-hundred grams silicon dioxide (Silica Gel, Sigma, mean particle diameter of approximately 48 μm, particle diameter of 75 μm or smaller) were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by the side spraying method (spraying liquid volume 18 g/min, spraying air pressure 3 kg/cm 2 , product temperature 30° C., inlet temperature 70° C.) to obtain nicardipine hydrochloride particles.
[0136] Separately, 54 g ethyl cellulose (Nissin Chemistry Co.) and 6 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 57 g purified water and 1,083 g methanol. Three-hundred grams nicardipine hydrochloride particles were introduced to a fluidized bed granulator (Freund Industries, uni-glatt) and coated with this solution by side spraying (spraying liquid volume of 8 g/min, spraying air pressure of 2.5 kg/cm 2 , product temperature of 39° C., inlet temperature of 70° C.) to obtain sustained-release fine particles.
[0137] Sixty grams of these sustained-release fine particles, 254.4 g mannitol (Towa Kasei Co., Ltd.) and 63.6 g lactose (Domomilk) that had been pulverized with a pin mill pulverizing device (Hosokawa Micron), and 12 g erythritol (Nikken Chemicals Co., Ltd.) were granulated (spraying liquid volume 15 g/min, spraying air pressure of 0.5 kg/cm 2 , product temperature of 39° C., inlet temperature of 50° C., spraying cycle of 5 seconds spraying-15 seconds drying) with an aqueous 5% w/w solution containing 8 g copolyvidone (BASF Co., brand name Kollidon VA64) in a fluidized bed granulator (Freund Industries, uni-glatt) to obtain the composition of the present invention. The ratio of ungranulated fine particles was 7.9%.
[0138] After further mixing 2 g magnesium stearate with the composition that was obtained, 400 mg tablets containing 20 mg nicardipine hydrochloride per tablet were made under an initial hardness of 0.6 kp using a rotary tableting machine. Next, these tablets were heated for 10 minutes at 130° C. using a program oven (model No. MOV-112P, Sanyo Corporation). Then they were cooled at room temperature for thirty minutes. The tablets that were obtained showed a hardness of 3.7 kp (n=5), friability of 0.1% or less (100 rounds) and disintegration time in the buccal cavity of 20 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=1.1%, proving that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 0.5 hour after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 2 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 5.5 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 10.3% at 0.5 hour, 12.8% at 2 hours, and 6.6% at 5.5 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
EXAMPLE 9
[0139] Eighty grams tamsulosin hydrochloride and 80 g hydroxypropylmethyl cellulose (TC5E, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 304 g purified water and 2,736 g methanol. Four-thousand grams Celphere 102 (brand name, Asahi Kasei, mean particle diameter of approximately 127 μm, particle diameter of approximately 50 to approximately 150 μm) were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with this solution by the side spraying method (spraying liquid volume 100 g/min, spraying air pressure 4 kg/cm 2 , product temperature 40° C., inlet temperature 80° C.) to obtain tamsulosin hydrochloride particles.
[0140] Separately, 561.6 g ethyl cellulose (Nissin Chemistry Co., Ltd.) and 158.4 g hydroxypropylmethyl cellulose (TC5E, brand name, Shin-Etsu Chemical Co., Ltd.) were dissolved in a mixture of 564 g purified water and 10,716 g methanol. Four-thousand grams tamsulosin hydrochloride particles were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with this solution by side spraying (spraying liquid volume of 40 g/min, spraying air pressure of 4 kg/cm 2 , product temperature of 40° C., inlet temperature of 54° C.) to obtain sustained-release fine particles.
[0141] Next, 4,000 g of these sustained-release fine particles were introduced to a fluidized bed granulator (Freund Industries, FLO-5) and coated with a mixture of 800 g Aquacoat (brand name, Asahi Kasei), 1,600 g Eudragit L30D55 (brand name, Röhm), 266.7 g Eudragit NE30D (brand name, Röhm), and 5,333 g purified water (spraying liquid volume of 60 g/min, spraying air pressure of 4.5 kg/cm 2 , product temperature of 50° C., inlet temperature of 84° C.) to obtain enteric sustained-release fine particles.
[0142] Then 392.7 g of these enteric sustained-release fine particles and 2,540.2 [g] mannitol (Towa Kasei Co., Ltd.) and 635.1 g lactose (Domomilk) that had been pulverized with a pin mill pulverizing device (Hosokawa Co., Ltd.) were granulated (spraying liquid volume 100 g/min, spraying air pressure of 1.5 kg/cm 2 , product temperature of 33° C., inlet temperature of 48° C., spraying cycle of 20 seconds spraying-30 seconds drying) with an aqueous 20% w/w solution containing 400 g maltose (Hayashibara Co., Ltd., brand name: Sunmalt S) in a fluidized bed granulator (Freund Industries, FLO-5) to obtain the composition of the present invention. The ratio of ungranulated fine particles was 1.1%.
[0143] After further mixing 32 g calcium stearate with the composition that was obtained, 300 mg tablets containing 0.4 mg tamsulosin hydrochloride per tablet were made under an initial hardness of 2.1 kp using a rotary tableting machine. Next, these tablets were kept for 24 hours while heating and humidifying at 25° C./75% RH using a thermostatic chamber at constant humidity (Tabaiespec Co., Ltd., PR-35C). Then they were dried for 3 hours at 30° C. and 40% RH. The tablets that were obtained showed a hardness of 4.1 kp (n=5), friability of 1.67% (100 rounds) and disintegration time in the buccal cavity of 20 seconds (n=1). Moreover, as a result of evaluating uniformity of content, CV %=1.6%, proving that there is good uniformity of content. Furthermore, when dissolution of the sustained-release fine particles and tablet was compared 2 hours after starting dissolution tests (time when there is approximately 30% dissolution of sustained-release fine particles), 4 hours after (time when there is approximately 50% dissolution of sustained-release fine particles), and 8 hours after (time when there is approximately 80% dissolution of sustained-release fine particles) and the difference was calculated, it was 7.5% at 2 hours, 6.4% at 4 hours, and 1.5% at 8 hours, confirming that acceleration of dissolution of sustained-release fine particles is prevented at any time.
INDUSTRIAL APPLICABILITY
[0144] The present invention relates to a composition comprising sustained-release fine particles for providing what at a glance are contradictory functions in that the tablets have sustained releasability even though they quickly disintegrate and dissolve in the buccal cavity. Moreover, the present invention is characterized in that it makes it possible to inhibit acceleration of the drug dissolution after making tablets that is the result of destruction of the sustained-release fine particles under tableting pressure when tablets are made, and to realize controlled dissolution, which is the design goal of sustained-release fine particle preparation, with good reproducibility, even after tablets have been made. Therefore, pharmaceutical preparation design of the sustained-release fine particles is simplified, and there is further the characteristic of making it possible to guarantee good uniformity of drug content. Furthermore, it is possible to present a composition comprising sustained-release fine particles that will have a profound effect in the development of an assortment of quick-disintegrating tablets in the buccal cavity during the step of making the quick-disintegrating tablets in the buccal cavity comprising sustained-release fine particles into a product, particularly during the step of industrial manufacture, and further, the step of quality assurance.
|
The present invention relates to a composition comprising sustained-release fine particles, characterized in that it contains sustained-release fine particles that can be used in quick-disintegrating tablets in the buccal cavity, one or more fillers selected from the group consisting of sugars or sugar alcohols, and one or more binders for quick-disintegrating tablets in the buccal cavity selected from the group consisting of sugars of high moldability and water-soluble polymer substances, and in that the sustained-release fine particles are granulated with filler and binder for quick-disintegrating tablets in the buccal cavity, and a manufacturing method thereof.
| 0
|
FIELD OF THE INVENTION
[0001] The present invention relates to a surgical implant or graft for soft tissue reconstruction.
BACKGROUND OF THE INVENTION
[0002] Surgical treatment of injury to soft tissues of the muscular-skeletal system of mammals caused by trauma, sudden overload, fatigue, sickness or other degenerative medical condition may in some cases benefit from or even require structural support to start healing. An example of such a situation is injuries to structures that do not heal spontaneously such as the intraarticular crucial ligaments. A text book or review paper on sports medicine in general starts out with a phrase stating that “ . . . anterior cruciate ligament (ACL) rupture is the most common chronically incapacitating injury . . . ” stresses the importance to find a cure for this condition. The golden standard surgical therapy for ACL reconstruction is to put a biological graft where the native ACL used to be. Biological grafts can be either of auto or allogenic origin. Since grafts of allogenic origin poses a risk for disease transmission autograft is preferred instead. However, also autografts have inherent problems such as donor site morbidity. Furthermore, before the angiogenesis of the graft has proceeded far enough to regain proper nutrition the graft goes through a necrotic phase that compromises its mechanical properties (Weiler, A. et al., Biomechanical properties and vascularity of an anterior cruciate ligament graft can be predicted by contrast - enhanced magnetic resonance imaging. A two - year study of sheep. Am J Sports Med 2001, 26(6): 751-761). This critical time of about 12 weeks restricts the intensity by which the rehabilitation program can proceed. Overload during this sensitive period can cause permanent elongation of the graft that inevitably ends up in a reconstruction failure. Hence, much effort has been put into development of alternative grafts of biological or synthetic origin.
[0003] There is a consensus in both the medical device industry and the scientific community that the stronger a soft tissue reconstruction can be made the better. For instance Wright Medical highlights the superior strength of their augmentation patch “GraftJacket MaxForce Extreme”. Also suture branding follows the same path as exemplified by Arthrex Inc. that profiles their FiberWire as: “FiberWire has greater strength than comparable size standard polyester suture. Multiple independent scientific studies document significant increases in strength to failure, stiffness, knot strength and knot slippage with much less elongation” and MaxBraid by Arthrotek Inc (today Biomet Sports Medicine) is labeled as “the incredible strength suture”. Not only should the suture be as strong as possible, there are also numerous scientific papers that aim for the most rigid suture configuration possible (Hirpara, K. M., et al., A biomechanical analysis of multistrand repairs with the Silfverskiold peripheral cross - stitch. J Bone Joint Surg Br 2007, 89(10): 1396-1401; Momose, T., et al., Suture techniques with high breaking strength and low gliding resistance: experiments in the dog flexor digitorum profundus tendon. Acta Orthop Scand 2001, 72(6): 635-641), e.g. for Achilles tendon repair.
OBJECTS OF THE INVENTION
[0004] It is an object of the invention to provide an implant for connective tissue reconstruction that is better adapted to its purpose than implants known in the art.
[0005] It is another object of the invention to provide a method of manufacture for such implant.
[0006] Further objects of the invention will become apparent from the following summary of the invention, preferred embodiments thereof illustrated in a drawing, and the appended claims.
SUMMARY OF THE INVENTION
[0007] In this application the terms “implant” and “graft” have the same meaning and designate implants and grafts prior to implantation and as well as in an implanted state. In this application “stiffness” refers to “tensile stiffness”. In this application “pre-stretched” and corresponding terms refer to the stretching of an implant or an implant material or portion during implantation and to fixate the implant in a stretched condition. In this application “shrinking”, “heat-set” and corresponding terms refers to thermally effected shrinkage of porous implant polymer matrices or scaffolds, in particular of warp knitted synthetic fiber fabrics such as poly(urethane urea) fiber fabrics and implants manufactured from them.
[0008] The present invention is based on the insight that an implant for reconstruction of soft tissues of the musculo-skeletal apparatus excluding bone and articular cartilage should have properties and be of a design adapted to the natural healing process of connective tissues, in particular dense connective tissues bearing substantial loads such as tendons, fasciae, periostea or ligaments. In this context “adapted to the natural healing process of dense connective tissue” comprises that the implant should, as far as possible, not interfere with the natural healing process of connective tissue. In this application, dense connective tissue to be reconstructed or being in a healing state is termed “target tissue”. “Native tissue” signifies connective tissue that has not been damaged. In this application reconstruction of connective tissue comprises reconstruction ab initio as well as reconstruction of damaged connective tissue. The healing process of damaged connective tissue such as a damaged tendon, fascia, periosteum, ligament or muscle starts by formation of disorganized scar tissue. This scar tissue, the physical properties of which do substantially differ from those of the corresponding uncompromised tissue, is mechanically significantly weaker and less stiff. Hence, loads cause larger deformations of a healing soft tissue than of the corresponding uncompromised native tissue. As the healing process proceeds matrix producing cells form functional tissues. During the healing process the regenerating target tissue matures progressively and increasingly resembles the native tissue (Matthew, C., M. J. Moore, and L. Campbell, A quantitative ultrastructural study of collagen fibril formation in the healing extensor digitorum longus tendon of the rat. J Hand Surg [Br] 1987, 12(3): 313-320). It is of paramount importance that a healing target tissue be offered adequate mechanical stimuli to make it form functional tissue resembling native tissue. The implant of the invention and the material(s) of which it is made is preferably biocompatible and biodegradable; if biodegradable, its degradation rate is slow, such as that it offers substantial mechanical support after one year from implantation and even two years or more from implantation. “Substantial mechanical support” is a mechanical support of from 20% to 50% or more of the mechanical support at the time of implantation. By selection of a proper material the biodegradation rate can be advantageously adapted to the expected healing rate of the tissue to be reconstructed.
[0009] According to the present invention is disclosed an implant for reconstructing soft tissues of the musculo-skeletal apparatus, in particular tendon, fascia, periosteum, ligament, muscle but excluding bone and articular cartilage having an initial tensile stiffness that is significantly lower than that of the tissue to be reconstructed. In this application “initial stiffness” is the tensile stiffness at the time of implantation. The implant of the invention has a porosity and texture capable of accommodating matrix producing cells to form a functional tissue. Furthermore, the implant material of the invention is capable of resisting long term stress relaxation and creep thereby avoiding plastic deformation of the implant. Stress relaxation that rapidly levels off (within, for instance, one minute) is acceptable while plastic deformation (elongation) is not. Plastic deformation or creep ruins the implant's ability to template the healing tissue to its desired dimensions ensuring correct kinematics. The ability to support an applied load with an initial stress relaxation that rapidly levels off asymptotically to a finite value is beneficial to the implant for two reasons. Firstly, the residual load generated from the prestretch procedure can reapproximate retracted tissues, a clinical condition often seen, for instance, in tendon injuries such as rotator cuff tears or in avulsion injuries. Secondly, the residual pre-stretch force of a pre-stretched implant used in joint surgery provides active joint stabilization. This kind of active joint stabilization is important for intra-articular ligament reconstruction according to the invention. The nature of stress relaxation of fabrics is two-fold. There are contributions both from the textile design and from the material itself. Depending on fiber interlocking the fibers slide in respect of each other; with an elastic material this sliding will be gradual and appear as a rapid stress relaxation. The material's resistance to stress relaxation is strongly dependent on inherent limitation of molecular mobility by cross-links that may be chemical or physical. Chemical cross-links are found in e.g. rubbers while physical cross-links of permanent character are found in e.g. poly(urethane urea). The limited molecular mobility also offers the ability to orient the molecular network by simply stretching the implant and thereby modulate its stiffness. The molecules orient along the direction of the applied pre-stretch. Thereby the implant is stiffened in the pre-stretch direction.
[0010] A property of paramount importance of the implant of the invention is that it should be made of a material or comprise a material of a relaxation behaviour such that its relaxation upon tensioning quickly approaches asymptotically a finite value. A preferred material of this kind is polyurethane, in particular poly(urethane urea).
[0011] The textile material of the invention is preferably a warp-knitted fabric. By this textile design the implant can be made particularly resistant to frying. Resistance to frying is a crucial factor in fixation of an implant to connective tissue when penetrating fixation elements such as sutures are being utilized. Except for articular cartilage, the soft tissues of the musculo-skeletal apparatus addressed by this implant may be connected to bone at one or both implant ends. For the implant to transfer load to and from tissue it is essential that it can be securely and conveniently attached to the tissue. Attachment to soft tissue is normally accomplished by suturing whereas fixation to bone is a more delicate task. Fixation to bone hinders movement at the bone-implant interface. Penetrating, holding or squeezing fixation elements may be considered, for instance, for bone-implant attachment. Examples of fixation elements for these kinds of fixation, i.e. penetrating, holding or squeezing fixation, are sutures and screws, button with a sling such as EndoButton™ and ACL/PCL interference screws that both may be metallic or bioresorbable.
[0012] The design of the implant governs how it can be applied and interfaced with host tissue. A square or rectangular fabric that permits bed side trimming in all directions enables adaptation to optimize fitting and attachment to its host structure by penetrating fixation devices. For a design with a high aspect ratio, such as a substantially linear implant in form of a rope or thin strip, intended to transfer a load in a direction of the implant's longitudinal extension, the implant is normally attached near its both ends by penetrating or squeezing fixation elements. In this application “aspect ratio” denotes a length to width ratio. The ability of an implant to transfer a load across the implant-fixation element interface depends on its stress distribution properties. Extreme stress concentrations need to be leveled or avoided. One fixation mode that distributes stresses efficiently is by a linear implant being folded over a holding fixation element, such as an integrated fibrous sling over a button element, a cross-pin or directly over a button or pin. Clinically utilized brands comprising such elements include EndoButton™, RetroButton™, ToggleLoc™, CrossPin™ and EndoButton Direct™.
[0013] As mentioned in the foregoing healing of native tissue by a target tissue is a slow process, extending over months and even years. In view of this the implant of the invention shall be made of a biocompatible material with a corresponding in vivo endurance, in particular one that ensures that at least half of the stiffness persists for at least one year, preferably at least two years upon implantation. Furthermore, it is preferred that the implant material of the invention be more adapted to deformation than the target tissue so as to ensure matrix continuity even if the healing target tissue is overstretched, causing partial or total laceration. In such case the healing of a damaged target tissue will restart and continue to be supported by the implant without the need for repeated surgery.
[0014] The present invention additionally discloses an implant made of the material of the invention manufactured into a porous matrix, a template, an added synthetic extracellular matrix, but most often referred to as a scaffold. The implant has a tensile stiffness significantly lower than that of the native tissue it is intended to reconstruct, for instance lower by at least 50% or at least 80% or 85% and even as much as 90% or more. The material of the invention has elastomeric characteristics, which ensures that the implant can be deformed without permanent elongation. The implant may be manufactured by processes with inherent ability to accomplish porosity such as foaming, porogen extraction from molded block, textile confection or non-woven structures made out of fibers. It is also possible to manufacture it from combinations of these processes such as a porous matrix reinforced by fibers or a fabric.
[0015] The invention will now be explained in greater detail by reference to preferred embodiments thereof illustrated in a rough drawing.
DESCRIPTION OF THE FIGURES
[0016] FIG. 1 a Top view of a transverse section of a warp knitted poly(urethane urea) fiber fabric;
[0017] FIG. 1 b The transverse section of the fabric of FIG. 1 a , heat-set (thermally crimped) and in the same view;
[0018] FIG. 2 Tensile force/elongation diagram illustrating of a cut-out strip of the fabric of FIG. 1 b , at three elongation rates;
[0019] FIG. 3 a Tensile force/time diagram of stretching a cut-out strip of the fabric of FIG. 1 b in three steps;
[0020] FIG. 3 b Tensile force/elongation diagram corresponding to the tensile force/time diagram of FIG. 3 a;
[0021] FIG. 4 Tensile force/time diagram of stretching a cut-out strip of the fabric of FIG. 1 b to 70% elongation, followed by superimposing for two weeks a daily (weekdays: Monday to Friday) 10% elongation harmonic at 1 Hz for one hour;
[0022] FIG. 5 Tensile force/elongation diagram of cut-out strips of the fabric of FIG. 1 b stretched to 70% elongation and relaxation of 3 hours, 48 hours, and 14 days at this elongation, in comparison with a non-prestretched strip.
[0023] FIGS. 6 a - c Wrapped-up cut-out strips of the fabric of FIG. 1 b; 6 mm diameter, 6 a, side view, 6 b, transverse section, enlarged; four mm diameter, 6 c, side view;
[0024] FIG. 7 Anterior (craniate) cruciate ligament implant of the invention according to FIG. 6 a, 6 b applied through bone tunnels in the femur and the tibia with extra-articular staple fixation, in a posterial view;
[0025] FIGS. 8 a, b Filled cylinder implant manufactured from four knitted poly(urethane urea) tubes of different diameter, consecutively heat-set on steel core wire, in a perspective view ( 8 a ); in a transverse, enlarged sectional view ( 8 b ) prior to removing the steel core wire;
[0026] FIG. 9 Tensile force/elongation diagram illustrating the tensile behaviour of the wrapped-up implant of FIG. 6 a, 6 b , and the filled tube-formed implants of FIGS. 8 a, 8 b and FIG. 10 b;
[0027] FIGS. 10 a, b Filled tube implant manufactured from two co-axially disposed tubes of warp-knitted poly(urethane urea) fabric, heat set, cut off and folded into a collar, in a perspective view ( 10 a ); implant blank prior to heat setting, in a transverse sectional view ( 10 b ), enlarged.
DESCRIPTION OF PREFERRED EMBODIMENTS
Example 1
[0028] Shrunk knitted poly(urethane urea) ribbon. Yarn: 13 Tex poly(urethane urea) (Artelon®, Artimplant AB, Goteborg, Sweden). Equipment: Comez DNB/EL-800 (Comez s.p.A., Cilavegna, Italy) double needle bed crochet machine, for the production of technical and medical articles. Machine specifications: 15 gauge, 6 weft bars, double needle bed, latch needles. Heat set unit: Comez HSD/800 comprising 2 heat-set cylinders. A plain ribbon W of 14 cm width was knit in the machine ( FIG. 1 ). The ribbon W was shrunk in the heat set unit at 130° C. to produce a shrunk ribbon Ws at a thickness of 0.8 mm ( FIG. 1 ).
[0029] Process parameters: Knitting speed: 26 cm/min; heat set unit speed: 14 cm/min; shrinkage along warp: about 45% (cf D 1 , width of ribbon W and d 1 , width of ribbon Ws); shrinkage across warp: about 45% (cf D t , 20 loops, and d t , 20 loops). Warp thickness is slightly increased by shrinking. The warp knitting pattern is shown in Table 1. It is a sequence of four steps with 12 loops/cm.
[0000]
TABLE 1
Warp knitting pattern of tricot ribbon
Loop
Binding device movement
Loops/
Alimentation device
row
2
4
5
cm
setting (warp feed)
1
2
2
3
3
2
2
12.00
1490
2610
1790
1450
2
2
1
2
1
2
3
12.00
1490
2610
1790
1450
3
1
1
3
3
2
2
12.00
1490
2610
1790
1450
4
1
2
4
5
2
1
12.00
1490
2610
1790
1450
5
2
2
3
3
2
2
12.00
1490
2610
1790
1450
6
2
1
2
1
2
3
12.00
1490
2610
1790
1450
7
1
1
3
3
2
2
12.00
1490
2610
1790
1450
8
1
2
4
5
2
1
12.00
1490
2610
1790
1450
Example 2
[0030] Tensile force v. elongation of strip samples of the fabric of Example 1. Ten millimeter wide strip samples were cut from the crimped knitted fabric As of Example 1. The elongation of three samples A, B, C at physiological elongation rates of 2%/s (A), 14%/s (B), and 100%/s (C) , gauge length of 20 mm, and physiological conditions, was recorded . Physiological conditions imply pH-buffered saline at 37° C. The curves for samples A and B were practically identical up 200% elongation. The samples burst at an elongation of about 220% and 230%, respectively. In contrast, sample C required an about 20% higher force for a given elongation and burst already at an elongation of about 210%.
Example 3
[0031] Tensile force v. time of a sample of the fabric of Example 1. A 10 mm wide cut-out strip sample of the crimped knitted fabric As of Example 1, gauge length 20 mm, was stretched in a first step I to an elongation of 95% at about 55 N, elongation rate of 100%/s ( FIG. 3 a ). Within a minute the force needed to keep the sample at that elongation dropped to about 35 N, step II. In a following step III the pre-stretched sample was kept at a reduced elongation of 70% for two weeks, during which period the free sample length remained constant. A bursting test at an elongation rate of 100%/s, step IV, concluded the experiment. The elongation of the sample during the stretching procedure is shown in FIG. 3 b.
Example 4
[0032] Tensile force v. time of a pre-stretched sample of the fabric of Example 1 under physiological load. The diagram of FIG. 4 illustrates how the sample of Example 3 endures daily exercise. Experimental conditions were those of Example 3 except for superposition of a 10% elongation harmonic at 1 Hz in step III, one hour daily during two periods of five days each separated by two days during which no such superposition was carried out.
Example 5
[0033] Tensile force v. elongation in dependence of relaxation time. Ten millimeter wide cut-out strip samples of crimped knitted fabric, as the fabric of Example 1, were pre-tensioned and allowed to relax at an elongation of 70% for 3 h (D), 48 h (E), and 14 days (F). Their elongation behavior at an elongation rate of 100% was nearly identical ( FIG. 5 ) and differed substantially from the elongation behavior of a non-prestretched sample (G).
Example 6
[0034] A 90 mm×33 mm strip was cut from the crimped knitted fabric As of Example 1. The strip was wrapped up to a 90 mm long, 6 mm diameter implant 4 ( FIGS. 6 a , 6 b ). The implant 4 had a porosity of about 50%. It was intra-synnovially implanted as a temporary prosthesis 4 into a stifle joint 1 , 2 of mid- and large size dogs ( FIG. 7 ). The prosthesis 4 provided essential stifle joint 1 , 2 stability while acting as a scaffold to recover the cranial cruciate ligament, CCL. The implant 4 was applied through transcortical femur 1 tunnels and tibia 2 tunnels (intra-articular opening at 9 , lateral opening at 10 ) with intra-synovial tunnel openings located at the respective center of the native CCL foot prints (bony ligament attachment sites). By metal staples 5 , 6 the implant 4 was extra-articularly fixated at the femur 1 at its upper 4 ′ and in the tibia 2 at its lower 4 ″ terminal sections protruding cranially from the femur 1 and the tibia 2 tunnels. Reference signs 3 , 7 , 8 designate the fibular and the lateral and medial menisci, respectively. The free length of the implant 4 for elongation upon loading was about 80 mm
[0035] The mechanical behaviour of this implant (“Roll graft”) is illustrated in FIG. 9 . In an in-vitro experiment the implant was subjected to a prestretch procedure followed by a tensile test. The prestretch procedure started by a load ramp to 180 N, which was maintained for 20 seconds when the load was reduced to 20 N. At 36 seconds it was ramped to 90 N. The 90 N load was maintained for the remainder of the 100 second prestretch procedure. All load ramps were 180 N/s. The deformation achieved at the end of the prestretch procedure was maintained for about 1 minute. The tensile behaviour of the implant was then tested at a rate of 100% elongation per second. The procedure was conducted under physiological conditions (in 37° C. buffer) at a starting free length of 20 mm. The prestretch procedure elongated the implant to 57 mm (elongation 37 mm) Tensile testing of the 57 mm long elongated implant gave a stiffness of 26 N/mm. In the clinical situation with staple fixation seen in FIG. 7 the working free implant length was about 80 mm Hence, the longer implant should be correspondingly more compliant, that is, have a stiffness of 26·57/80=19 N/mm. This is only a fraction of the 148 to 348 N/mm CCL stiffness of dogs reported in literature (Wang, J. H., Mechanobiology of tendon. J Biomech, 2006, 39(9): 1563-1582; Gelberman, R. H. et al., The effect of gap formation at the repair site on the strength and excursion of intrasynovial flexor tendons. An experimental study on the early stages of tendon - healing in dogs. J Bone Joint Surg Am 1999, 81(7): 975-982; Palmes, D. et al., Achilles tendon healing: long - term biomechanical effects of postoperative mobilization and immobilization in a new mouse model. J Orthop Res 2002, 20(5): 939-946). Preliminary data from an ongoing clinical evaluation in 28 dogs indicate that this implant has restored the stifle joint stability of every individual with a follow up time of up to one year.
Example 7
[0036] The 4 mm diameter implant illustrated in FIG. 6 c was made from a 20 mm wide, 70 mm long cut-out strip of the crimped fabric As of Example 1. With a prestretch procedure that caused the same elongation as the implant described in Example 6 the stiffness of the 4 mm implant was scaled accordingly. Its shorter working length (approximately 60 mm) also affects its stiffness: 19·20/33·80/60 N/mm=15 N/mm Two small dogs were successfully CCL reconstructed with this thinner implant (follow-up period of 6 months).
Example 8
[0037] A cylindrical implant 100 ( FIGS. 8 a , 8 b ; length 120 mm, diameter 6 mm) was assembled from four tricot tubes 101 , 102 , 103 , 104 of matching diameter inserted into each other. The tubes 101 , 102 , 103 , 104 had been warp knitted from poly(urethane urea) fiber in the machine described in Example 1 where the 6 weft bars were equipped with either, 3 (tube 104 ), 5 (tube 103 ), 6 (tube 102 ) or 7 (tube 101 ) threads and an equivalent number of needles. The knitting pattern for the tubes is shown in Table 2.
[0000]
TABLE 2
Warp knitting pattern of tricot tubes.
Loop
Binding device movement
Loops/
Alimentation device
row
1
2
4
5
7
8
cm
setting (warp feed)
1
2
2
2
2
2
1
1
1
2
3
2
1
12.00
1550
1650
1650
1550
2
2
1
2
3
2
1
1
1
2
2
1
1
12.00
1550
1650
1650
1550
3
1
1
2
2
2
2
1
2
2
1
1
2
12.00
1550
1650
1650
1550
4
1
2
2
1
2
2
1
2
2
2
2
2
12.00
1550
1650
1650
1550
[0038] The assembly of the tubes 101 , 102 , 103 , 104 was carried out as follows. A 1.2 mm diameter steel core wire 105 was inserted into the lumen of the 3-needle tube 104 . The tube was thermally crimped by pulling it with the inserted steel core wire through a four mm inner diameter steel tube heated to 150° C. Next, the 3-needle tube 104 crimped on the steel core wire 105 was inserted into the lumen of the 5-needle tube 103 and the crimping process repeated by use of a steel tube heated to 150° C. of correspondingly larger inner diameter. In the same manner, the 6-needle tube 102 and the 7-needle tube 101 were crimped step-wise on the already crimped-on tubes 104 , 103 . After allowing the completed assembly to cool to room temperature and withdrawing the core 105 the implant blank 100 was transversally cut into a number of 120 mm long cylindrical multi-layer implants. In FIG. 9 the elongation response of the tubular implant 100 (“Tube”) of this Example is compared with that of the wrapped-up implant 4 of Example 8 (“Roll”), both attributed to the force controlled prestretch procedure described in Example 6. Both the elongation caused by the prestretch procedure and the slope of the tensile curves starting at S show that the multi-layer implant 100 is stiffer than the wrapped-up (rolled) implant 4 of Example 6. At otherwise identical experimental conditions the higher stiffness of the multi-layer cylindrical 100 implant provides higher joint stability than the wrapped-up implant 4 . Tensile testing of the multi-layer implant 100 consecutive to the prestretch procedure showed a stiffness of 37 N/mm Although this stiffness is higher than that of the implant 4 (26 N/mm) it is still only a fraction of native tissue stiffness.
Example 9
[0039] Yet another implant design is shown in FIGS. 10 a, 10 b. A folded tubular implant blank 200 ′ was manufactured from two 6-needle warp knitted tubes cut to same length manufactured in accordance with the parameters of Table 2, one of them 201 having been inserted in a longitudinally folded state into the other 202 ( FIG. 10 b ). A suitable length of the combination of inner tube 201 and outer tube 202 was wound around a 100 mm diameter stainless steel tube in an about radial plane over an angle of about 335°, clamped at both ends and heat-set in an oven at 120° C. for 20 min, making the assembly 201 , 202 to shrink radially so as to form implant 200 having a flattened face 203 where the outer tube 202 had been abutting the stainless steel tube. As seen in FIG. 9 application of the force controlled prestretch procedure described in Example 6 caused the implant to elongate by 6.6 mm (stiffness 52 N/mm) The “Double” tensile force/elongation curve of FIG. 9 was obtained with the doubled graft of FIG. 10 . Although this implant is stiffer than the pre-stretched implants of the other examples its stiffness is still only a fraction of that of a native CCL.
[0040] In another set of experiments at physiological conditions samples of the double tube graft were exposed to a static load for periods of up to seven days. The static load, normally denoted creep load, of about one third of the graft's ultimate load maintained for periods of up to 7 days caused the elongation to increase from 52% 17 sec after loading to 71% after seven days of creep.
Example 10
[0041] To decrease or increase the thickness of the implant and the method of manufacture accounted for in Example 8 can be varied to comprise a greater or smaller number of concentric warp knitted tubes in order to decrease or increase the thickness of the implant. Also the number of needles employed to knit the individual tubes will alter the features of the product. Furthermore, restrictions and or loads applied during the heat setting may be utilized to alter the dimensions and mechanical properties of the implant.
Example 11
[0042] To increase or decrease the thickness of the implant of FIG. 8 the design and method of manufacture of Example 9 can be applied to smaller or larger assemblies of more or less co-axially disposed warp knitted tubes. Variation of loads on the implant applied during the heat setting can be utilized to alter the dimensions and mechanical properties of the implant.
|
Implant for reconstructing tissue of the musculo-skeletal apparatus selected by the group consisting of tendon, fascia, periosteum, ligament, muscle, includes a porous matrix or scaffold of a polymeric material having a tensile stiffness lower by 50% or more than the tensile stiffness of the native tissue it is intended to reconstruct.
| 3
|
FIELD OF INVENTION
The present invention relates to a method, system and apparatus involving a communications client program for electronically sending and receiving mail items and/or for conducting real-time audio and video communications in a secure manner. The present invention also relates to a corresponding transfer server which facilitate the said communications. A mail item may be any item of correspondence that bears an addressee's street address (i.e. number, street, suburb, state and post code) or an advertising item that does not necessarily bear an addressee, but includes nominations for preferred destinations.
BACKGROUND OF THE INVENTION
The conventional postal system delivers street addressed mail items and “junk mail” advertising materials. Senders of mail items are not verified and receiver verification is inbuilt in that receivers of said mail items have to reside in the address to access the sent mail items. The only prerequisite the mail sender has to have is access to the addressee's postal address. This current mail system is in need of an electronic alternative to lift productivity levels, increase competition and add services that can only be delivered through an electronic platform.
At present, the existing electronic alternatives, email and web spaces for mail storage (e.g. bank statements) has not provided a comprehensive solution, partly due to the essentially unauthenticated nature of email correspondence and the inconvenience of the latter. Forging an email address is trivial and therefore the integrity of the entire email system can be compromised. Identity authentication via digital certificates and secure transmission through encryption is available as an add-on service for email services which only partially solves the problem of secure and authenticated communications. Public key infrastructure (PKI) design requires that every email account holder has public keys corresponding to every other email account holder that they may like to communicate with, which severely limits the scalability of the authenticated email service as a public alternative.
At the heart of internet communications lies a problem of authentication. The internet protocol (IP) addressing scheme does not include a default user authentication mechanism prior to accessing the internet. Web browsers access the internet using static and dynamic IP addresses. However, various organisations have adopted the PKI and use digital certificates signed by third party certificate authorities (CA) to identify themselves to users on the internet. Financial institutions use a digital certificate to confirm their identity to customers. What ensues is a one-way authenticated secure channel of communication. Authenticity and security are essential aspects that encourage participation in various activities including economic activities via the internet. So far most individuals who access the internet for communication purposes do not have an authenticated digital certificate that attest to individual or entity identity.
Unsolicited “junk mail” which fills conventional mailboxes has a location specificity. For example, the “pizza restaurant specials leaflet” from the local pizza restaurant get sent to nearby street addresses. “Junk mail” is from organisations and businesses that hope to attract attention from a target market selected largely by geographic locality. At present, recipients of such mail items do not have an opportunity to pre-select areas of interests and the lack of correlation between advertisers intent and a customers interest result in an enormous waste of energy and resources.
A comprehensive alternative approach for electronic delivery of location specific advertising items does not exist. Furthermore recipients of advertising mail items in existing platforms do not have a means of specifying their preferences. For example, recipients cannot specify that they may be interested in advertising material regarding local retail sales but not necessarily interested in local supermarket promotions.
Voice and video communications over the internet such as services provided by “Skype” lacks user authentication prior to engagement. Apart from users who are part of a private network or a virtual private network, user authenticated secure channel for audio and video communications do not exist in the public domain.
Accordingly, there is a need for a method and system for providing a secure and user identity authenticated communications service to overcome aforementioned problems and limitations. It is desirable to provide an integrated communications system where all participants are authenticated prior to engagement. Furthermore, it is desirable that the default addressing scheme be the street address scheme used by the postal services, which allows existing mail senders to use the electronic system using the information they already have. The use of street addresses also facilitate the required separation from existing email systems. It is also desirable for participants to be able to nominate areas of advertising interests or a lack thereof, enhancing the ability of advertisers to target advertising material with the establishment of a correlation between customer interest and advertiser intent.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a method of registering a user for secure communications, the method comprising the steps of:
a server receiving application data from a user device, the application data including a name of the user and a corresponding postal address of the user, and a user device identification key generated by the user device based on an identifier of the user device;
the server outputting an activation key based on the user device identification key, for posting to the user in a postal mail item bearing the name of the user and the corresponding postal address of the user received by the server;
the user device receiving an input comprising the activation key;
the user device transmitting the activation key to the server; and
the server registering the user for secure communications, by storing in a database the name of the user and the corresponding postal address of the user in response to receipt of the activation key.
In a second aspect, the present invention provides a method of transmitting content of a postal mail item from a first user to a second user, the method comprising the steps of:
a first user device establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key and a postal mail folder, the secure channel of communication established by:
(i) the first user device generating a first user device identification key based on an identifier of the first user device;
(ii) the first user device transmitting to the server an activation key based on the first user device identification key, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database; and
(iii) the server receiving the activation key transmitted from the first user device;
the first user device generating an electronic copy of content of a postal mail item bearing the name and postal address of the second user;
the first user device transmitting the electronic copy to the server via the secure channel of communication;
the server locating from the plurality of names and postal addresses stored in the database a name and postal address corresponding to the name and postal address of the second user transmitted from the first user device; and
the server storing the electronic copy in the postal mail folder associated with the located name and postal address, for collection by the second user.
In a third aspect, the present invention provides a method of transmitting content of an advertising mail item from a first user to one or more second users, the method comprising the steps of:
a first user device establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key, interests information and an advertising mail folder, the secure channel of communication established by:
(i) the first user device generating a first user device identification key based on an identifier of the first user device; (ii) the first user device transmitting to the server an activation key based on the first user device identification key, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database; and (iii) the server receiving the activation key from the first user device;
the first user device generating an electronic copy of the content of the advertising mail item;
the first user device receiving interests information related to the electronic copy;
the first user device transmitting the electronic copy and the interests information related to the advertising mail item to the server via the secure channel of communication;
the server locating from the plurality of names and postal addresses stored in the database one or more second user names and postal addresses based on the interests information transmitted from the first user device, by comparing the interests information respectively associated with the plurality of names and postal addresses stored in the database to the interests information transmitted from the first user device;
the server storing an electronic copy of the content of the advertising mail item transmitted from the first user device in each one of the one or more advertising mail folders respectively associated with the located names and postal addresses, for collection by the one or more second users.
In a fourth aspect, the present invention provides a method of enabling audio or video communication between a first user and a second user, the method comprising the steps of:
a first user device establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key and an Internet Protocol (IP) address, the secure channel of communication established by:
(i) the first user device generating a first user device identification key based on an identifier of the first user device; (ii) the first user device transmitting to the server an activation key based on the first user device identification key, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database; and (iii) the server receiving the activation key from the first user device;
the first user device transmitting to the server a request for a communication channel with the second user, the request comprising the name and address of the second user;
the server locating from the plurality of names and postal addresses stored in the database a name and postal address corresponding to the name and postal address of the second user transmitted from the first user device; and
the server enabling audio or video communication between the first user and the second user, by transmitting to the first user device the IP address associated with the located name and postal address.
In a fifth aspect, the present invention provides a method of registering a user for secure communications, the method comprising the steps of:
receiving a name of the user and a corresponding postal address of the user;
generating a user device identification key based on an identifier of a user device;
generating application data including the name of the user and the corresponding postal address of the user and the user device identification key;
transmitting the application data to a server;
receiving an input comprising an activation key based on the user device identification key, the activation key posted to the user in a postal mail item bearing the name of the user and the corresponding postal address of the user included in the application data transmitted to the server; and
transmitting the activation key to the server.
In a sixth aspect, the present invention provides a method of transmitting content of a postal mail item from a first user to a second user, the method comprising the steps of:
establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key and a postal mail folder, the secure channel of communication established by:
(i) generating a first user device identification key based on an identifier of a first user device; and (ii) transmitting to the server an activation key based on the first user device identification key, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database;
generating an electronic copy of the content of the postal mail item bearing the name and postal address of the second user; and
transmitting the electronic copy to the server via the secure channel of communication, for storage in the postal mail folder associated with the name and postal address of the second user.
In a seventh aspect, the present invention provides a method of transmitting content of an advertising mail item from a first user to one or more second users, the method comprising the steps of:
establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key, interests information and an advertising mail folder, the secure channel of communication established by:
(i) generating a first user device identification key based on an identifier of a first user device; and (ii) transmitting an activation key based on the first user device identification key to the server, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database;
generating an electronic copy of the content of the advertising mail item;
receiving interests information related to the electronic copy; and
transmitting the electronic copy and the interests information to the server via the secure channel of communication, for storage in the one or more advertising mail folders respectively associated with one or more names and postal addresses located from the names and postal addresses stored in the database based on the interests information.
In an eighth aspect, the present invention provides a method of enabling audio or video communication between a first user and a second user, the method comprising the steps of:
establishing a secure channel of communication with a server in communication with a database storing a plurality of names and postal addresses, each name and postal address associated with an activation key, the secure channel of communication established by:
(i) generating a first user device identification key based on an identifier of a first user device; and (ii) transmitting an activation key based on the first user device identification key to the server, the activation key corresponding to the activation key associated with one of the names and postal addresses stored in the database;
generating a request for a communication channel with the second user, the request comprising the name and address of the second user; and
transmitting the request to the server via the secure channel of communication, for enabling audio or video communication between the first user and the second user.
In a ninth aspect, the present invention provides a method of registering a user for secure communications, the method comprising the step of:
receiving application data from a user device, the application data including a name of the user and a corresponding postal address of the user, and a user device identification key generated by the user device based on an identifier of the user device;
outputting an activation key based on the user device identification key received from the user device, for posting to the user in a postal mail item bearing the name of the user and the corresponding postal address of the user;
receiving from the user device an input comprising the activation key; and
registering the user for secure communications, by storing in a database the name of the user and the corresponding postal address of the user in response to receipt of the activation key.
In a tenth aspect, the present invention provides a method of transmitting content of a postal mail item from a first user to a second user using a database storing a plurality of a plurality of names and postal addresses, each name and postal address associated with an activation key and a postal mail folder, the method comprising the step of:
establishing a secure channel of communication with a first user device by receiving from the first user device an activation key (i) generated by the first user device based on an identifier of the first user device, and (ii) corresponding to an activation key associated with one of the plurality of names and postal addresses stored in a database;
receiving an electronic copy of the content of the postal mail item bearing the name and postal address of the second user from the first user device via the secure channel of communication; locating from the plurality of names and postal addresses stored in the database a name and postal address corresponding to the name and postal address of the second user received from the first user device; and
storing the electronic copy in the postal mail folder associated with the located name and postal address, for collection by the second user.
In an eleventh aspect, the present invention provides a method of transmitting content of an advertising mail item from a first user to one or more second user using a database storing a plurality of a plurality of names and postal addresses, each name and postal address associated with an activation key, interests information and an advertising mail folder, the method comprising the step of:
establishing a secure channel of communication with a first user device by receiving from the first user device an activation key (i) generated by the first user device based on an identifier of the first user device, and (ii) corresponding to an activation key associated with one of the plurality of names and postal addresses stored in the database;
receiving from the first user device via the secure channel of communication an electronic copy of the content of the advertising mail item and interests information related to the advertising mail item;
locating one or more names and postal addresses from the plurality of names and postal addresses stored in the database based on the interests information transmitted from the first user device, by comparing the interests information respectively associated with the plurality of names and postal addresses stored in the database to the interests information received from the first user device;
storing an electronic copy of the content of the advertising mail item received from the first user device in each one of the one or more advertising mail folders respectively associated with the located names and postal addresses, for collection by the one or more second users.
In a twelfth aspect, the present invention provides a method of enabling audio or video communication between a first user and a second user using a database storing a plurality of a plurality of names and postal addresses, each name and postal address associated with an activation key and an Internet Protocol (IP) address, the method comprising the step of:
establishing a secure channel of communication with a first user device by receiving from the first user device an activation key (i) generated by the first user device based on an identifier of the first user device, and (ii) corresponding to an activation key associated with one of the plurality of names and postal addresses stored in the database;
receiving from the first user device via the secure channel of communication a request for a communication channel with the second user, the request comprising the name and postal address of the second user;
locating from the plurality of names and postal addresses stored in the database a name and postal address corresponding to the name and postal address of the second user received from the first user device; and
transmitting to the first user device the IP address associated with the located name and postal address.
The present invention also provides a system, method and apparatus for a user identity authenticated communications client program for secure and onymous electronic communications and a corresponding transfer server which facilitate the said communications. In the event that the communication is by mail, the method includes the steps of:
providing a communications client program to authenticated participants to send and receive mail items;
providing a transfer server having an associated database containing participants details;
authenticated participant sender establishing a secure channel of communication with the transfer server;
authenticated participant sender sending an encrypted item of mail to an addressee bearing street address or in the case of an advertisement, target audience preferences;
the transfer server receiving the mail item;
the transfer server verifying the intended recipient is a participant;
the transfer server decrypting the message and encrypting the said message with recipient public key;
the transfer server storing the mail item in the recipient(s) mail folder for collection by the said recipient;
the authenticated participant recipient establishing a secure channel of communication with the transfer server;
the transfer server delivering the mail item to the recipients communications client program in electronic form;
the recipient communications client sending a message digest notification to the transfer server if required;
the recipient decrypting the mail item, and in the event that the communication is either audio or video, the method includes the steps of:
providing a communication client program to authenticated participants for audio and video communications;
providing a transfer server containing participant details;
authenticated participant initiator establishing a secure channel of communication with the transfer server;
authenticated participant initiator requesting a communication channel with an addressee from the transfer server;
the transfer server discovering whether the addressee is a participant and if indeed a participant whether the addressee is available for communications;
upon success, providing the initiator with the addressees IP address;
the initiator communications client program establishing a secure channel of communications with the addressee communications client program;
upon successful communication, terminating the established connection.
The invention provides a technical solution that parallels in many respects the conventional postal service albeit the solution is an electronic one. It uses the postal service street addressing scheme, which every individual and legal entity has an association with, as opposed to a system specific identifier or conventional email address. The method and system overcomes the postal services weaknesses by providing an advertising platform that accounts for customer interest or a lack thereof. Use of the conventional street addressing scheme also means that any user who participates in the system can send sender authenticated secure mail items to anyone who participates in the system, provided they know the receivers street address. Location specific messages and advertising messages can be sent by anyone on the system and the correlation between advertiser intent and customer interest is resolved at the transfer server. The method and system extends conventional postal services by providing audio and video channels for secure and authenticated communications.
Furthermore, the invention can significantly improve on the conventional email system. All participant identities are verified prior to engagement and mail items are encrypted preventing non-intended recipients from access. Default message digest notifications provide added certainty and security to the transferred mail items within the system. Integrity of the onymous communication system is robust in comparison with conventional email systems and thus provide a suitable digital alternative for secure communications in the public domain, which as of yet does not exist.
Conventional postal operators mail boxes receive unsolicited mail items mainly from local entities. There is no method to correlate a mail box owners particular preferences in an area of advertising with an advertisers intent of attracting a potential customer. “Spam” mail on email systems have become the digital equivalent of “junk mail” and clutter email in-boxes. The invention improves significantly on existing practices by firstly eliciting participant preferences in the form of nominations of areas of interest and then by providing the opportunity for advertisers to simply send advertisements to the transfer server with target market descriptions and the transfer server matching participants nominations and forwarding mail items only to interested participants. In this respect participants have an added control in soliciting potentially interesting information and blocking unwanted material.
Furthermore, the mail sending process is streamlined with electronic sending of mail items and thus mitigates the inconveniences of having to print, envelope, stamp and take the mail item to a collection location, significantly improving productivity and reducing carbon footprint.
In accordance with an embodiment of the invention, the identity of participants is established and verified prior to participation. The method preferably includes a primary authentication process, which includes the steps of:
the potential participant installing a communications client program on a PC or a suitable hand-held device e.g. PDA;
the transfer server receiving a participation application from the potential participant via the communications client program;
the participant request including participant information enabling the identity of the participant to be validated;
validating the identity of the participant using the participant information;
if validation is successful, accepting the participant request, creating a corresponding participant entry in the database, issuing a signed certificate and corresponding private key to the participant or otherwise rejecting the potential participant request.
The primary authentication process is carried out by sending an “activation key” to the participant via conventional post services. This method confirms that the participant has access to the physical postal address and by association confirms the name address correlation. Secondary method of authentication includes the participant sending copies of original identity documents e.g. passport, drivers licence or utility bills via the communications client program to the transfer server and manual or automated audit of the said documents at the transfer server. A tertiary method of authentication includes participant presenting original identity documents. e.g. passport, drivers licence or utility bills to be verified, photocopied and sent to the transfer server at a nominated physical outlet (e.g. the local post office) by an attendee. Other methods of identity verification which are known to a person skilled in the relevant art may additionally be used.
Subsequently, once the initial identity validation is successful, in accordance with the invention, the participant is issued with a private key and a corresponding CA signed digital certificate to persist the validity of identification. The transfer server acts as the certificate authority by issuing, signing and managing the associated public key infrastructure. The authentication mechanism goes further than a common digital certificate assignment. The three levels of authentication introduces extended levels of authentication reliability associated with the issued digital certificate in conjunction with the authentication levels recorded at the transfer server. Additional authentication is guaranteed by having the devise specific “activation key” presented with each connection to the transfer server. Even if the digital certificate is compromised, access to the transfer server is not granted unless the appropriate “activation key is presented. Additional functions carried out by the transfer server as the Certificate Authority is apparent to those skilled in the relevant art.
In an embodiment, the invention is advantageously able to substantially eliminate issues relating to security and identity in electronic mail transfer systems in the public domain. The invention provides an improved ability for individuals and entities to communicate over the internet onymously (identity verified). Law enforcement agencies and other governmental organisations may be able to communicate with the general public over the internet legally using the invention. A further outcome of onymous communications is the ability to integrate existing real-time communication methods including audio and video with the benefits of onyminity.
Increased uptake of the invention is anticipated to reduce paper-based mail communications, which will result in reduced levels of resource consumption, increased productivity, increased local correspondences (location specific) and social, economic and environmental benefits that flow as a consequence.
Government and non government organisations will have the ability to integrate location specific communications once the invention has a high level of participation. Early warning systems (e.g. flood and bush fire alerts) which essentially operate with a location specificity can integrate the invention to communicate with the intended audience effectively. Medical epidemic situations can be monitored more effectively by geographic region and vital information exchanged through the services provided the invention.
It is preferred that the method be internet-based i.e. that the transfer server is provided having an internet connection such that participant activities can be executed via the internet. It is also preferred that the participant communication client program is provided having an internet connection to communicate with the transfer server.
In accordance with a preferred embodiment of the invention, access to and from the transfer server for participants is provided via a stand-alone or an integrated communications client program installed by the participant. Participants cannot use any available web browser to access the transfer server. Participants can only use the communication client program installed in their respective device(s). Participants may install the communication client program on one or more devices that they wish to use as a gateway to the transfer server. For example, a participant may wish to install the communication client program on a PC and/or a hand-held device e.g. PDA. Both instances of the communication client program has to be registered with the transfer server prior to use. Once the identity validation of the participant is carried out successfully using the “activation key” which is delivered by conventional postal service to the participant, the specific instance of the communication client program is activated. The “activation key” is generated by the communication client program using a hardware specific identifier (e.g. MAC address in PCs, IMEI number in mobile devices) so as to prevent unauthorised use of the communication client program. Communication client program maybe stand alone or integrated with existing email client programs such as Microsoft Exchange or Apple Mail. The anticipated advantage of using a nominated point(s) of entry to the transfer server is that all participants are able to send and receive mail items securely without compromising the integrity of the system. A further anticipated advantage is the sense of security the participants feel having their important documents delivered to device(s) nominated by the said participant. The communication client program may act as a vault for documents. Participants may wish to store external documents in a folder on the mail client program which then may be synchronised with a web storage space on the transfer server.
Access to the transfer server is initiated by participants both when receiving and sending mail items and message digest notifications, which is analogous to standard email client programs implementing POP or IMAP protocols. However when required, as is in the case when the transfer server queries a participant for audio/video communications availability, the transfer server may initiate contact with the participant. Firewalls and access control methods are implemented at the transfer server to restrict unauthorised access and to identify participants accessing the system. A “client-authenticated TLS and SSL handshake” may be initiated at participant login request.
Access to the transfer server is provided through the installed communications client program and therefore correspondence is available from anywhere in the world as long as the participant has a registered device and an internet connection.
The present invention also provides a transfer server for the transfer of mail items to corresponding recipient(s) and for establishing a audio or video communication channel. The transfer server including:
at least one processor;
a database containing participant details including name and street address;
a database containing participant public key;
a database containing advertising category preference nominations;
at least one data communications interface operatively coupled to the processor;
at least one storage medium operatively coupled to the processor, the storage medium containing program instructions to execute the steps of:
facilitating potential participant registration and activation process;
facilitating the authenticated participant sender establish a secure channel of communication with the transfer server via the installed communications client program;
the transfer server receiving an item of mail sent by the participant mail sender;
the transfer server verifying the intended recipient is a participant;
the transfer server decrypting the message and encrypting the sent message with recipient public key;
the transfer server storing the mail item in the recipients secure mail folder for collection by the said recipient;
facilitating the authenticated participant recipient establish a secure channel of communication with the transfer server;
the transfer server delivering the mail item to the recipients communication client program in electronic form;
the recipient communication client sending a message digest notification to the transfer server;
the transfer server storing the message digest notification in the message senders mail folder for collection,
and in the event a mail item is either an item of advertising or information:
facilitating authenticated participant sender establish a secure channel of communication with the transfer server;
the transfer server establishing a single participant or a group of participants who have subscribed to the category that the mail item belongs to and are within the locality that the sender of the said mail item has nominated;
if the mail item is encrypted, decrypt the mail item and encrypt the mail item with the intended recipient(s) public key;
the delivery server storing the mail item in the recipient(s) message folder(s);
the recipient(s) establishing a secure communication channel with the transfer server;
the transfer server delivering the mail item to the recipient(s) communication client program,
and furthermore if the communication request is for an audio/video channel:
authenticated participant initiator establishing a secure channel of communication with the transfer server;
authenticated participant initiator requesting a communication channel with an addressee from the transfer server;
the transfer server discovering whether the addressee is a participant and if indeed a participant whether the addressee is available for communications;
upon success, providing the initiator with the addressees IP address;
the initiator communications client program establishing a secure channel of communications with the addressee communications client program;
upon successful communication, terminating the established connection.
In another aspect, the present invention provides a transfer server with accordance with the invention, including:
means for establishing a secure channel of communication with participants communication client programs;
means for transferring mail items via the said communication channel;
means for facilitating an audio/video communication channel.
The transfer server preferably contains further programming instructions to execute the various functions of a certificate authority including key and certificate generation, certificate signing, certificate exchange management functions and other “CA” functions apparent to a person skilled in the relevant art.
It is to be understood that the method is extensible to a large number of participants, accordingly the transfer server and the underlying infrastructure is extensible as apparent to persons skilled in the relevant art.
The present invention also provides a communication client program for participants to send and receive mail items and establish audio/video communication channel. The communication client program includes;
program instructions to execute the steps of:
the participant applying for registration and activation;
the authenticated participant sender sending mail items securely;
the authenticated participant receiving mail items securely;
the authenticated participant decrypting and storing mail items.
and in the event the communication is either audio or video:
the authenticated participant requesting an audio/video communication channel;
the authenticated participant establishing and using an audio/video communication channel with the addressee participant.
According to the invention, the communication client program will comprise necessary means to execute the said operations. Instruction sets and device components that are apparent to persons skilled in the relevant art will additionally be used.
The transfer server and the communication client program is preferably computer-implemented and the means for effecting functionality include suitable interface hardware at the server for interfacing to a communications network such as the internet and may further include one or more software components executed by at least one processor of the server computer including instructions to effect corresponding functionality.
Further preferred features and advantages of the invention will be apparent to those skilled in the relevant art from the following description of preferred embodiments of the invention, which should not be considered to be limiting of the scope of the invention as detailed in the preceding statements or in the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention will now be described referring to the accompanying drawings, wherein like reference numbers refer to like features, and in which:
FIG. 1A is a schematic diagram of a system electronically transferring an addressed mail item in accordance with a preferred embodiment of the invention;
FIG. 1B is a schematic diagram of a system electronically transferring an advertisement item to multiple recipients in accordance with a preferred embodiment of the invention;
FIG. 1C is a schematic diagram of a system with multiple participants;
FIG. 1D is a block diagram illustrating a transfer server and communication client program in an internet-based implementation of the system in FIG. 1A and FIG. 1B ;
FIG. 1E is a schematic diagram of participants conducting real-time audio/video communications in accordance with a preferred embodiment of the invention;
FIG. 2 is a flowchart illustrating steps in a method for electronically transferring mail items according to a preferred embodiment of the invention;
FIG. 3 is a flowchart of an exemplary application and account creation process according to a preferred embodiment of the invention.
FIG. 4 is a flowchart of an exemplary account registration initialisation process according to an embodiment of the invention.
FIG. 5A is a flowchart an exemplary primary method of identity authentication according to a preferred embodiment of the invention;
FIG. 5B is a flowchart of a secondary method of identity authentication according to a referred embodiment of the invention;
FIG. 5C is a flowchart of a tertiary method of identity authentication according to a preferred embodiment of the invention;
FIG. 6 is a flowchart of the account creation process according to a preferred embodiment of the invention;
FIG. 7A is a flowchart of an address change process according to a preferred embodiment of the invention;
FIG. 7B is a flowchart of a device add process according to a preferred embodiment of the invention.
FIG. 8A is a flowchart of the mail sending process according to a preferred embodiment of the invention;
FIG. 8B is a flowchart of the mail receiving process according to a preferred embodiment of the invention;
FIG. 8C is a flowchart of establishing and conducting audio or video communications according to a preferred embodiment of the invention;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to a preferred embodiment of the present invention, here are provided methods and apparatus for providing a communications client program and an associated transfer server for onymous and secure communications. FIG. 1A , FIG. 1B and FIG. 1C show schematic diagram of an exemplary system 100 for the transfer of mail items in accordance with the invention. FIG. 1D show an internet implementation of a preferred embodiment of the system 100 through an exemplary block diagram illustrating specific component arrangements.
The system 100 includes a transfer server 102 which in a preferred embodiment is a computer or computer system with one or more central processing units 122 , operatively coupled with a database 123 . The database 123 includes participant details and mail items as described in detail below. The transfer server 102 further includes at least one storage medium 120 with instruction code 121 , to be executed by the processor 122 .
The transfer server additionally includes one or more network interfaces 124 to facilitate connection to the internet 80 . The network interface 124 may be any suitable interface such as Ethernet, ADSL or a wireless network interface.
It is preferred that communications to and from the transfer server 102 be conducted via the firewall 125 to prevent unauthorised access to, or malicious attacks upon, the transfer server 102 .
The system 100 includes communication client program 103 which in a preferred embodiment is a computer program which is implemented with one or more central processing units 128 , operatively coupled with storage medium 126 having instruction code 127 and a network interface 130 .
Connection to the transfer server is facilitated via a participants communication client program instance.
Logical connectivity between two participants is depicted in FIG. 1A . Connectivity is available between participant 111 and the transfer server 102 for the sending of mail items and connectivity is available between transfer server 102 and the addressed mail recipient participant 112 for the collection of said mail item.
Logical connectivity between participants when sending advertising mail items is depicted in FIG. 1B . Connectivity is available between participant 111 and the transfer server 102 for the sending of advertising mail items and connectivity is available between participants 112 , 113 and 114 and the transfer server 102 for the collection of said mail item. Assignment of the advertising mail item is conducted by reconciling participant advertising nominations with the “intended audience” selection of the sent advertising mail item. The “intended audience” selection is a category and geographic location selection.
Logical connectivity between plurality of participants is facilitated via the transfer server 102 , as depicted in FIG. 1C in a preferred embodiment of the invention.
All participants are able to send and receive mail items and advertising mail items.
The purpose of the mail system is to provide one or more participants with a mail transfer service to send and receive mail items and advertising items in electronic form onymously, using a communications client program. A participant can send mail items to any other participant provided that the said participant has the street address of the intended participant recipient. It is a particular feature of the transfer system that participants nominate advertising interests and senders of advertising mail items nominate “intended audience” so that reconciliation of advertising mail receivers can be carried out at the transfer server 102 . Participant information including advertising nominations are not shared with third parties.
FIG. 1E depicts a real-time audio/video connection between two participants in accordance with the invention. A connection is established between participants 115 and 116 through the installed communications client program. Participant 115 queries the transfer server 102 for participant 116 s availability and IP address. The transfer server 102 determines whether participant 116 is indeed a participant and if so whether participant 116 is available for communications by querying participant 116 with the last known IP address. If participant is available for communications, the relevant IP address is transmitted to the initiating participant 115 . Participant 115 can then establish an audio/video communication channel with participant 116 .
With reference to FIG. 2 , a flowchart illustrating essential steps of the onymous mail transfer service according to a preferred embodiment of the invention, participation is initiated at step 201 when the prospective participant installs a communication client program. At step 202 , the prospective participant makes an application to register with the transfer server. The process is described in detail below with reference to FIGS. 3, 4 and 5A . However in summary, the application includes applicants name, street address as well as other contact information. The application also includes an “activation key” which is a hash generated by the installed communication client program 103 using a device specific identity (e.g. MAC address on PCs or IMEI number on mobile devices). The “activation key” is generated and transferred to the transfer server unbeknownst to the participant. At step 203 the participant name and street address is verified by sending the “activation key” via the postal services to the prospective participants street address and then having the prospective participant enter the “activation key” through the communication client program 103 through to the transfer server 102 . The identity validation process 203 is described in detail below with reference to FIGS. 5A and 5B .
Once the identity validation carried out in step 203 is successfully processed, participant advertising nominations are obtained at step 204 . Advertising nominations are areas of interest that the participant may wish to receive advertising mail items about. For example, live music acts within a 5 km radius of the participant street address. An essential benefit of the invention is that participants can send/receive location specific advertisements cost-effectively because of the correlation provided by the mail transfer service.
Participants may change their advertising nominations at any given time.
At step 205 participant account is created. The process is described in detail below with reference to FIG. 6 . As part of the account creation process, public key infrastructure components such as a key pair and digital certificate are generated at the transfer server 102 at step 206 and transferred to the participants mail access client program in order to persist the validated identity of the authenticated participant. Participant PKI components are managed by the transfer server 102 and the communication client program 103 , participants are not actively involved in the process. This automation is for the ease and benefit of participants. A copy of participant private key may be stored in an external database as back up and may be requested by the account holder participant or relevant law enforcement authorities.
At step 207 , the participant creates mail items addressed to a particular participant. For example a participant utility company may create, address and send a monthly bill to a participant customer in electronic form. Advertising mail items with “intended audience” specifications can also be created according to a preferred embodiment of the invention. For example, a participant may send out an invitation to nearby resident book lovers to form a book club. Addressed mail items include a message digest notification request to establish non-repudiation claim. However the request for a message digest notification may be omitted by the mail sender.
In accordance with the invention, a mail item is any item of traditional post mail converted to electronic form in any file format inclusive of but not limited to, plain text, PDF, XML for text and/or GIF and JPEG for image. Additionally in accordance with the invention, a mail item is an audio or video message in electronic form in any file format including but not limited to, mop, wma or au for audio and swf, wmv and mpg for video.
A secure connection is established at step 208 with the transfer server 102 for the purposes of forwarding the mail item(s) created in step 207 . A “client-authenticated SSL connection” is an exemplary implementation of a secure connection according to a preferred embodiment of the invention. Additionally, the “activation key” is requested by the transfer server 102 when establishing a secure connection with the transfer server 102 as an additional safety measure to verify the device making the request. Mail items are encrypted using a combination of hashing, data compression, symmetric-key cryptography and public-key cryptography. Step 208 is described in detail below with reference to FIG. 8A .
At step 209 , the sent mail items are verified for address validity. If the addressee of the said mail item is not a participant of the onymous mail transfer service, a notice is sent back to the mail sender. Additionally, access is provided for government organisations to send mail items to all participants in any area. Authority levels are described in detail below with reference to FIG. 6 . Participant individuals and businesses are bound by participant advertising nominations as described in step 204 and cannot send mail items to all participants.
Sent Mail items are sorted by the transfer server 102 and stored on recipient(s) mail folders to be collected by the said recipients at step 210 . Name and Street Address is used as the default addressing regime as opposed to email address, IP address or system specific unique identifier. Advertising mail items are addressed by category and geographic locality and reconciliation with participant specific street addresses is carried at step 210 . Advertising categorisation and the provision of the service is aimed at exposing participants to various products, services, events and functions that may spark a potential interest.
At step 211 , the participant recipient(s) of the sent mail item establishes a secure connection to the transfer server 102 as described in step 208 above and the sent mail item is transferred to the recipient(s) communications client program. Participants may connect to the transfer server periodically to check mail or they may establish a persistent connection to the transfer server 102 and query the server for new mail items intermittently according to a preferred embodiment of the invention.
The onymous mail transfer system additionally provides for a massage digest notification to be transmitted at step 212 . The message digest notification (MDN) is requested at step 207 when mail items are sent and the generated MDN is deposited at the transfer server in the mail senders folder for collection by the said sender.
While the foregoing description with reference to FIG. 1A, 1B, 1D and FIG. 2 illustrate the operation of system 100 , transfer server 102 and mail access client program 102 from the perspective of a single participant, it will be appreciated that this is exemplary only of the general operation of system 100 , the transfer server 102 and the mail access client program, which provide a service for onymous transfer of mail items to and from a plurality of participants as illustrated in FIG. 1C .
FIG. 3 is a flowchart 300 of an exemplary mail client installation, application and account creation process according to a preferred embodiment of the invention. At step 301 , a potential participant installs a communications client program and at step 202 submits an application for registration with the transfer server. The application structure is described in detail below with reference to FIG. 4 . At step 302 , the accounts database is queried for existing accounts and cross-referenced with the applicant details to determine whether an account already exists. As is illustrated at step 304 , if an account already exists, an account exist notification 305 is generated and the process is terminated at step 306 .
Given that the application is for a new account, registration initialisation is carried out at step 307 , which is described in detail below with reference to FIG. 4 . Identity authentication is of significant importance in a preferred embodiment of the invention. Primary identity authentication is carried out at step 308 by sending the “activation key” by conventional post services to the applicant and having the said applicant input the “activation key” with an activation request via the communications client program to the transfer server. The applicants access to the post address confirms the name and street address of the said applicant with the minimum of inconvenience to the applicant. Failure of the identification process leads to a failure notification at step 309 and process termination at step 306 . Successful identity authentication leads to the account creation process at step 312 . The primary identity authentication method is detailed below with reference to FIG. 5A .
Secondary and tertiary authentication carried out at steps 310 and 311 are progressively stringent measures to validate the identity of a participant. Secondary and tertiary authentication methods are detailed below with reference to FIGS. 5B and 5C respectively. These additional levels of authentication makes the onymous mail transfer service, according to the invention, more scalable and provides different degrees of authentication rigour for specific activities. For example, it is plausible to envisage an electronic voting system implemented via the onymous mail transfer service, where tertiary authentication is mandated by the respective government.
The account creation at step 312 follows the successful primary identity authentication process at step 308 , in which an account is created as described below in detail with reference to FIG. 6 , and persisted in the accounts database at 303 .
At step 313 , private key and corresponding signed digital certificate is transferred to the applicants communications client program using the secure connection established to activate the user account. Alternatively, the key pair and the digital certificate may be generated at the communications client program and the digital certificate forwarded to the transfer server to be signed by the transfer server as the certificate authority. According to a preferred embodiment of the invention, the transfer server performs the functions of a conventional certificate authority by issuing signed digital certificates to participants in the onymous mail transfer system. In addition to traditional functions carried out by a certificate authority, the transfer server also generates the key pair and forward the private key to the applicant in step 313 .
According to a preferred embodiment of the invention, participants communications client program acts as the gateway to onymous and secure communications via the Internet. Apart from sending and receiving discrete mail items, the communications client program is used as the point of authentication for real-time, onymous and secure audio and video communications.
FIG. 4 is a flowchart showing further details of a preferred embodiment of the registration initialisation process 307 . According to the embodiment, the application is submitted through the installed mail access client program via the internet. The application must meet the minimum requirements 405 , which must include the applicants full name 411 , street address 412 and generated “activation key” 413 . The “activation key” is generated by the mail access client program using a hardware specific identifier such as the MAC address or IMEI number on mobile devises and a suitable cryptographic algorithm. The purpose of the “activation key” is to restrict unauthorised mail client program copy installations as well as to identify specific instance of a mail client program independent of the associated digital certificate so as to corroborate the devise that is used to access the transfer server with the associated digital certificate. In the unlikely event that the participants mail access device (eg PC or PDA) is compromised and digital certificate stolen, the attacker still needs to generate the “activation key” to establish a connection with the transfer server. The “activation key” is generated and transferred unbeknownst to the applicant.
At step 408 , the provided street address is validated against existing street addresses available in a specific region through third party providers and if the address is invalid, invalid address notice is generated and the application rejected at step 404 . Once the minimum requirements are met at step 403 , a key pair and the corresponding digital certificate is generated at step 406 and stored in a provisional account store at step 407 .
FIG. 5A is a flowchart showing further details of a preferred embodiment of the primary identity authentication process 308 . According to the embodiment, the “activation key” received in with the application is sent to the applicant via the postal services at step 502 . At step 503 the applicant inputs the received “activation key” via the mail access client program through to the transfer server in the activation request confirming that the applicant has access to the physical mail box and therefore by association bears the name and resides at the street address.
At step 504 , the information received with the activation request is compared against entries in the provisional account store and if the information does not corroborate at step 505 a validation error message is generated at step 506 and application rejected at step 404 . Successful primary identity authentication at step 504 leads to persisting the identity data at step 508 .
FIG. 5B is a flowchart showing further details of a preferred embodiment of the secondary identity authentication process 310 . According to the embodiment, captured identity data is presented to the transfer server via the mail access client program at step 520 . By way of document example, passport 521 and utility bill 521 is shown for individuals, and company registration documents 522 for companies. The examples are in no way limiting the scope of identity verification but rather an example to illustrate the process of secondary authentication. The validation benchmark at step 523 provides the specific document requirements and this may vary from region to region and country to country. The validation benchmark is some appropriate standard against which the persuasiveness of the proof of identity data or documentation may be measured, so as to provide a formal and uniform standard of proof of identity.
At step 524 , a document audit is carried out either manually or electronically to establish the authenticity of the documents and the information they contain, comparing the received information with perssited identity data at 508 . Failure of the audit process results in rejecting the secondary authentication request in step 525 . Successful audit of the captured identity data leads to step 526 , where the secondary authentication data is persisted as identity data.
FIG. 5C is a flowchart showing further details of a preferred embodiment of the tertiary identity authentication process 311 . According to the embodiment, original authentication documents are presented at a nominated center or outlet. (eg the post office) By way of document example, passport 521 and utility bill 521 is shown for individuals, and company registration documents 522 for companies. The examples are in no way limiting the scope of identity verification but rather an example to illustrate the process of tertiary authentication. The validation benchmark at step 531 provides the specific document requirements and this may vary from region to region and country to country. The validation benchmark is some appropriate standard against which the persuasiveness of the proof of identity data or documentation may be measured, so as to provide a formal and uniform standard of proof of identity.
At step 532 , a manual document audit is carried out by the outlet representative and successful audit leads to step 534 , where the authenticated identification data is logged to the transfer server through a secure connection, to be persisted as identity data. Failure of documentation audit leads to step 533 , where the tertiary authentication is rejected.
FIG. 6 is a flowchart showing further details of a preferred embodiment of the account creation process 312 . According to the invention, inputs to the account creation process 312 are data from the provisional account store 407 and data from the identity data store 508 . The account framework incorporates division of functionality and employs different data structures to implement the required functionality. At step 611 the generated digital certificate is signed by the transfer server acting as the certificate authority and stored along with other “PKI” data at step 602 and a copy to be transferred to the participant following the account creation process as described above in step 313 with reference to FIG. 3 . Additionally a copy of the private key is persisted in an external database 612 , for situations where the private key is lost or destroyed due to some unforseen reason and needs to be replaced. Optionally participants may request their private key to be destroyed after successful completion of step 313 with reference to FIG. 3 as described above.
At step 602 , identity data is collated with PKI information to form the identification description. Without limitation, the identification description includes participant name, street address, “activation key” and participants public-key.
Secondary and tertiary authentications are persisted through security clearance levels as depicted in step 607 . Without limitation, clearance levels 1 , 2 and 3 correspond with primary, secondary and tertiary levels of authentication. An additional level 4 clearance is provided for various government organisations and law enforcement agencies to communicate with participants without restrictions.
At step 603 , secure mail folder is created where all addressed mail items are deposited, awaiting collection by the account holder participant. The addressed mail items may additionally be encrypted before storage with the account holder participants public-key. Advertising nominations folders are generated at step 605 to store advertising mail items received by the account holder participant. A clear distinction is enforced by the onymous mail transfer service to separate addressed mail items from advertising mail items at the mail creation process where the mail sender is explicitly required to declare advertisements. Non-compliance may result in restrictions being imposed upon the offending participants. Advertising nominations may be changed any time according to the wishes of the account holder participant.
Additionally a synchronised folder is created at step 609 to facilitate files and folder storing on the transfer server as an online back-up storage for the account holder participant. The participant may wish to store important documents such as receipts, resumes, photocopies of important identity documents and so forth.
At step 610 , the generated account structure is persisted to the accounts database 303 .
FIG. 7A is a flowchart showing details of a preferred embodiment of the address change request process 701 . When participants change their permanent address, an accompanying address change request is to be lodged with the transfer server via the mail access client program. At step 308 , primary identity authentication is carried out as described above with reference to FIG. 5A to verify the new address proposed by the participant. Failure of the identity authentication process results in a request rejection at step 702 . Following successful identity authentication the accounts database 303 is updated at step 703 .
FIG. 7B is a flowchart showing details of a preferred embodiment of the add device to account request process 711 . If participants wish to add an additional access device with a mail access client installed, a request is send through the mail access client program to the transfer server. At step 308 , primary identity authentication is carried out as described above with reference to FIG. 5A to verify that the participant has access to the proposed device as well as the street address. Following successful identity authentication the accounts database 303 is updated at step 713 .
FIG. 8A is a flowchart showing details of the mail sending process according to a preferred embodiment of the invention. At step 802 mail items are created and at steps between 803 and 804 , a secure Internet protocol (IP) connection is established with the transfer server using, without limitation, HTTP(S), (S)FTP or secure SMTP protocols. The mail access client program initiates the connection. Two-way client-authenticated SSL connection is used as a preferred method of secure connection. At step 805 login authentication is carried out by the transfer server using the participant digital certificate and the device specific “activation key”. It must be noted that steps 802 - 805 are interconnected steps that enable secure sending of mail items. Mail items are encrypted using a combination of hashing, data compression, symmetric-key cryptography and public-key cryptography. Additional methods that are evident to a person skilled in the relevant art may be used. At step 806 , the transfer server processes the sent mail item(s) and deposits them in the relevant folders of the intended recipient(s) and the mail sender logs off at step 807 .
FIG. 8B is a flowchart showing details of the mail collection process according to a preferred embodiment of the invention. Steps 803 - 805 are as described above with reference to FIG. 8A . At step 808 , the transfer server obtains new mail items from the participants relevant folders and at step 809 mail items are transferred to the participants mail access client program where the mail items are processed and decrypted and a message digest notification transferred back to the transfer server if required.
The real-time audio and video communications process is illustrated in FIG. 8C , in accordance with a preferred embodiment of the invention. The communications client program makes a connection request with an addressee 822 . Steps 803 - 805 are described above in detail with reference to FIG. 8A . At step 823 , the transfer server queries the accounts database to verify that the addressee is indeed a participant and if so queries the addressee 822 using the last known IP address for availability. Upon success, the addressees IP address is transferred to the initiator client. At step 825 a secure connection is established for real-time audio and video communications using methods and protocols apparent to a person skilled in the relevant art.
The invention is not to be considered as any way limited by the foregoing descriptions of preferred embodiments, which are provided by way of example, but rather the scope of the invention is defined by the claims appended.
It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention, in particular it will be apparent that certain features of embodiments of the invention can be employed to form further embodiments.
It is to be understood that any reference to prior art made herein does not constitute an admission that the prior art formed or forms a part of the common general knowledge in the art, in Australia or any other country.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
|
The present invention provides a communications client program and an associated transfer server for onymous and secure communications over the internet. The communications client program is used for electronically sending and receiving mail items and for conducting realtime audio and video communications in a secure manner. A mail item is any item of correspondence that bears an addressee's street address (i.e. number, street, suburb, state and post code) or an advertising item that does not necessarily bear an addressee, but includes nominations for preferred destinations.
| 7
|
FIELD OF THE INVENTION
The present invention relates generally to highway signs and, more particularly, to assemblies for connecting warning flags to highway signs.
BACKGROUND OF THE INVENTION
Highway signs are generally used for promoting the safe passage of motor vehicles and/or pedestrians by advising of, for example, approaching unsafe driving conditions. These highway signs are generally provided with various highway legends, and are generally configured to flex in response to prevailing winds and wind gusts created by motor vehicles and the like.
Conventional highway signs are generally colored brightly to attract the attention of passersby. Additionally, these highway signs are commonly provided with warning flags secured thereto for flapping in the wind and for drawing additional attention of motorists to the legend on the highway sign.
A flexible, lightweight highway sign allows for convenient transportation and storage of the sign. Such a sign may have reinforcing battens for holding the sign in a message display position. These reinforcing battens are conventionally constructed of flexible, lightweight plastic materials. U.S. Pat. No. 4,426,800 discloses structure for mounting a highway sign using reinforcing battens and a stand. Warning flags are conventionally mounted on highway signs with flag arms, which are generally constructed of lightweight, flexible plastic. These warning flags enhance the visibility of the highway signs and give advance warning to motorists at a greater distance. U.S. Pat. No. 4,980,984 discloses a clamping member for attaching flag arms to a reinforcing batten of a highway sign. The clamping member disclosed in this patent, however, while providing excellent functionality, is somewhat complex in design and relatively expensive to manufacture. A need exists in the prior art for clamping members of simple, lightweight, and inexpensive design, for efficiently securing flag arms to highway signs.
SUMMARY OF THE INVENTION
The flag holders of the present invention are simple in design and relatively inexpensive to manufacture. These flag holders secure flag arms to reinforcing battens of highway signs without unnecessary bulk, weight, and complexity. According to one broad aspect of the present invention, a flag holder includes a flag arm bracket having a generally U-shaped body with two opposing edges. The U-shaped body wraps around a frame member, such as a reinforcing batten, of the highway sign, to thereby align the flag arm bracket with the frame member. An aperture in the flag arm bracket accommodates a shaft, such as a bolt. The shaft passes through both the aperture of the flag arm bracket and also through an aperture in the frame member of the highway sign. The bolt secures the flag arm bracket to the frame member. The flag arm bracket further includes an attachment portion for attaching at least one flag arm to the flag arm bracket.
The attachment portion of this flag arm bracket may include a sleeve for accommodating a corresponding flag arm. The bolt passes through the sleeve and through an aperture in the flag arm, to thereby prevent the flag arm from passing too far through the sleeve. The sleeve is oriented to hold the flag arm at either a thirty or forty-five degree angle, relative to the vertical reinforcing batten.
The attachment portion of the flag arm bracket may include the actual flag arm, instead of a sleeve. According to this broad aspect of the present invention, the flag arm is integrally molded with the flag arm bracket. This flag arm may be integrally formed with the flag arm bracket to extend at an angle of either thirty or forty-five degrees, relative to the vertical reinforcing batten. The flag arm bracket is secured to the vertical reinforcing batten using a shaft, for example, and the flag arm bracket may be rotated about the shaft to downwardly orientate the flag arm in a direction parallel to the vertical reinforcing batten for storage.
According to another broad aspect of the present invention, the flag arm bracket contacts a first side of the vertical reinforcing batten, and a second, similarly configured flag arm bracket may be mounted on an opposing side of the vertical reinforcing batten. The shaft, which passes through and secures the first flag arm bracket, also passes through and secures the second flag arm bracket. The second flag arm bracket holds a second flag arm in a similar orientation to the first flag arm, relative to the vertical reinforcing batten. A third flag arm may be optionally mounted in an aperture of either of the two flag arm brackets. This flag arm bracket assembly has a smaller number of moving parts, and allows for convenient storage, compared to the prior art. Additionally, the integrally molded flag arms may have I-beam configurations for added strength.
The present invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying illustrative drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the flag arm bracket assembly of the present invention, securing three warning flags to a highway sign;
FIG. 2 is a perspective view illustrating the flag arm bracket assembly of a first preferred embodiment secured to a vertical reinforcing batten of the highway sign;
FIG. 3 is an exploded view of the flag arm bracket assembly shown in FIG. 2;
FIG. 4 is a first cross-sectional view of the flag arm bracket assembly shown in FIG. 2;
FIG. 5 is a second cross-sectional view of the flag arm bracket assembly shown in FIG. 2;
FIG. 6 is a front elevational view showing movement directions of the flag arm bracket assembly of the first preferred embodiment;
FIG. 7 is a front elevational view showing the flag arm bracket assembly of the first preferred embodiment in a storage configuration;
FIG. 8 is a perspective view of the flag arm bracket assembly according to a second preferred embodiment; and
FIG. 9 is a top planar view of the flag arm bracket assembly shown in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the flag arm bracket assembly 12 of the present invention. The flag arm bracket assembly 12 is shown connected to a highway sign. Two side flag arms 33 and one center flag arm 34 are connected by the flag arm bracket assembly to the highway sign 11. Warning flags 31 are attached to each of the flag arms 33, 34.
The highway sign 11 comprises a sign stand 13 having legs 15, a base 17, and a stem 19. The sign stand 13 may be readily folded for transport and unfolded for mounting of the highway sign 11 thereon. In one preferred embodiment, the stem 19 of the sign stand 13 can be connected to the bottom pocket and connector 21 of the highway sign 11 to thereby mount the highway sign 11 in an upright configuration.
The highway sign 11 comprises a flexible material 29, which comprises a highway safety legend of a preselected type on one side thereof. A vertical reinforcing batten 23 fits into the bottom pocket and connector 21 at one end and into the flag arm bracket assembly 12 and a top pocket (not shown) at the other end thereof. A horizontal reinforcing batten 25 fits into two corner pockets 27 of the highway sign 11. The vertical reinforcing batten 23 and the horizontal reinforcing batten 25 preferably comprise a flexible material that will allow the highway sign 11 to respond to wind or gusts impinging thereon by bending, without breaking or tipping over. These reinforcing battens 23, 25 may comprise, for example, glass reinforced polyester, plastic pultrusions that are commercially available. The flexible material 29 of the highway sign 11 preferably comprises a lightweight, flexible material, such as reflective vinyl plastic and a fluorescent mesh that allows the sign to be readily rolled up, and in this condition, keeps the sign faces and legends in good working order.
FIG. 2 is a perspective view of one embodiment of the flag arm bracket assembly 12 attached to the vertical reinforcing batten 23. The flag arm bracket assembly 12 comprises two flag arm brackets 41, each of which includes a clamping portion 43 and a flag arm 33. Each clamping portion 43 is preferably integrally molded with a corresponding flag arm 33. As presently embodied, each integrally molded flag arm bracket 41 is injection molded, using a glass-filled plastic, for example. The flag arm 33 preferably comprises ribs 47. A warning flag 31 may be attached to each flag arm 33 either at manufacture, or by the user on site.
The clamping portion 43 of each flag arm bracket 41 is configured to snugly fit against the vertical reinforcing batten 23. In the presently preferred embodiment, the vertical reinforcing batten 23 has a rectangular cross section, and the clamping portion 43 comprises two lips 45 for fitting around a side 46 of the vertical reinforcing batten 23. The two lips 45 of each clamping portion 43 prevent the clamping portion 43 from rotating due to torque exerted by a corresponding flag arm 33, or from other forces such as wind.
In addition to having an integrally molded flag arm 33, the clamping portion 43 of the flag arm bracket 41 further comprises a rectangular aperture 44 for optionally receiving a rectangular center flag arm 34. The aperture 44 is partially disposed within a raised portion 49 of the clamping portion 43. This raised portion 49 has a U-shaped slot 53, which defines a finger member 55. The finger member 55 comprises an inwardly extending detent 57 thereon. No fasteners are utilized for securing the flag arm 34 within the rectangular aperture 44, since the flag arm and aperture are relatively sized to create a slightly interference fit, thereby frictionally securing the flag arm.
A recessed portion 51 of the clamping portion 43 includes an aperture 65 (FIG. 3). As shown in FIG. 3, the vertical reinforcing batten 23 also includes an aperture 67 for accommodating a shaft 63. The shaft 63 is inserted through a washer 37, a spring washer 61, the aperture 65 of the clamping portion 43, and the aperture 67 of the vertical reinforcing batten 23. Each side of the clamping portion 43 includes a recess 68 for receiving and centering the spring washer 61 (FIGS. 3 and 4). A push nut 62 fits over an end of the shaft 63, and the distal end of the shaft 63 can then be secured against a side of the vertical reinforcing batten 23 opposite the side 46 of the vertical reinforcing batten 23 contacting the clamping portion 43. For example, the shaft 63 may have threads on its distal end for accommodating a wing nut, or another push nut 62 may secure the shaft on the opposing side of the vertical reinforcing batten 23.
In the presently preferred embodiment, a second flag arm bracket 41, having a second aperture 65, fits against the opposing side of the vertical reinforcing batten 23. In this preferred embodiment, the shaft 63 is inserted through the second aperture 65 of the second flag arm bracket 41, and is also inserted through a corresponding spring washer 61, washer 37, and push nut 62.
A cross-sectional view of the flag arm bracket assembly 12, taken along the line 4--4 shown in FIG. 2, is illustrated in FIG. 4. The two spring washers 61 allow the two corresponding clamping portions 43 to move toward and away from the vertical reinforcing batten 23. When one of the spring washers 61 is compressed, a corresponding one of the clamping portions 43 may be slightly moved away from the surface of the vertical reinforcing batten 23. When the spring washer 61 is in a slightly expanded position, the two lips 45 of the corresponding clamping portion 43 fit around two corresponding sides of the vertical reinforcing batten 23 to thereby allow the inner channel 69 (FIG. 3) of the clamping portion 43 to contact three surfaces of the vertical reinforcing batten 23. In other words, when a flag arm bracket 41 is rotated about the shaft 63 into an orientation out of alignment with the vertical reinforcing batten 23, the corresponding spring washer 61 is slightly compressed. The spring washers 61, in combination with the lips 45 of the clamping portions 43, provide locking fits between the clamping portions 43 and vertical reinforcing batten 23. FIG. 5 illustrates a cross-sectional view of the clamping portion 43 shown in FIG. 3, taken along the line 5--5. As shown in FIG. 5, the inwardly extending detent 57 may slightly protrude into the rectangular aperture 44.
FIG. 6 illustrates the two flag arm brackets 41 in their locked positions, where the inner channels 69 of each clamping portion 43 (FIG. 3) contact an opposing surface of the vertical reinforcing batten 23. In the presently preferred embodiment, this locked position holds the respective flag arms 33 in a first working configuration at angles of either thirty or forty-five degrees, depending on preference, relative to the vertical reinforcing batten 23. The two flag arm brackets 41 may be rotated in the directions of arrows A1 and A2, respectively, to move the two flag arm brackets 41 into the position shown in FIG. 7. In FIG. 7, which illustrates a second working configuration for the flag arms, each of the flag arms 33 is parallel to the vertical reinforcing batten 23 to thereby allow for a compact storage of the vertical reinforcing batten 23, and the two flag arm brackets 41. In an alternative embodiment, the two flag arm brackets 41 may be secured to the vertical reinforcing batten 23 using nuts and bolts, for example. In this alternative embodiment, the two flag arm brackets 41 may or may not be separated from the vertical reinforcing batten 23 for storage.
FIG. 8 shows a flag arm bracket assembly 12 according to a second preferred embodiment. The flag arm bracket assembly 12 comprises two flag arm brackets 71 secured to opposite faces of the vertical reinforcing batten 23. Each flag arm bracket 71 comprises a flanged plate 75 and U-shaped member 73 attached thereto. As presently embodied, the flanged plate 75 and the U-shaped member 73 are metal, and the U-shaped member is welded to the flanged plate 75 at an angle that is either thirty degrees or forty-five degrees from the vertical reinforcing batten 23, depending upon the desired flag orientation angle. Each flanged plate 75 comprises two flanges 77 for fitting around opposing edges or sides 78, 78a of the vertical reinforcing batten 23. When the flanged plate 75 is secured to the vertical reinforcing batten 23, the flanged plate 75 contacts three adjacent surfaces of the vertical reinforcing batten 23. This snug fit prevents rotation of the flanged plate 75 when a flag arm 33 is secured between the flanged plate 75 and the U-shaped member 73.
Each flag arm bracket 71 is firmly attached to the vertical reinforcing batten 23 using a single carriage bolt 79. The bolt passes through an aperture in each U-shaped member 73, and also through an aperture in the flanged plate 75. The bolt 79 also passes through an aperture in the vertical reinforcing batten 23, through apertures in a second flag arm bracket 71, and through apertures in the flag arms 33. A wing nut 85 is applied to the threaded portion 83 of the carriage bolt 79 to firmly secure the two flag arm brackets 71 onto opposing sides 46 and parallel edges 78, 78a of the vertical reinforcing batten 23. In addition to providing this securing function, the bolt 79 operates to prevent the flag arms 33 from completely passing too far through respective U-shaped members 73. A top view of the flag arm bracket assembly 12 shown in FIG. 8 is illustrated in FIG. 9. Although two flag arm brackets 71 are presently preferred, a single flag arm bracket 71 may be used to hold a single flag. In the presently preferred embodiment, the threaded portion 83 is slightly damaged or coated with an appropriate material, to prevent disengagement of the wing nut 85 from the bolt 79. The aperture in each U-shaped member 73 is preferably rectangular shaped, and a portion just beneath the bolt head 81 preferably has a matching rectangular shape. The rectangular shaped carriage bolt just beneath the bolt head 81 fits into the rectangular aperture of the U-shaped member 73, to thereby prevent rotation of the bolt 79 as the wing nut 85 is threaded onto the threaded portion 83.
Although exemplary embodiments of the invention have been shown and described, many other changes, modifications and substitutions, in addition to those set forth in the above paragraph, may be made by one having ordinary skill in the art without necessarily departing from the spirit and scope of this invention.
|
Flag holders that are simple in design and relatively inexpensive to manufacture are disclosed. These flag holders secure flag arms to reinforcing battens of highway signs without unnecessary bulk, weight, and complexity. A flag holder includes a flag arm bracket having a generally U-shaped body with two opposing edges. The U-shaped body wraps around a frame member, such as a reinforcing batten, of the highway sign, to thereby align the flag arm bracket with the frame member. An aperture in the flag arm bracket accommodates a shaft, such as a bolt. The shaft passes through both the aperture of the flag arm bracket and also through an aperture in the frame member of the highway sign. The bolt secures the flag arm bracket to the frame member. The flag arm bracket further includes an attachment portion for attaching at least one flag arm to the flag arm bracket.
| 4
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to cryogenic systems and, more particularly, to a multifunction cryogenic valve adapted to evacuate, seal off, and monitor vacuum levels and relieve over-pressure for cryogenic vacuum insulated systems.
[0002] Current evacuation valves for cryogenic vacuum insulated systems require additional components to make their valves function. The added components require additional space and clearance to operate; require more maintenance, spare parts, cleaning; and pose additional potential leak points and risk of breakage. The added components are needed to provide vacuum pump down, and monitoring of the vacuum, as well as an external operator and thermocouple isolation valve to evacuate and monitor the customers systems. Moreover, isolation valves require thread sealant on the thermocouple to keep the threads from leaking. Thread sealant is a concern in liquid oxygen systems because of the potential for ignition and fire. Thread sealant deteriorates after a period of time and requires replacement which makes it a maintenance requirement.
[0003] As can be seen, there is a need for a multifunction valve adapted to evacuate, seal off, monitor vacuum levels and relieve over-pressure for cryogenic vacuum insulated systems, wherein no thread sealant is necessary.
SUMMARY OF THE INVENTION
[0004] In one aspect of the present invention, a cryogenic vacuum valve includes a valve body forming a wide body cavity fluidly communicating with a narrower narrow body cavity; a valve plug defined by a circumferential surface dimensioned and adapted to snugly fit within the narrow body cavity; a top plug o-ring groove formed along an upper portion of the circumferential surface; a bottom plug o-ring groove formed along an lower portion of the circumferential surface so as to be spaced apart from the top plug o-ring groove, wherein the bottom plug o-ring groove is omega shape, and wherein the omega shape has a upper apex and a remaining portion; a thermocouple exposure slot formed along the circumferential surface so as to be disposed downward of the upper apex; and a thermocouple vacuum exposure hole formed through the valve body to fluidly communicate with the narrow body cavity, wherein the valve plug is movable from a go position to a stop position communicating the thermocouple vacuum exposure hole with the thermocouple exposure slot.
[0005] In another aspect of the present invention, a cryogenic multi-function vacuum valve includes a valve body forming a wide body cavity fluidly communicating with a narrower narrow body cavity; a valve plug defined by a circumferential surface dimensioned and adapted to snugly fit within the narrow body cavity; a top plug o-ring groove formed along an upper portion of the circumferential surface; a bottom plug o-ring groove formed along an lower portion of the circumferential surface so as to be spaced apart from the top plug o-ring groove, wherein the bottom plug o-ring groove is omega shape, and wherein the omega shape has a upper apex and a remaining portion; a thermocouple exposure slot formed along the circumferential surface so as to be disposed downward of the upper apex; a thermocouple vacuum exposure hole formed through the valve body to fluidly communicate with the narrow body cavity; a cap rotatably mounted to an upper portion of the valve body, wherein the cap forms a central projection forming a cavity through which is secured a cap roll pin; and a valve shaft interconnecting the cap and the valve plug, wherein the valve shaft has an upper end operatively engaging the central projection, wherein the upper end forms a shaft cap pin slot adapted to operative engage the cap roll so that rotating the cap moves the valve plug between the go position and the stop position communicating the thermocouple vacuum exposure hole with the thermocouple exposure slot, wherein the go position comprises the thermocouple vacuum exposure hole being disposed downward of the remaining portion of the bottom plug o-ring groove, and wherein the go position comprises the thermocouple vacuum exposure hole being disposed downward of the remaining portion of the bottom plug o-ring groove.
[0006] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a front perspective view of an exemplary embodiment of the present invention;
[0008] FIG. 2 is a rear perspective view of an exemplary embodiment of the present invention;
[0009] FIG. 3 is an exploded view of an exemplary embodiment of the present invention;
[0010] FIG. 4 is a detailed reverse exploded view of an exemplary embodiment of the present invention;
[0011] FIG. 5 is a section view of an exemplary embodiment of the present invention;
[0012] FIG. 6 is a section view of an exemplary embodiment of the present invention;
[0013] FIG. 7 is a detailed section view of an exemplary embodiment of the present invention;
[0014] FIG. 8 is a detailed section view of an exemplary embodiment of the present invention;
[0015] FIG. 9 is a detailed section view of an exemplary embodiment of the present invention;
[0016] FIG. 10 is a section view of an exemplary embodiment of the present invention;
[0017] FIG. 11 is a section view of an exemplary embodiment of the present invention;
[0018] FIG. 12 is a section view of an exemplary embodiment of the present invention;
[0019] FIG. 13 is a section view of an exemplary embodiment of the present invention;
[0020] FIG. 14 is a perspective view of an exemplary embodiment of the present invention;
[0021] FIG. 15 is a perspective view of an exemplary embodiment of the present invention;
[0022] FIG. 16 is a section view of an exemplary embodiment of the present invention;
[0023] FIG. 17 is a perspective view of an exemplary embodiment of the present invention, illustrating turning an exemplary embodiment of a valve cap 45 degrees and lifting the connected assembly upward;
[0024] FIG. 18 is a section view of an exemplary embodiment of the present invention;
[0025] FIG. 19 is a section view of an exemplary embodiment of the present invention; and
[0026] FIG. 20 is a section view of an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0028] Broadly, an embodiment of the present invention provides a multifunction cryogenic valve adapted to evacuate, seal off, monitor vacuum levels and relieve over-pressure in cryogenic vacuum insulated systems.
[0029] Referring to FIGS. 1 through 20 , the present invention may include a multifunction cryogenic valve 10 adapted to evacuate, seal off, monitor and relieve cryogenic vacuum insulated systems. The multifunction cryogenic valve 10 may include a valve body 16 forming a tubular wide body cavity 68 fluidly communicating to a narrower narrow body cavity 70 via a conical transition as illustrated in FIGS. 19 and 20 . The wide body cavity 68 may extend from the conical transition to a top portion, wherein the top portion forms a top opening. The top portion may form a body o-ring groove 88 near an outer periphery thereof and a sunken top recess inward from the outer periphery. The body o-ring groove 88 may be dimensioned to snugly receive a body o-ring 42 ; and the sunken top recess may form a top o-ring groove 90 for snugly receiving a top o-ring 46 , as illustrated in FIG. 3 .
[0030] It should be understood, that the valve body 16 forms the body cavities 68 , 70 along a shared longitudinal axis, wherein each cavity 68 , 70 is concentric about, though consecutively along. As a result, terminology such as “upward”, “downward”, “upper”, “lower”, “top”, “bottom” is reference relative to positioning about the longitudinal axis, and not necessarily as relative to the force of gravity.
[0031] The multifunction cryogenic valve 10 may also provide a valve top 14 dimensioned and adapted to be snugly received within the top opening so that a top flange portion may be supported by the sunken top recess, as illustrated in FIG. 13 . The top flange portion may form at least one wrench hole 96 for installation purposes. The valve top 14 may have a tubular projection adapted and dimensioned to extend from the top flange portion into the wide body cavity 68 . Said tubular projection may form peripheral threading 74 to securely engage operating body cavity threading 76 . Said tubular projection forms a top shaft hole 98 , wherein at least one peripheral shaft ring groove is formed along its circumference, each dimensioned to snugly receive a shaft o-ring 34 .
[0032] The multifunction cryogenic vacuum valve 10 may also provide a valve plug 20 adapted and dimensioned to frictionally engage the narrow body cavity 70 . A centrally disposed plug shaft hole 108 may be formed in a plug shaft that extends upwardly from the center of a body of the valve plug 20 so as to project toward the wide body cavity 68 . The plug shaft hole 108 may form a plug pin hole 100 . The body of the valve plug 20 may form spaced-apart top and bottom plug o-ring grooves 102 , 104 , each dimensioned to snugly receive top and bottom plug o-rings 40 , 38 , respectively. The bottom plug o-ring 104 and thus the snugly-fitting bottom plug o-ring 38 may be omega-shaped, as illustrated in FIG. 3 . The omega shape may include an upward projecting segment 39 , whose upper apex is elevated above a majority of the remaining portion of the bottom plug o-ring 38 . The body of the valve plug 20 may form a thermocouple exposure slot 106 along a circumferential surface thereof, as illustrated in FIG. 4 . The thermocouple exposure slot 106 is disposed to align with the upward projecting segment 39 .
[0033] The multifunction cryogenic vacuum valve 10 may also provide a valve shaft 18 extending from an upper end to a lower end, wherein the lower end is dimensioned and adapted to be snugly received through the top shaft hole 98 , through a lumen of a body spring 32 , extending into the wide body cavity 68 so as to be at least partially received within the plug shaft hole 108 . Thereby, forming an annular space between the valve shaft 18 and the circumference of the body cavity 68 . The valve shaft 18 may be periscope shaped, wherein the upper end may form a generally rectangular shape, as illustrated in FIG. 13 . The lower end may form an elongated shaft plug pin slot 94 dimensioned to slidably receive a plug roll pin 58 to ride therein, as illustrated in the Figures. The upper end may form a step-shaped shaft cap pin slot 92 .
[0034] The multifunction cryogenic vacuum valve 10 may also provide a cap 12 having a body portion and, extending from the body portion, an annular ring dimensioned and adapted to snugly receive a portion of the top portion, as illustrated in FIGS. 5 and 13 . The body portion may form a central projection 91 , wherein the central projection 91 and the annular ring are separated by a space, as illustrated in FIG. 6 . The central projection 91 may form a cap shaft slot 86 dimensioned to receive the upper end of the valve shaft 18 . A narrow cap pin hole 80 may be formed in the central projection 91 so as to generally align with the shaft cap pin slot 92 , wherein a cap roll pin 56 is dimensioned to slidably be received through both, as illustrated in FIG. 10 .
[0035] The annular ring may form diametrically opposing wide cap pin holes 78 that generally align with the narrow cap pin hole 80 , wherein a pair of cap hole pins 54 are dimensioned to slidably and securely be received into the wide cap pin holes 78 . The annular ring may form a cap outer slot 82 extending along a periphery thereof, wherein a wider cap outer slot opening 84 may be disposed generally midpoint along the cap outer slot 82 , as illustrated in FIGS. 2 and 12 . A body pin 64 may be disposed along a periphery of the valve body 16 , for example, protruding from a formed body pin hole 110 , wherein the body pin 64 is adapted and dimensioned to ride along the cap outer slot 82 when the cap 12 rotates about the portion of the top portion, as illustrated in FIG. 12 .
[0036] A lower portion of the valve body 16 may form a thermocouple threaded hole 112 fluidly communicating to the narrow body cavity 70 via a thermocouple. A thermocouple seal 36 may be disposed in the thermocouple threaded hole 112 so as to operatively engage the thermocouple vacuum exposure hole 114 . The thermocouple vacuum exposure hole 114 may be disposed along the lower portion of the valve body 16 so as to sufficiently align with the thermocouple exposure slot 106 .
[0037] A side body opening 72 may be formed into the valve body 16 . A tubular valve flange 66 may be provided so as to be operatively welded by a fillet weld 138 , such as a TIG weld, along a periphery of side body opening 72 . The valve flange 66 may provide on one end flange threading 124 and a flange o-ring groove 122 , the groove 122 being dimensioned to snugly receive a flange o-ring 44 .
[0038] The present invention may include a relief valve assembly 150 . The relief valve assembly 150 may include a relief valve poppet 52 sandwiching a relief valve body 26 against the one end of the valve flange 66 , and held in place by a coupling nut 24 providing inner threading 126 and a retainer slot 128 . The relief valve body 26 may form a body portion forming a centrally disposed relief valve body center hole 134 surrounded by a plurality of relief valve body exhaust holes 136 , wherein a retainer ring 130 may be formed along the periphery of said body portion, wherein the retainer ring 130 operatively engages the retainer slot 128 . A body portion of the relief valve poppet 52 may form at least one tether slot 120 and a relief valve o-ring groove, said groove being dimensioned to snugly receive a relief valve o-ring 28 . A relief valve poppet shaft 116 may be centrally disposed and extend from the body portion of the relief valve poppet 52 . The relief valve poppet shaft 116 may form a relief valve pin hole 118 dimensioned to slidably receive a relief valve roll pin 30 . The relief valve poppet shaft 116 may extend through the relief valve body center hole 134 , wherein a relief valve spring 60 is disposed, so that the relief valve roll pin 30 is held in place by the relief valve washer 62 , as illustrated in FIG. 9 .
[0039] Evacuation and Seal Off:
[0040] To evacuate a system, the relief valve assembly 150 may be removed and allowed to hang from its tether cable 48 operatively engaging the at least one tether slot 120 by means of a tether crimp 50 . A user may attach evacuation equipment to the valve flange 66 by way of a coupling tube 22 forming a peripheral retainer ring 132 and a second coupling nut 140 having threading 142 and a second retainer slot 144 , as illustrated in FIG. 14 , wherein the second retainer slot 144 operatively engages the retainer ring 132 , as illustrated in FIG. 16 . The user then starts his pump and when the vacuum level is satisfactory, the cap 12 is lifted and shifted to the left and rotated up 90 degrees to the vertical position, whereby the cap roll pin 56 rides along the shaft cap pin slot 92 , as illustrated in FIG. 20 . This enables the pump to begin pumping on the annular space between the inner vessel and the outer shell. Once a satisfactory vacuum level has been reached the cap 12 is rotated down to the closed position which seals off the systems vacuum annular space.
[0041] Vacuum Monitoring:
[0042] Vacuum level monitoring can be accomplished any time the present invention is in the closed position, wherein the cap 12 is down. The bottom plug o-rings groove 104 and thus the bottom plug o-ring 38 enable the thermocouple to be exposed when the top of the bottom plug o-ring 38 rises above the thermocouple exposure hole 114 , as illustrated in FIGS. 6 and 7 . This is accomplished by turning the cap 12 90 degrees to a thermocouple stop position where it is secured with the body pin 64 riding within and along the cap outer slot 82 , as illustrated in FIG. 12 . When in the thermocouple stop position, the thermocouple hole 114 communicates with the exposure slot 106 as a result of the upward projecting segment 39 of the bottom plug o-ring 38 disposed relative to the thermocouple hole 114 , as illustrated in FIG. 7 . The multifunction cryogenic vacuum valve 10 can stay in this position for as long as the user requires, since the system is still sealed off with the top plug o-ring 40 . If the vacuum level is satisfactory, the cap 12 is turned 90 degrees back the other way—to a thermocouple go position—causing the bottom plug o-ring 38 to transition below the thermocouple hole 114 and providing a two o-ring—top and bottom plug o-rings 40 , 38 —seal to maintain a more reliable vacuum seal off. This position is the standby or normal position and the cap 12 is secured to the assembly by the body pin 64 riding within the along the cap outer slot 82 .
[0043] Pressure Relief:
[0044] Pressure relief is required if there is a leak in the inner vessel and the cryogen begins to expand in the narrow body cavity 70 . The present invention provides for over pressure relief by the incorporation of the relief valve assembly 150 mounted on the flange 66 . When there is an increase in the annular pressure within the narrow body cavity 70 above a predetermined threshold the valve plug 20 rises on the valve shaft 18 by way of the plug roll pin 58 riding along the elongated shaft plug pin slot 94 , as illustrated in FIG. 9 . The predetermined threshold specified by the user through the selection of a predetermined body spring 32 and relief valve spring 60 . This allows the relief valve assembly 150 to be exposed to the overpressure and it will push the relief valve poppet shaft 116 of the relief valve assembly 150 open and vent the over pressure to atmosphere. When the pressure is reduced to the design pressure the relief valve assembly 150 will close to maintain system cleanliness and integrity. This relief action will continue for as long as required until the over pressure is corrected.
[0045] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
|
A multifunction cryogenic vacuum valve adapted to evacuate, seal off, and monitor vacuum levels and relieve cryogenic vacuum insulated systems is provided, wherein no thread sealant is necessary for the thermocouple threads.
| 5
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] FOR NON-PROVISIONAL OF PROVISIONAL—This application claims the benefit of U.S. Provisional Application No. 62/040,682, filed Aug. 22, 2014, the disclosures of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Stationary bicycle trainers have been popular in the last few decades as a means to use an existing bicycle on a stationary device that provides resistance to pedaling without the need to also balance, as is required with a bicycle roller.
[0003] In the current art, most bicycle trainers and a variety of resistance mechanisms, that rely on the bicycle's own tire to drive a resistance device, use a framework to rigidly mount the rear wheel while holding the bicycle upright. In all of these applications, the resistance mechanism is located behind the rear wheel and pivotally attached to the framework below the resistance device, or “upstream” of the tire's direction of rotation. This is a convenient place to locate a pivot, and allows the driven cylinder of the resistance mechanism to be adjusted into the tire to a degree that reduces or eliminates slippage at the highest torque the cyclist can put out. This method of compressing a driven cylinder into the bicycle tire will be referred to as “Fixed Compression” herein.
[0004] For example; for a cyclist to put out a maximum of 700 watts the resistance device must compress the rear tire sufficiently to prevent slipping. Realistically, however, most of the time a user will spend on a trainer is at much lower wattage, such as 150 to 200. Therefore, most of the time the tire is compressed and distressed unnecessarily.
[0005] This causes three problems; A) the tire will wear quickly if it is highly distressed. In fact, many manufacturers make a special “trainer tire” that is a harder rubber compound capable of lasting longer in trainers. These tires cannot be used on the road because their hard composition causes reduced coefficient of friction to a road surface and is relatively easy for a cyclist to lose control. B) high distress at low power consumes power that limits the minimum effort for the cyclist and C) high distress with no power input consumes inertia from relatively light bicycle wheels, requiring heavier flywheels to compensate for the loss. Bicycle trainer manufacturers typically design for a certain degree of inertia to provide for a smooth stroke since it is nearly impossible to power through a 360 degree pedal rotation with constant power. Uneven power application will cause exaggerated changes in wheel speed, especially with lightweight bicycle wheels unless a heavier flywheel (integral to the bicycle trainer) is employed to better control wheel speed, acceleration, and deceleration. An improved tire compression device is needed.
SUMMARY OF THE INVENTION
[0006] The resistance mechanism is mounted to the framework, allowing it to pivot “downstream” of the tire's rotation. By doing this, the tangential force on the resistance mechanism (caused by the frictional interface between the tire and the driven cylinder) translates to a rotational force about the pivot of the resistance mechanism pivot arm which drives the driven cylinder harder against the tire. The intent of the design is that the pivot point will be strategically positioned so that the ratio of normal force to tangential force matches or exceeds the coefficient of friction between the tire and the driven cylinder, in which case the tire will never slip and a minimal amount of normal force is necessary by the application of a spring to maintain contact with the tire with little to no power load from the cyclist. This will be referred to as “Automatic Compression” herein.
[0007] An alternative embodiment is also proposed which has several advantages: A) a smaller flywheel can be used because the speed of the flywheel can be increased as compared to the speed of the driven cylinder by using different pulley or sprocket diameters between the driven cylinder and the resistance mechanism. A smaller flywheel may be desired to reduce the overall weight and cost of the device. B) Moving the mass to the pivot center of the pivot arm reduces the overall moment of inertia of the pivot arm assembly, comprising the pivot arm, driven cylinder, resistance mechanism, and associated components. Reducing the moment of inertia makes the pivot arm more responsive to sudden changes in speed of the bicycle wheel, further avoiding any potential for slippage between the bicycle tire and the driven cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] A preferred embodiment of this invention has been chosen wherein:
[0009] FIG. 1 is an isometric side view of the system as mounted to a bicycle;
[0010] FIG. 2 is a side view section 2 - 2 of the system in FIG. 1 ;
[0011] FIG. 3 is a top view of partial section 3 of the system in FIG. 1 ;
[0012] FIG. 4 is a simplified side view showing the forces and mounting points of the system;
[0013] FIG. 5 is a graph showing the power vs speed for fixed and automatic compression;
[0014] FIG. 6 is a side view of an alternate embodiment of the system; and
[0015] FIG. 7 is a side view of an alternate embodiment of the system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] An automatic tire compression bicycle trainer system 10 as shown in FIG. 1 is designed to be attached to the rear axle of a typical bicycle 12 . As is commonly known in the art, a rear wheel 14 is driven by a crank 16 through a chain 20 and series of sprockets. As the user rotates the crank 16 , the driving gear 18 pulls on the chain 20 . Movement of the chain 20 causes the rear sprocket 22 to begin turning. The rear sprocket 22 drives the rear wheel 14 about the driving axis 26 . Attached to the rear wheel 14 and forming the outermost diameter is a rear tire 24 , FIG. 2 . Tires on most bicycles are pneumatic, meaning that air pressure internal to the tire causes the tire to maintain its shape. The air also acts as a cushion to absorb surface irregularities and allows the user to adjust ride quality by increasing or decreasing the pressure.
[0017] The system 10 , as shown in FIG. 1 , is made up of a frame 28 with a front stabilizing portion 30 , a rear portion 32 with a bridge portion 38 , and an axle mounting portion 34 . The front stabilizing portion 30 and the bridge portion 38 have a lower surface 36 which is designed to rest on the ground. Since gyroscopic forces on both wheels assist the user in maintaining balance on the bike, a trainer where one wheel is stationary requires the bicycle 12 be held upright and fixed from movement to the frame 28 as is shown in FIG. 1 . The portions 30 and 32 connect at the mounting portion 34 . As shown in FIG. 1 , the bridge portion 38 has a resistance mounting portion 39 that holds a resistance device 60 . The mounting portion 34 is adapted to attach to the rear axle of the bicycle 12 . The frame 28 is shown attaching directly to the rear axle but it is contemplated that the device could attach to any portion of the frame of the bicycle. As shown in FIG. 2 , the resistance mounting portion 39 has a pivot point 40 where a pivot arm 42 rotates. The pivot arm 42 includes a driven cylinder 44 that rotates about a driven axis 46 . The driven cylinder 44 has an outside diameter 48 where it contacts the outside surface of the rear tire 24 at a contact point 50 . As shown in FIG. 4 , the contact point 50 is tangent to both the rear tire 24 and the driven cylinder 44 .
[0018] In one embodiment, the driven cylinder 44 is a resistance device 52 as is shown in FIGS. 4 , 6 , and 7 . The resistance device 52 rotates about the driven axis 46 and resists rotation. The resistance device 52 can use different methods to resist rotation. It is desired that the resistance device 52 increases resistance as the rotational speed increases. One style involves eddy currents (shown in FIG. 3 ), which use magnets 51 in proximity to a metal (usually aluminum) drum. Another option uses viscous fluid, friction material 53 , or other mechanical means. Other options involve fans or a combination of the previously mentioned styles. In the eddy current drive, magnets 51 ride on a carrier that may be eccentric to the driven axis 46 . As the outside cylinder rotates, magnets that ride on the internal carrier generate eddy currents in the outside cylinder. In this embodiment, a progressive resistance device is used where the outside cylinder is typically the outside diameter 48 of the resistance device 52 . As the eddy currents increase in the cylinder, the drag force created pulls the magnets about the offset axis, causing them to become closer to the drum, and therefore further increasing the drag. The offset axis is spring loaded to allow the offset axis to return the magnets back to a nominal position inside the drum. The eddy current resistance mechanism is known in the art and the subject of other utility patents. It is contemplated that the resistance is located on the driven axis 46 but offset to the side to allow for clearance or increased size without requiring a taller frame 28 .
[0019] In another embodiment, the driven cylinder 44 contains no resistance device but contains a pulley or sprocket 54 , FIGS. 2 and 3 that drives a belt or chain 56 , which in turn drives another pulley or sprocket 58 which is attached to the resistance device 60 . As stated previously, resistance devices are well known in the art of bicycle trainers. The driven cylinder 44 typically would have a lower mass or rotational inertia than a normal resistance device. The driven cylinder 44 drives a chain or belt 56 to the resistance device mounted at or close to the pivot point of the pivot arm. Using different sized pulleys or sprockets, as is shown in FIGS. 2-3 , the ratio between the driven cylinder and the resistance device can be multiplied or divided. The separate resistance device allows the system to be more responsive to sudden changes in the rotational speed of the wheel 24 .
[0020] The outside diameter 48 is held in biased contact with the outside surface of the tire 24 via a spring 41 . The spring 41 holds the pivot arm 42 with enough static force (shown as normal force 76 in FIG. 4 ) for the tire 24 to begin rotating against the driven cylinder 44 without slippage. The spring 41 is shown in FIG. 1 and removed in other FIGS. for simplicity. As shown, the spring 41 applies tension to a portion of the pivot arm 42 to bias the outside diameter 48 wheel 14 . It is contemplated that the spring 41 is implemented in compression to accomplish the same task. It is further contemplated that a balancing mechanism is implemented instead of a spring in order to maintain biased contact at contact point 50 .
[0021] As shown in FIG. 4 , the tire 24 increasing in speed causes the driven cylinder 44 to create drag by resisting rotation. It either creates drag directly or has drag created by another driven device. This drag creates a line of applied force 62 that travels from the contact point 50 to the pivot point 40 . This is shown in FIG. 4 as applied force 62 . Because the pivot point 40 is not located on the tangent line or the normal force line, the applied force 62 is split into a tangent force 70 and a normal force 76 . The normal force 76 is increased as a proportion of the force 62 . If the pivot point 40 was intersected by the tangent force 70 , the normal force 76 would remain the same regardless of the drag in the system. If the pivot point 40 was intersected by the normal force 76 , the driven cylinder 44 would be simply pushed out of the way as the tire 24 rotates.
[0022] As is shown in FIG. 5 , drag and torque are directly related. The tangential force 70 creates a moment about the pivot point 40 of the pivot arm 42 calculated as tangential force*dimension 74 . This moment is reacted by the normal force*dimension 72 . These two forces are constrained to be equal, so tangential force*dimension 74 =normal force*dimension 72 . This can be rewritten as dimension 72 /dimension 74 =Tangential force/Normal force. The coefficient of friction is the force required to move the two sliding surfaces over each other (tangential force), divided by the force holding them together, (normal force). So long as the ratio of tangential force to normal force remains lower than the coefficient of friction between the tire and the driven cylinder 44 , the tire will not slip. This relationship also defines the relationship of dimension 72 to dimension 74 . This is all visible in FIG. 4 .
[0023] At rest, the normal force 76 from the driven cylinder 44 is from the spring 41 . Once the driven cylinder 44 begins moving, the resistance device 52 , 60 begins to cause drag in the system. The drag creates a force 62 that is a line that intersects the contact point 50 and the pivot point 40 . Because the force 62 is at an angle to the tangential force 70 and the normal force 76 , the force 62 resists the tangential force 70 created by the tire 24 . The force is a compressive force between the pivot point and the point of contact between the outside surface 50 and the outside diameter 48 of the driven cylinder 44 . The reaction force is split into two components, one of those components adds into the normal force 76 . The moment as shown in FIG. 6 is counterclockwise when the wheel 14 is rotating clockwise. The moment as shown in FIG. 7 is counterclockwise when the wheel 14 is rotating clockwise.
[0024] The calculated effect of automatic compression versus fixed compression can be seen in the graphs shown in FIG. 5 . With fixed compression 33 , there is a predetermined amount of drag on the tread surface of the tire regardless of speed. At higher speeds it becomes irrelevant and matches the drag caused by automatic compression 35 . At lower speeds, the automatic compression drag force is significantly reduced. The drag vs. speed graph is shown in FIG. 5 .
[0025] One of the effects, as mentioned earlier, is to simulate the effect of a flywheel, where on the sudden application of high power the additional resistance caused by higher tire distress provides the same net effect as pushing against a flywheel. Likewise, the sudden removal of power decreases tire distress and allows the wheel to spin more freely, also providing the same net effect as a flywheel.
[0026] The chart in FIG. 5 is drag vs. speed, assuming a resistance device is employed that provides non-linear power vs speed such as a typical fluid mechanism, or the progressive resistance device. The upper curve 33 is the drag that would be represented by a fixed compression device. The lower curve 35 represents the drag present by the automatic compression device. It allows for a more highly non-linear relationship of power and speed, which provides the designer of a training system more flexibility in tuning a power curve to suit the needs of the consumer.
[0027] As shown in FIGS. 1-4 and 6 , the driven cylinder 44 or resistance device 60 is shown with the rotating tire causing a compressive force on the pivot arm 42 . It is possible to accomplish the same tire compression compensation by relocating the pivot point 40 on the opposite side of the tangent line. This setup is shown in FIG. 7 . In this embodiment, the pivot point 40 is located closer to the rotating axis of the rear tire 24 . As the resistance device 52 begins to generate drag, the applied force 62 translates to a tangent force 70 and a normal force 76 .
[0028] It is understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. No specific limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Modifications may be made to the disclosed subject matter as set forth in the following claims.
|
A self-compensating tire compression device is provided for use with a trainer. The device attaches to a frame, such as a bicycle, that holds the axis of a driving wheel fixed. The device has a pivoting portion that presses a driven portion of a resistance device against the driving wheel. The pivoting point of the pivoting portion is located on the trainer to provide a static contact pressure between the driving wheel and the driven wheel, and when the driving wheel begins to rotate and the resistance device begins to resist the rotation, the contact pressure between the driving wheel and the driven wheel increases to prevent slippage between the two wheels.
| 0
|
[0001] The subject application claims benefit under 35 USC §119(e) of U.S. provisional Application No. 62/018,890, filed Jun. 30, 2014. The entire contents of the above-referenced patent application are hereby expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to microfluidic test cartridges for medical diagnostics, and more specifically to tests requiring no onboard fluidic controls and with on-board calibrators.
BACKGROUND OF THE INVENTION
[0003] A fluid system, in general, may comprise a fluidic device that operates by the interaction of streams of fluid. In recent years, miniature fluidic devices, such as microfluidic devices and biochips, have attracted more and more attention, for example, in the field for point-of-care testing. Miniaturization is a trend of medical devices in this field. A fluidic device in this field usually provides integration of multiple analytical steps into a single device. A fluidic device may perform one or more assays. For the purposes of the instant disclosure, an assay may be defined as a procedure for quantifying the amount or the functional activity of an analyte in a liquid sample. A typical on-chip assay may involve a variety of on-board operations, such as sample introduction and preparation, metering, sample/reagent mixing, liquid transport, and detection, etc.
[0004] Typical diagnostic assays involve manipulating very small volumes of fluid with highly precise control. A traditional microfluidic flow device with microfluidic channels, valves and other flow control mechanisms pose specific challenges to ensure the required precision due to several effects including fluid loss in transport, capillary effects, impact of gravity, trapped air and others. Additionally, several assay processes such as mixing and incubation can also pose unique challenges in the microfluidic environment. For a disposable device, the ideal choice would be to limit or eliminate the need for flow and flow control, and yet provide the level of precision needed to deliver the required assay performance. This has been accomplished in macro-scale instrumentation, but typically not in a single use disposable format compatible with a small form factor instrument.
[0005] Most current diagnostic single use microfluidic devices require flow to move sample and/or reagents through the disposable from the loading to the detection site. These may use on-board or off-board pumping, capillary or lateral flow, and a variety of fluid control mechanisms, including external valving, mixing methods etc. Precision is typically achieved using appropriate actuation mechanisms. Other sources of potential errors are typically controlled using on- or off-chip components such as bubble traps and capillary barriers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily understood by reference to the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 shows a microfluidic device according to one embodiment of the present invention.
[0008] FIG. 2 shows a microfluidic device according to another embodiment of the present invention.
[0009] FIG. 3 shows a system according to another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] Referring now to the drawings in which like reference characters designate identical or corresponding parts throughout the several views, a preferred embodiment of the invention will now be described with reference to FIG. 1 .
[0011] This invention includes a device with no active fluid control required on-board. Precision control mechanisms are moved off the disposable to the instrument which allows them to be reusable and therefore potentially more expensive. The consumable is extremely simple and potentially very cost effective as a high-volume disposable.
[0012] The consumable is a test device for conducting an in-vitro diagnostics test that can be read optically. This may include immunoassays, chemistries, or hematological assays or any other assessment of bodily fluid components that can be analyzed through optical detection. Examples of assays that may be carried out during the use of the invention described herein include, but are not limited to, tests for blood gases, clotting factors, immunogens, bacteria, and proteins. In one embodiment the assays that may be detected with the test device is a “luminescent 02 channel assay” (LOCI®) which includes the use of for example, Sandwich Assays based on an analyte-specific antibody and a biotinylated antibody wherein specific wavelengths are generated by the fluid subsample and detected by the test device. Reagent configurations for the assay method include for example Sandwich Formats based on an antigen or an antibody, a Competitive Format, or a Sandwich Format with Extended Linker and may be used in immunoassays, infectious disease testing, and DNA testing. Specific blood chemicals which may be measured include, but are not limited to, TSH, free T4, free T3, Total PSA, free PSA, AFP, CEA, CA15.3, CA 19-9, CA 125, Cardiac Troponin-I, NT-pro BNP, myoglobin, mass CKMB (MMB), BNP, Ferritin, Vitamin B12, Folate, total B-HCG, FSH, LH, prolactin, estradiol, testosterone, progesterone, and digoxin.
[0013] Fluorescent detection also can be useful for detecting analytes in the presently claimed and disclosed inventive concepts. Useful fluorochromes include, but are not limited to, DAPI, fluorescein, lanthanide metals, Hoechst 33258, R-phycocyanin, B-phycoerythrin, R-phycoerythrin, rhodamine, Texas red and lissamine Fluorescent compounds, can be chemically coupled to antibodies without altering their binding capacity. When activated by illumination with light of a particular wavelength, the fluorochrome-labelled antibody adsorbs the light energy, inducing a state of excitability in the molecule, followed by emission of the light at a characteristic color visually detectable with a light microscope. Radioimmunoassays (RIAs) can be useful in certain methods of the invention. Such assays are well known in the art. Radioimmunoassays can be performed, for example, with 125I-labeled primary or secondary antibody.
[0014] Separation steps are possible in which an analyte is reacted with reagent in a first reaction chamber and then the reacted reagent or sample is directed to a second reaction chamber for further reaction. In addition, a reagent can be re-suspended in a first reaction chamber and moved to a second reaction chamber for a reaction. An analyte or reagent can be trapped in a first or second chamber and a determination made of free versus bound reagent. The determination of a free versus bound reagent is particularly useful for multizone immunoassay and nucleic acid assays. There are various types of multizone immunoassays that could be adapted to this device Immunoassays or DNA assay can be developed for detection of bacteria such as Gram negative species (e.g., E. coli, Enterobacter, Pseudomonas, Klebsiella ) and Gram positive species (e.g., Staphylococcus aureus, Enterococcus ) Immunoassays can be developed for complete panels of proteins and peptides such as albumin, hemoglobin, myoglobulin, α-1-microglobulin, immunoglobulins, enzymes, glycoproteins, protease inhibitors, drugs and cytokines. The device may be used in analysis of urine for one or more components therein or aspects thereof, such as, but not limited to, leukocytes, nitrites, urobilinogen, proteins, albumin, creatinine, uristatin, calcium oxalate, myoglobin, pH, blood, specific gravity, ketone, bilirubin and glucose.
[0015] The consumable, in non-limiting embodiments, may be made of plastics such as polycarbonate, polystyrene, polyacrylates, or polyurethane, alternatively or in addition to, they can be made from silicates, and/or glass. When moisture absorption by the plastic is not a substantial concern, the plastics preferably used may include, but are not limited to, ABS, acetals, acrylics, acrylonitrile, cellulose acetate, ethyl cellulose, alkylvinylalcohols, polyaryletherketones, polyetheretherketones, polyetherketones, melamine formaldehyde, phenolic formaldehyde, polyamides (e.g., nylon 6, nylon 66, nylon 12), polyamide-imide, polydicyclopentadiene, polyether-imides, polyethersulfones, polyimides, polyphenyleneoxides, polyphthalamide, methylmethacrylate, polyurethanes, polysulfones, polyethersulfones and vinyl formal. When moisture absorption is of concern, preferably the plastics used to make the chip include, but are not limited to: polystyrene, polypropylene, polybutadiene, polybutylene, epoxies, Teflon™, PET, PTFE and chloro-fluoroethylenes, polyvinylidene fluoride, PE-TFE, PE-CTFE, liquid crystal polymers, Mylar®, polyester, LDPE, HDPE, polymethylpentene, polyphenylene sulfide, polyolefins, PVC, and chlorinated PVC.
[0016] The consumable of the presently claimed and disclosed inventive concepts typically use smaller channels (referred to herein as microchannels or microconduits) than have been used by previous workers in the field. In particular, the microchannels (microconduits) used in the presently claimed and disclosed inventive concept(s) typically have widths in the range of about 5 μm to 1000 μm, such as about 10 μm to 500 μm, or in one preferred embodiment 20 μm, whereas channels an order of magnitude larger have typically been used by others when capillary forces are used to move fluids. Depths of the microchannels are typically in a range of 5 μm to 100 μm. In one preferable embodiment, the depth is 20 μm. The minimum dimension for the microchannels is generally about 5 μm, unless it is desired to use smaller channels to filter out components in the sample being analyzed. It is also possible to control movement of the samples in the microchannels by treating the microchannels to become either hydrophilic or hydrophobic depending on whether fluid movement is desired or not. The resistance to movement can be overcome by a pressure difference, for example, by applying pumping, vacuum, electroosmosis, heating, or additional capillary force. As a result, liquids can move from one region of the device to another as required for the analysis being carried out.
[0017] The consumable devices of the presently claimed and disclosed inventive concepts, also referred to herein as “chips” or “microfluidic chips”, are generally small and flat, typically, but not limited to, about 0.5 to 2 square inches (12.5 to 50 mm 2 ) or disks having, but not limited to, a radius of about 15 to 60 mm. The volume of apportioned fluid sample introduced into a particular microfluidic circuit will be small. By way of non-limiting example, the sample typically will contain only about 0.1 to 10 μL for each assay, although the total volume of a specimen may range from 10 to 200 μL. In one embodiment, the consumable of the presently claimed and disclosed inventive concepts comprises a square or rectangular strip or card, or disk. The consumable (chips) used in the presently claimed and disclosed inventive concepts generally are intended to be disposable after a single use. Generally, disposable chips will be made of inexpensive materials to the extent possible, while being compatible with the reagents and the samples which are to be analyzed.
[0018] In one embodiment, the test device 10 includes a first well 12 with an on-board reagent and a second well 14 with an on-board calibrator. On-board means that they were placed in the test as part of a manufacturing process rather than at the time of conducting the assay. Each of the first and second wells have a flow path 16 through which the sample mixed with reagent and calibrator, respectively, may flow. The sample is placed in each of the wells via a pipette. Samples 5-50 μl range with around 20 μl used in a preferred embodiment consistent with the volume of a traditional finger stick sample. The pipette may be part of an automated or semi-automated analyzer, or may be handled manually by an operator. The metering and mixing necessary for the reaction are handled via the pipette. This reduces the complexity of managing these critical functions on the consumable.
[0019] The flow paths have a transparent or translucent portion 18 . These transparent portions are where the test can be read optically by a detection device. The flow paths are arranged closely to one another and are aligned such that the detection device can capture images from both flow paths simultaneously. The flow paths may end in a vent, well, or aperture connected to a pump 20 to move the fluid through the flow path.
[0020] Referring now to FIGS. 2 and 3 , in another embodiment, an analytical system in accordance with the invention includes a test cartridge and an instrument having a pipetting system, a pump, and a detector. The consumable may be used, for example, for a complete blood count and a white blood cell differential. The consumable has on-board reagents and a calibrator. The reagents may be standard reagents and calibrators known in the art of hematology. The reagent may also include sheath fluid. It is understood that this invention may be used for any analysis that can be read optically by substituting the appropriate reagents and adding additional wells and flow paths, if necessary.
[0021] The consumable may be foil sealed across top. A sample is loaded into sample well A. An instrument 30 dispenses metered sample in wells B and C utilizing an automated pipette 34 . The pipette may be on a track to access multiple wells. Wells B and D contain Staining reagents for RBC and WBC's. Example stains include Eosin or Wright's stains. Well C is contains a cell lysis reagent. Several commercial lysis reagents are commonly available such as EasySep or Roche. A fixed volume of sample is transferred from well C to well D for staining utilizing the pipette. Well E contains calibrator. The calibrator may consist of precise volume of particles (fluorescent or colored) that can be used to normalize dimensional errors in manufacturing. The particles are highly precise in concentration and size distribution and are typically polystyrene from commercial vendors such as Polysciences or Spherotech. When samples in wells B and D are ready, flow commences through a 3-channel array using an external pump on the instrument. The pump 18 may be connected to a pressure sensor and a feedback control. The pump, for example, may be a syringe pump, a peristaltic pump, a piezoelectric pump, or the like, which provides a required flow rate. The connecting element for connecting the pump to the consumable may be a tube or hose.
[0022] The Field of View (FOV) for the imager's 36 high-objective lens must accommodate simultaneous imaging. Typical magnification ranges from 10-40× with the working length being dependent on the type of objective used. Images are captured on conventional imagers such as a CCD or CMOS imager that can capture the desired FOV and has the resolution to adequately discriminate the particles. These images are conventionally available from commercial vendors. Images are captured through precise apertures that define the FOV with high accuracy. This allows normalizing the field of view with the calibrator reducing the sensitivity to the depth. The primary impact of a variable depth in the microchannel is to change the concentration of the particles relative to the buffer—i.e., the viewed volume contains a different volume of the original sample from the nominal depending on the change in depth (note that the other two dimensions are controlled by the precision aperture). Since the calibrator exhibits the same variability, however with a well-known concentration, it can be used to normalize the impact of depth.=Specialized analytical software is then used to analyze the image utilizing the known volume of the sample calculated utilizing the dimensions of the pinhole apertures and the calibrant to quantify the analyte in the bodily fluid sample. The instrument can then print out the result on a screen, onto paper, or export the data into an informatics system or data collection unit.
[0023] The invention also includes a method for conducting an assay. The first step is providing a consumable in accordance with the invention described above. Metering sample into at least one well having on-board reagent. If necessary for the reaction, mixing the sample with the reagent using a pipette. Causing the sample/reagent mixture and a calibrator to flow through respective flow paths to a transparent portion of the flow path. Imaging all flow paths simultaneously. Analyzing the image utilizing the known volume of the sample calculated utilizing the dimensions of the apertures for image capture and the calibrant for depth to quantify the analyte in the bodily fluid sample. Printing out the result on a screen, onto paper, or export the data into an informatics system or data collection unit.
[0024] While the present invention has been described in connection with the exemplary embodiment of the figure, it is not limited thereto and it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiments for performing the same function of the present invention without deviating therefrom. Furthermore, numerous reaction chambers and calibrators may be used with additional flow paths. Other assays such as immunoassays or other microscopic analysis such as urine sediment may be analyzed rather than hematology and where the sample may be any bodily fluid, not limited to blood. Therefore, the present invention should not be limited to any single embodiment, but rather should be construed in breadth and scope in accordance with the appended claims. Also, the appended claims should be construed to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the true spirit and scope of the present invention.
|
A microfluidic test device and analyzer, the test device includes a sample well, at least one reaction well and a calibrator well fluidicly connected to a waste well which in turn is connected to a pump port. When vacuum pressure from the analyzer is applied through the pump port, fluid from the reaction well and the calibrator well are moved to the waste well via transparent flow paths. The analyzer detects objects in the flow paths and calibrates its measurement of the objects in the sample utilizing beads from the calibrator well.
| 1
|
RELATED APPLICATIONS
[0001] This application claims benefit under 35 USC 119(e) to provisional application Ser. No. 60/699,656 filed on Jul. 15, 2005, which is incorporated herein by reference in its entirety
FIELD OF THE INVENTION
[0002] The present invention relates to 2-arylbenzothiazoles of the general formula (I) or a salt or a prodrug or a stereoisomer thereof. The compounds of the invention are exceptionally useful for the treatment of diseases associated with abnormal and hyperproliferation of cells in a mammal, especially humans. In particular, they are useful for the treatment of all forms of cancer.
[0003] Furthermore a process of preparing said 2-arylbenzothiazole derivatives is disclosed.
BACKGROUND OF THE INVENTION
[0004] Protein kinases play a central role in the regulation of cellular functions. This includes processes like cell growth and division, cell differentiation and cell death, but also many other cellular activities. Protein kinases catalyze the transfer of phosphate residues from ATP on target proteins which as a consequence of this protein kinase mediated phosphorylation change their three-dimensional structure and thereby their physiological function. Depending on the amino acid which is phosphorylated by a protein kinase these enzymes are grouped in two families, the so-called serine/threonine protein kinases and the tyrosine protein kinases.
[0005] Based on the human genome project it is known that in human beings there exist 518 DNA sequences which encode for a protein kinase-like protein sequence. For several of these 518 proteins it could be shown in the last about 20 years that modifications in their related gene sequences (e.g. point mutations, deletions or gene amplifications) result in pathological changes of the cellular activities of the corresponding protein kinase. This is in particular true for protein kinases which are involved in cell proliferation and cell cycle control, in survival of cells and cell death, in tumor angiogenesis, and in formation of tumor metastases.
[0006] Several so-called oncogenes are pathologically modified genes which in their proto-oncogenic form encode for protein kinases involved in normal, physiological regulation of cell growth and division.
[0007] Since protein kinases are key regulators of cell functions and since they can show dysregulated enzymatic activity in cells they are promising targets for the development of therapeutic agents. There are many ongoing drug discovery projects in the pharmaceutical industry with the goal to identify modulators of protein kinases. The major focus is currently on protein kinases involved in inflammation and cancer, but besides this protein kinases are currently discussed as promising targets in almost every area of diseases.
[0008] In the field of tumors the first protein kinase inhibitors (Gleevec, Iressa) have already reached the market. In addition, a great number of protein kinase inhibitors are currently in various phases of clinical development. In most cases these compounds are either targeting subtypes of the EGF (Epidermal Growth Factor) receptor family or of the VEGF (Vascular Endothelial Growth Factor) receptor family. All these compounds have been developed with the goal to specifically inhibit one particular protein kinase, for which there is evidence that it interferes with one of the four major molecular processes of tumor progression. These four processes are (1) cell proliferation/cell cycle control, (2) regulation of programmed cell death (apoptosis) and cell survival, (3) tumor angiogenesis and (4) tumor metastasis.
[0009] The present invention relates to 2-arylbenzothiazole derivatives which may be useful for inhibition of protein kinases involved in diseases besides cancer, but which are especially useful as anti-tumor agents. This includes monospecific protein kinase inhibitors, which preferentially inhibit one protein kinase which is causatively involved in tumor progression, but also so-called multi-target protein kinase inhibitors, which inhibit at least two different protein kinases which either relate to the same or to two or more different molecular mechanism of tumor progression. As an example, such a compound could be an inhibitor of tumor angiogenesis and, in addition, also a stimulator of apoptosis.
[0010] The concept of multi-target protein kinase inhibitors is a new approach although the idea of developing “multiplex protein kinase inhibitors” has already been described by J. Adams et al., Current Opinion in Chemical Biology 6, 486-492, 2002. Therein compounds are described, which, at the same time, inhibit several protein kinases, which however all are involved in one molecular mechanism of tumor progression, namely tumor angiogenesis.
[0011] The object of the present invention is solved by the subject-matter of the independent claims. Further advantageous features, aspects and details of the invention are evident from the dependent claims, the description, the figures, and the examples of the present application.
[0012] Considering the lack of currently available treatment options for the majority of the conditions associated with protein kinases like ABL1, AKT1, AKT2, AKT3, ARK5, Aurora-A, Aurora-B, Aurora-C, BRK, CDK1, CDK2, CDK3, CDK4, CDK5, CDK6, CDK7, CDK9, CHK1, CK2, COT, CSK, DAPK1, EGF-R, EPHA1, EPHA2, EPHA4, EPHB1, EPHB2, EPHB3, EPHB4, ERBB2, ERBB4, FAK, FGF-R1, FGF-R3, FGF-R4, FGR, FLT3, GSK3-beta, IGF1-R, IKK-beta, IKK-epsilon, INS-R, IRAK4, ITK, JAK2, JAK3, JNK3, KIT, LCK, LYN, MET, MST4, MUSK, NEK2, NEK6, NLK, PAK1, PAK2, PAK4, PBK, PCTAIRE1, PDGFR-alpha, PDGFR-beta, PDK1, PIM1, PIM2, PKC-alpha, PKC-beta1, PKC-beta2, PKC-delta, PKC-epsilon, PKC-eta, PKC-gamma, PKC-iota, PKC-mu, PKC-theta, PKC-zeta, PLK1, PRK1, RET, ROCK2, S6K, SAK, SGK1, SGK3, SNK, SRC, SYK, TIE2, TSF1, TSK2, VEGF-R1, VEGF-R2, VEGF-R3, VRK1, WEE1, YES, ZAP70 especially with protein kinases like EGF-R (cell proliferation), ERBB2 (cell proliferation), PDGFR (cell proliferation), Aurora-A (cell cycle control), Aurora-B (cell cycle control), IGF 1-R (apoptosis), VEGF-R2 (angiogenesis), VEGF-R3 (angiogenesis), TIE2 (angiogenesis), EPHB4 (angiogenesis), and SRC kinase (metastasis), there is still a great need for new therapeutic agents that inhibit these protein targets.
[0013] 2-Arylbenzothiazole derivatives described herein are a new group of protein kinase inhibitors which show differential inhibition of protein kinases, each of which can be assigned to one of the four molecular mechanisms of tumor development.
[0014] In WO 0149686 2-Phenyl-benzothiazoles substituted by an aminotriazine are described as UV-filters used as skin and hair sunscreens.
[0015] Similar compounds are described in WO 9825922, in EP 841341 and in JP 11060573, all of them also substituted by a aminotriazine.
[0016] In EP 711818 2-Phenyl-benzothiazoles are claimed as liquid crystal compositions.
SUMMARY OF THE INVENTION
[0017] The present invention relates to compounds of the general formula (I) or a salt or a prodrug or a stereoisomer thereof,
[0018] Wherein Y independently represents a divalent linkage selected from S, O, NR 2 , SO, SO 2 ;
[0019] A independently represents a divalent linkage selected from a five- or six-membered aromatic carbocycle or heterocycle each of which is optionally substituted by one to four substituents selected from R 3 and R 4 , with the proviso that A-Y is not NR 2 attached at the 2- or 4-position of a pyrimidine ring represented by A and A-Y is not NR 2 attached to 2-halopyridine represented by A;
[0020] R 2 independently represents H, alkyl, cycloalkyl, —COR 11 , —SOR 11 , —SO 2 R 11 , —CN, hydroxyalkyl, haloalkyl, haloalkyloxy, or alkylamino;
[0021] R 3 independently represents H, —COR 11 , —CO 2 R 11 , —SOR 11 , —SO 2 R 11 , —SO 3 R 11 , —NO 2 , —CN, —CF 3 , —OCH 3 , —OCF 3 , alkyl, cycloalkyl, alkoxy, NH 2 , alkylamino, —NR 8 COR 11 , halogen, —OH, —SH, alkylthio, hydroxyalkyl, haloalkyl, or haloalkyloxy;
[0022] R 4 independently represents H, —COR 11 , —CO 2 R 11 , —SOR 11 , —SO 2 R 11 , —SO 3 R 11 , —NO 2 , —CN, —CF 3 , —OCH 3 , —OCF 3 , alkyl, cycloalkyl, alkoxy, —NH 2 , alkylamino, —NR 8 COR 11 , halogen, —OH, —SH, alkylthio, hydroxyalkyl, haloalkyl, haloalkyloxy, aryl or heteroaryl;
[0023] R 5 independently represents H, —COR 11 , —CO 2 R 11 , —SOR 11 , —SO 2 R 11 , —SO 3 R 11 , —NO 2 , —CN, —CF 3 , —OCH 3 , —OCF 3 , alkyl, cycloalkyl, alkoxy, —NH 2 , alkylamino, —NR 8 COR 11 , halogen, —OH, —SH, alkylthio, hydroxyalkyl, haloalkyl, haloalkyloxy, aryl or heteroaryl;
[0024] R 6 independently represents H, —COR 11 , —CO 2 R 11 , —SOR 11 , —SO 2 R 11 , —SO 3 R 11 , —NO 2 , —CN, —CF 3 , —OCH 3 , —OCF 3 , alkyl, cycloalkyl, alkoxy, —NH 2 , alkylamino, —NR 8 COR 11 , halogen, —OH, —SH, alkylthio, hydroxyalkyl, haloalkyl, haloalkyloxy, aryl or heteroaryl;
[0025] R 7 independently represents H, —COR 11 , —CO 2 R 11 , —SOR 11 , —SO 2 R 11 , —SO 3 R 11 , —NO 2 , —CN, —CF 3 , —OCH 3 , —OCF 3 , alkyl, cycloalkyl, alkoxy, —NH 2 , alkylamino, —NR 8 COR 11 , halogen, —OH, —SH, alkylthio, hydroxyalkyl, haloalkyl, haloalkyloxy, aryl or heteroaryl;
[0026] R 8 independently represents H, alkyl, cycloalkyl, —COR 11 , —SOR 11 , —SO 2 R 11 , hydroxyalkyl, haloalkyl, haloalkyloxy; aryl or heteroaryl;
[0027] R 9 independently represents H, alkyl, cycloalkyl, hydroxyalkyl, haloalkyl, haloalkyloxy, aryl or heteroaryl;
[0028] R 11 independently represents H, alkyl, cycloalkyl, —NR 8 R 9 , —NR 8 NR 8 R 9 , —ONR 8 R 9 , —NR 8 OR 9 , alkylamino, arylamino, aryl or heteroaryl;
[0029] R 1 independently represents one of the following groups:
[0030] where * indicates the point of attachment
[0031] Z independently represents O, NR 8 , or S;
[0032] R 12 independently represents H, —NHR 8 ; or one of the following groups:
[0033] where **indicates the point of attachment.
[0034] R 12a independently represents one of the following groups:
[0035] where ** indicates the point of attachment.
[0036] R 13 independently represents H, halogen, nitro, —CN, trifluoromethyl, alkyl, aryl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0037] R 13a independently represents H, nitro, —CN, trifluoromethyl, alkyl, aryl, or heteroaryl;
[0038] R 14 independently represents H, halogen, nitro, —CN, trifluoromethyl, alkyl, aryl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0039] R 15 independently represents H, halogen, nitro, —CN, trifluoromethyl, alkyl, aryl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0040] R 16 independently represents H, halogen, nitro, —CN, trifluoromethyl, alkyl, aryl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0041] R 16a independently represents H, halogen, nitro, —CN, trifluoromethyl, alkyl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0042] R 17 independently represents H, halogen, nitro, trifluoromethyl, alkyl, aryl, heteroaryl, —NR 8 R 9 , or —X 2 R 18 ;
[0043] X 2 independently represents a direct bond, —O—, —CH 2 —, —OCO—, CO, —S—, —SO—, —SO 2 —, —NR 8 CO—, —CONR 8 —, —SO 2 NR 8 —, —NR 8 — or —NR 8 SO 2 —;
[0044] R 18 independently represents H, alkyl, cycloalkyl, —COR 11 , —SOR 11 , —SO 2 R 11 , —OCH 3 , —OCF 3 , hydroxyalkyl, haloalkyl, haloalkyloxy, or one of the following groups:
[0045] where # indicates the point of attachment
[0046] m independently represents an integer from 1-3;
[0047] L is absent or represents a divalent linkage group selected from alkylen, cycloalkylen, heterocyclylen, arylen, or heteroarylen, wherein one or more of the (—CH2—) groups may be replaced by an oxygen or a NR8, and wherein one or more carbon atoms may be independently substituted by one or two substituents selected from halogen, hydroxy, alkoxy, haloalkyloxy, phoshonooxy, or phoshonooxyalkyl;
[0048] X3 independently represents —COOH, —COOalkyl, —CONR8R9, —OH, —NR8R9, —SH, —SO3H, or —SO2NR8R9;
[0049] R19 independently represents H, alkyl, cycloalkyl, alkylamino, or alkoxy;
[0050] R20 independently represents H, phosphonooxy, or phosphonooxyalkyl;
[0051] wherein
[0052] an alkyl group, if not stated otherwise, denotes a linear or branched C 1-C6-alkyl, preferably a linear or branched chain of one to five carbon atoms, a linear or branched C2-C6-alkenyl or a linear or branched C2-C6-alkinyl group, which can be substituted by one or more substituents R′;
[0053] the C 1 -C 6 -alkyl, C 2 -C 6 -alkenyl and C 2 -C 6 -alkinyl residue may be selected from the group comprising —CH 3 , —C 2 H 5 , —CH═CH 2 , —C≡CH, —C 3 H 7 , —CH(CH 3 ) 2 , —CH 2 —CH═CH 2 , —C(CH 3 )═CH 2 , —CH═CH—CH 3 , —C≡C—CH 3 , —CH 2 —C≡CH, —C 4 H 9 , —CH 2 —CH(CH 3 ) 2 , —CH(CH 3 )—C 2 H 5 , —C(CH 3 ) 3 , —C 5 H 11 , —C 6 H 13 , —C(R′) 3 , —C 2 (R′) 5 , —CH 2 —C(R′) 3 , —C 3 (R′) 7 ,
[0054] —C 2 H 4 —C(R′) 3 , —C 2 H 4 —CH═CH 2 , —CH═CH—C 2 H 5 , —CH═C(CH 3 ) 2 , —CH 2 —CH═CH—CH 3 ,
[0055] —CH═CH—CH═CH 2 , —C 2 H 4 —C≡CH, —C≡C—C 2 H 5 , —CH 2 —C≡C—CH 3 , —C≡C—CH═CH 2 ,
[0056] —CH═CH—C≡CH, —C≡C—C≡CH, —C 2 H 4 —CH(CH 3 ) 2 , —CH(CH 3 )—C 3 H 7 , —CH 2 —CH(CH 3 )—C 2 H 5 , —CH(CH 3 )—CH(CH 3 ) 2 , —C(CH 3 ) 2 —C 2 H 5 , —CH 2 —C(CH 3 ) 3 , —C 3 H 6 —CH═CH 2 ,
[0057] —CH═CH—C 3 H 7 , —C 2 H 4 —CH═CH—CH 3 , —CH 2 —CH═CH—C 2 H 5 , —CH 2 —CH═CH—CH═CH 2 ,
[0058] —CH═CH—CH═CH—CH 3 , —CH═CH—CH 2 —CH═CH 2 , —C(CH 3 )═CH—CH═CH 2 ,
[0059] —CH═C(CH 3 )—CH═CH 2 , —CH═CH—C(CH 3 )═CH 2 , —CH 2 —CH═C(CH 3 ) 2 , C(CH 3 )═C(CH 3 ) 2 , —C 3 H 6 —C≡CH, —C≡C—C 3 H 7 , —C 2 H 4 —C≡C—CH 3 , —CH 2 —C═C—C 2 H 5 , —CH 2 —C≡C—CH═CH 2 , —CH 2 —CH═CH—C≡CH, —CH 2 —C≡C—C≡CH, —C≡C—CH═CH—CH 3 , —CH═CH—C≡C—CH 3 ,
[0060] —C≡C—C≡C—CH 3 , —C≡C—CH 2 —CH═CH 2 , —CH═CH—CH 2 —C≡CH, —C≡C—CH 2 —C≡CH,
[0061] —C(CH 3 )═CH—CH═CH 2 , —CH═C(CH 3 )—CH═CH 2 , —CH═CH—C(CH 3 )═CH 2 , —C(CH 3 )═CH—C≡CH, —CH═C(CH 3 )—C≡CH, —C≡C—C(CH 3 )═CH 2 , —C 3 H 6 —CH(CH 3 ) 2 , —C 2 H 4 —CH(CH 3 )—C 2 H 5 , —CH(CH 3 )—C 4 H 9 , —CH 2 —CH(CH 3 )—C 3 H 7 , —CH(CH 3 )—CH 2 —CH(CH 3 ) 2 , —CH(CH 3 )—CH(CH 3 )—C 2 H 5 , —CH 2 —CH(CH 3 )—CH(CH 3 ) 2 , —CH 2 —C(CH 3 ) 2 —C 2 H 5 , —C(CH 3 ) 2 —C 3 H 7 , —C(CH 3 ) 2 —CH(CH 3 ) 2 , —C 2 H 4 —C(CH 3 ) 3 , —CH(CH 3 )—C(CH 3 ) 3 , —C 4 H 8 —CH═CH 2 , —CH═CH—C 4 H 9 , —C 3 H 6 —CH═CH—CH 3 , —CH 2 —CH═CH—C 3 H 7 , —C 2 H 4 —CH═CH—C 2 H 5 , —CH 2 —C(CH 3 )═C(CH 3 ) 2 , —C 2 H 4 —CH═C(CH 3 ) 2 , —C 4 H 8 —C≡CH, —C≡C—C 4 H 9 , —C 3 H 6 —C≡C—CH 3 ,
[0062] —CH 2 —C≡C—C 3 H 7 , —C 2 H 4 —C≡C—C 2 H 5 ;
[0063] R′ independently represents H, —CO 2 R″, —CONHR″, —CR″O, —SO 2 NR″, —NR″—CO-haloalkyl, —NO 2 , —NR″—SO 2 -haloalkyl, —NR″—SO 2 -alkyl, —SO 2 -alkyl, —NR″—CO-alkyl, —CN, alkyl, cycloalkyl, aminoalkyl, alkylamino, alkoxy, —OH, —SH, alkylthio, hydroxyalkyl, hydroxyalkylamino, halogen, haloalkyl, haloalkyloxy, aryl, arylalkyl or heteroaryl;
[0064] R″ independently represents H, haloalkyl, hydroxyalkyl, alkyl, cycloalkyl, aryl, heteroaryl or aminoalkyl;
[0065] an alkylene group denotes a divalent linear or branched C 1 -C 6 -alkylene, preferably a linear or branched chain of one to five carbon atoms, a linear or branched C 2 -C 6 -alkenylene or a linear or branched C 2 -C 6 -alkynylene group, which may be substituted by one or more substituents R′;
[0066] a cycloalkylene group denotes a divalent non-aromatic ring system containing three to eight carbon atoms, preferably four to eight carbon atoms, wherein one or more of the carbon atoms in the ring may be substituted by a group E, E being O, S, SO, SO 2 , N, or NR″, R″ being as defined above;
[0067] a heterocyclylene group denotes a 3 to 8-membered divalent heterocyclic non-aromatic group which contains at least one heteroatom selected from O, N, and S, wherein the heterocyclylene group may be fused to another non-aromatic ring and may be substituted by one or more substituents R′, wherein R′ is as defined above;
[0068] an arylene group denotes an aromatic divalent group having five to fifteen carbon atoms, which may be substituted by one or more substituents R′, and may be fused to another aromatic ring, where R′ is as defined above;
[0069] a heteroarylene group denotes a divalent 5- or 6-membered heterocyclic group which contains at least one heteroatom selected from O, N, and S, wherein the heterocyclylene group may be fused to another aromatic ring and may be substituted by one or more substituents R′, wherein R′ is as defined above;
[0070] a cycloalkyl group denotes a non-aromatic ring system containing three to eight carbon atoms, preferably four to eight carbon atoms, wherein one or more of the carbon atoms in the ring can be substituted by a group E, E being O, S, SO, SO 2 , N, or NR″, R″ being as defined above; the C 3 -C 8 -cycloalkyl residue may be selected from the group comprising -cyclo-C 3 H 5 , -cyclo-C 4 H 7 , -cyclo-C 5 H 9 , -cyclo-C 6 H 11 -cyclo-C 7 H 13 , -cyclo-C 8 H 15 , morpholine-4-yl, piperazinyl, 1-alkylpiperazine-4-yl;
[0071] an alkoxy group denotes an O-alkyl group, the alkyl group being as defined above; the alkoxy group is preferably a methoxy, ethoxy, isopropoxy, t-butoxy or pentoxy group;
[0072] an alkylthio group denotes an S-alkyl group, the alkyl group being as defined above;
[0073] an haloalkyl group denotes an alkyl group which is substituted by one to five halogen atoms, the alkyl group being as defined above; the haloalkyl group is preferably a —C(R 10 ) 3 , —CR 10 (R 10′ ) 2 , —CR 10 (R 10′ )R 10″ , —C 2 (R 10 ) 5 , —CH 2 —C(R 10 ) 3 , —CH 2 —CR 10 (R 10′ ) 2 , —CH 2 —CR 10 (R 10′ )R 10″ , —C 3 (R 10 ) 7 , or —C 2 H 4 —C(R 10 ) 3 wherein R 10 , R 10′ , R 10″ represent F, Cl, Br or I, preferably F;
[0074] a hydroxyalkyl group denotes an HO-alkyl group, the alkyl group being as defined above;
[0075] an haloalkyloxy group denotes an alkoxy group which is substituted by one to five halogen atoms, the alkyl group being as defined above; the haloalkyloxy group is preferably a —OC(R 10 ) 3 , —OCR 10 (R 10′ ) 2 , —OCR 10 (R 10′ )R 10″ , —OC 2 (R 10 ) 5 , —OCH 2 —C(R 10 ) 3 , —OCH 2 —CR 10 (R 10′ ) 2 , —OCH 2 —CR 10 (R 10′ )R 10″ , —OC 3 (R 10 ) 7 or —OC 2 H 4 —C(R 10 ) 3 , wherein R 10 , R 10′ , R 10″ represent F, Cl, Br or I, preferably F;
[0076] a hydroxyalkylamino group denotes an (HO-alkyl) 2 -N— group or HO-alkyl-NH-group, the alkyl group being as defined above;
[0077] an alkylamino group denotes an HN-alkyl or N-dialkyl group, the alkyl group being as defined above;
[0078] an arylamino group denotes an HN-aryl, or N-diaryl, or —N-aryl-alkyl group, the alkyl and aryl group being as defined above;
[0079] a halogen group is fluorine, chlorine, bromine, or iodine;
[0080] an aryl group denotes an aromatic group having five to fifteen carbon atoms, which can be substituted by one or more substituents R′, where R′ is as defined above; the aryl group is preferably a phenyl group, -o-C 6 H 4 —R′, -m-C 6 H 4 —R′, -p-C 6 H 4 —R′, 1-naphthyl, 2-naphthyl, 1-anthracenyl or 2-anthracenyl;
[0081] a heteroaryl group denotes a 5- or 6-membered heterocyclic group which contains at least one heteroatom like O, N, S. This heterocyclic group can be fused to another aromatic ring. For example, this group can be selected from a thiadiazole, thiazol-2-yl, thiazol-4-yl, thiazol-5-yl, isothiazol-3-yl, isothiazol-4-yl, isothiazol-5-yl, oxazol-2-yl, oxazol-4-yl, oxazol-5-yl, isooxazol-3-yl, isooxazol-4-yl, isooxazol-5-yl, 1,2,4-oxadiazol-3-yl, 1,2,4-oxadiazol-5-yl, 1,2,5-oxadiazol-3-yl, 1,2,5-oxadiazol-4-yl, 1,2,4-thiadiazol-3-yl, 1,2,4-thiadiazol-5-yl, isothiazol-3-yl, isothiazol-4-yl, isothiazol-5-yl, 1,2,5-thiadiazol-3-yl, 1-imidazolyl, 2-imidazolyl, 1,2,5-thiadiazol-4-yl, 4-imidazolyl, 1-pyrrolyl, 2-pyrrolyl, 3-pyrrolyl, 2-furanyl, 3-furanyl, 2-thienyl, 3-thienyl, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyranyl, 3-pyranyl, 4-pyranyl, 2-pyrimidinyl, 4-pyrimidinyl, 5-pyrimidinyl, pyrid-2-yl, pyrid-3-yl, pyrid-4-yl, pyrid-5-yl, pyrid-6-yl, 3-pyridazinyl, 4-pyridazinyl, 2-pyrazinyl, 1-pyrazolyl, 3-pyrazolyl, 4-pyrazolyl, 1,2,3-triazol-4-yl, 1,2,3-triazol-5-yl, 1,2,4-triazol-3-yl, 1,2,4-triazol-5-yl, 1H-tetrazol-2-yl, 1H-tetrazol-3-yl, tetrazolyl, acridyl, phenazinyl, carbazolyl, phenoxazinyl, indolizine, 2-indolyl, 3-indolyl, 4-indolyl, 5-indolyl, 6-indolyl, 7-indolyl, 1-isoindolyl, 3-isoindolyl, 4-isoindolyl, 5-isoindolyl, 6-isoindolyl, 7-isoindolyl, 2-indolinyl, 3-indolinyl, 4-indolinyl, 5-indolinyl, 6-indolinyl, 7-indolinyl, benzo[b]furanyl, benzofurazane, benzothiofurazane, benzotriazol-1-yl, benzotriazol-4-yl, benzotriazol-5-yl, benzotriazol-6-yl, benzotriazol-7-yl, benzotriazine, benzo[b]thiophenyl, benzimidazolyl, benzothiazolyl, quinazolinyl, quinoxazolinyl, cinnoline, quinolinyl, tetrahydroquinolinyl, isoquinolinyl, or tetrahydroisoquinolinyl, purine, phthalazine, pteridine, thiatetraazaindene, thiatriazaindene, isothiazolopyrazine, isothiazolopyrimidine, pyrazolotriazine, pyrazolopyrimidine, imidazopyridazine, imidazopyrimidine, imidazopyridine, imidazolotriazine, triazolotriazine, triazolopyridine, triazolopyrazine, triazolopyrimidine, triazolopyridazine group. This heterocyclic group can be substituted by one or more substituents R′, wherein R′ is as defined above;
[0082] a phosphonooxy group is —O—P(═O)(OH) 2 or a salt thereof;
[0083] a phosphonooxyalkyl group denotes an -alkyl-O—P(═O)(OH) 2 group or a salt thereof, alkyl being as defined above.
[0084] The invention also provides a pharmaceutical composition comprising a compound of formula (I), in free form, or in the form of a pharmaceutically acceptable salt, or a prodrug thereof, together with a pharmaceutically acceptable diluent or carrier therefore.
[0085] The term “physiologically functional derivative” as used herein refers to compounds which are not pharmaceutically active themselves but which are transformed into their pharmaceutical active form in vivo, i.e. in the subject to which the compound is administered. Examples of physiologically functional derivatives are prodrugs such as those described below in the present application.
[0086] The term “prodrug” as used herein refers to compounds which are not pharmaceutically active themselves but which are transformed into their pharmaceutical active form in vivo, i.e. in the subject to which the compound is administered. Prodrugs of the compounds of the present invention include but are not limited to: esters, which are transformed in vivo into the corresponding active alcohol, esters, which are transformed in vivo into the corresponding active acid, imines, which are transformed in vivo into the corresponding amines, imines which are metabolized in vivo into the corresponding active carbonyl derivative (e.g. aldehyde or ketone), 1-carboxy-amines, which are decarboxylated in vivo into the active amine, phosphoryloxy-compounds, which are dephosporylated in vivo by phosphateases into the active alcohols, and amides which are metabolized into the corresponding active amine or acid respectively.
[0087] The term “stereoisomer” as used herein refers to compound with at least one stereogenic center, which can be R- or S-configurated. It has to be understood, that in compounds with more than one stereogenic center each of which independently from each other can be R- or S-configurated. The term “stereoisomer” as used herein also refers to salts of the compounds herein described with optically active acids or bases. The term “stereoisomer” also means cis/trans or E/Z isomerism. More particularly, the possible double bond(s) present in the various substituent of the compounds of the present invention can be E or Z configuration. These pure or impure geometrical isomers, alone or as a mixture, form an integral part of the compounds of the present invention. The term “stereoisomer” includes also all the isomeric forms, alone or as mixture, resulting from the presence of one or more axes and/or centers of symmetry in the molecules, and resulting in the rotation of a beam of polarized light. More particularly, it includes enatiomers and diastereomers, in pure form or as a mixture.
[0088] In addition, the present invention provides methods for preparing the compounds of the invention such as compounds of formula (I).
[0089] The compounds of formula (I) may be obtained via various methods. One possibility for the synthesis of compounds of formula (I) comprises the step of reacting a compound of formula (VII), wherein R 5 , R 6 , R 7 , A, and Y are defined as above, with a compound of formula (VIII), wherein R 1 is as defined above and LG comprises a leaving group such as Cl, Br, or I. Either nucleophilic substitution or palladium-catalyzed cross-coupling may be applied. If Y═NR2, R 2 may be added before or after addition of R 1 .
[0090] Compounds of formula (VII) can be synthesized by reaction of a thioamine according to formula (X) with an carboxylic acid of the formula (IX).
[0091] Alternatively an activated acid derivative (e.g. acid chloride) may be used instead of the acid according to formula (IX).
[0092] Another way to synthesize compounds of the formula (VII) is the conversion of compounds of formula (XI), a disulfide, into the benzothiazole of formula (VII) by reduction of the disulfide and subsequent condensation.
[0093] In some cases in the synthesis of compounds of the formula (VII) and formula (XI) Y may be protected. This protection group has to be removed before converting them into compounds of the formula (I). Carboxylic acids of formula (IX) may arise from nitrile hydrolysis.
[0094] Compounds of the formula (XI) may be obtained by reaction of a disulfide according to formula (XII) with a compound of formula (IX) or alternatively an activated carboxylic acid derivative.
[0095] As far as compounds of the general formula (X) and formula (XII) could not be purchased, they were synthesized from the benzothiazoles, 2-aminobenzthiazoles or 2-methyl-benzothiazoles of formula (XIII) e.g. by hydrolysis under basic conditions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0096] A preferred embodiment of the invention are compounds of the formula (I) wherein Y is NR 2 or O.
[0097] A preferred embodiment of the invention are compounds of the formula (II)
[0098] Wherein
[0099] Q independently represents C, N, CH;
[0100] Y is as defined above; R 1 , R 3 , R 4 , R 5 , R 6 and R 7 are as defined above.
[0101] In a more preferred embodiment of the invention, in the compounds of formula (II) are the compounds where Q independently represents C or CH.
[0102] In a more preferred embodiment of the invention, in the compounds of formula (II) are the compounds where Y is attached at the 3- or 4-position of the cycle A.
[0103] A preferred embodiment of the invention are compounds of the formula (II) wherein Y is NR 2 or O.
[0104] A preferred embodiment of the invention are compounds of the formula (II) wherein Y is NR 2 or O and where Y is attached at the 3- or 4-position of the cycle A.
[0105] A preferred embodiment of the invention are compounds of the formula (II) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0106] A preferred embodiment of the invention are compounds of the formula (II) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0107] A preferred embodiment of the invention are compounds of the formula (II) wherein Y is NR 2 or 0 and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0108] A preferred embodiment of the invention are compounds of the formula (II) wherein Y is NR 2 or 0 and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0109] In an even more preferred embodiment of the invention are compounds of the formula (III)
[0110] Wherein
[0111] Q independently represents C, N, CH;
[0112] Y, R 3 , R 4 , R 5 , R 6 , R 7 , R 13 , R 14 , R 15 and R 16a are as defined above.
[0113] In a more preferred embodiment of the invention, in the compounds of formula (III) are the compounds where Y is attached at the 3- or 4-position of the cycle A.
[0114] A preferred embodiment of the invention are compounds of the formula (III) wherein Y is NR 2 or O.
[0115] A preferred embodiment of the invention are compounds of the formula (III) wherein Y is NR 2 or O and where Y is attached at the 3- or 4-position of the cycle A.
[0116] A preferred embodiment of the invention are compounds of the formula (III) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0117] A preferred embodiment of the invention are compounds of the formula (III) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0118] A preferred embodiment of the invention are compounds of the formula (III) wherein Y is NR 2 or O and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0119] A preferred embodiment of the invention are compounds of the formula (III) wherein Y is NR 2 or O and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0120] Another preferred embodiment of the invention are compounds of the formula (IV)
[0121] Wherein
[0122] Q independently represents C, N, CH;
[0123] Y, R 3 , R 4 , R 5 , R 6 , R 7 and R 13 are as defined above.
[0124] In a more preferred embodiment of the invention, in the compounds of formula (IV) are the compounds where Y is attached at the 3- or 4-position of the cycle A.
[0125] A preferred embodiment of the invention are compounds of the formula (IV) wherein Y is NR 2 or O.
[0126] A preferred embodiment of the invention are compounds of the formula (IV) wherein Y is NR 2 or O and where Y is attached at the 3- or 4-position of the cycle A.
[0127] A preferred embodiment of the invention are compounds of the formula (IV) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0128] A preferred embodiment of the invention are compounds of the formula (IV) wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0129] A preferred embodiment of the invention are compounds of the formula (IV) wherein Y is NR 2 or O and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 .
[0130] A preferred embodiment of the invention are compounds of the formula (IV) wherein Y is NR 2 or O and wherein Q is C or CH and R 3 is F, Cl, or OCH 3 and where Y is attached at the 3- or 4-position of the cycle A.
[0131] Exemplary compounds of formula (I) of the present invention include, but are not limited to, the following:
Name Compound (4-Benzothiazol-2-yl-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 1 (4-Benzothiazol-2-yl-2-methyl-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 2 (3-Benzothiazol-2-yl-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 3 (5-Benzothiazol-2-yl-2-chloro-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 4 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 5 2-Benzothiazol-2-yl-5-(4,6-dimethyl-pyrimidin-2-ylamino)-phenol 6 2-Benzothiazol-2-yl-4-(4,6-dimethyl-pyrimidin-2-ylamino)-phenol 7 (5-Benzothiazol-2-yl-2-methyl-phenyl)-(4,6-dimethyl-pyrimidin-2-yl)-amine 8 (4-Benzothiazol-2-yl-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 9 (4-Benzothiazol-2-yl-phenyl)-[4-(4-methyl-piperazin-1-yl)-pyrimidin-2-yl]-amine 10 N2-(4-Benzothiazol-2-yl-phenyl)-N4-(5-methyl-1H-pyrazol-3-yl)-pyrimidine-2,4-diamine 11 (3-Benzothiazol-2-yl-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 12 2-Benzothiazol-2-yl-5-(6,7-dimethoxy-quinazolin-4-ylamino)-phenol 13 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 14 (4-Benzothiazol-2-yl-phenyl)-(9H-purin-6-yl)-amine 15 (3-Benzothiazol-2-yl-phenyl)-(9H-purin-6-yl)-amine 16 (4-Benzothiazol-2-yl-2-methyl-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 17 (5-Benzothiazol-2-yl-2-chloro-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 18 (5-Benzothiazol-2-yl-2-methyl-phenyl)-(6,7-dimethoxy-quinazolin-4-yl)-amine 19 2-Benzothiazol-2-yl-4-(6,7-dimethoxy-quinazolin-4-ylamino)-phenol 20 (3-Benzothiazol-2-yl-phenyl)-[4-(4-methyl-piperazin-1-yl)-pyrimidin-2-yl]-amine 21 N2-(3-Benzothiazol-2-yl-phenyl)-N4-(5-methyl-1H-pyrazol-3-yl)-pyrimidine-2,4-diamine 22 N2-(4-Benzothiazol-2-yl-phenyl)-N4-methyl-pyrimidine-2,4-diamine 23 N4-(4-Benzothiazol-2-yl-phenyl)-N2-methyl-pyrimidine-2,4-diamine 24 N4-(4-Benzothiazol-2-yl-phenyl)-6,7-dimethoxy-N2-methyl-quinazoline-2,4-diamine 25 N4-(4-Benzothiazol-2-yl-phenyl)-6J-dimethoxy-N2-(5-methyl-1H-pyrazol-3-yl)-quinazoline- 26 2,4-diamine N4-(3-Benzothiazol-2-yl-phenyl)-6,7-dimethoxy-N2-methyl-quinazoline-2,4-diamine 27 N2-(3-Benzothiazol-2-yl-phenyl)-N4-methyl-pyrimidine-2,4-diamine 28 N4-(3-Benzothiazol-2-yl-phenyl)-N2-methyl-pyrimidine-2,4-diamine 29 N4-(3-Benzothiazol-2-yl-phenyl)-6,7-dimethoxy-N2-(5-methyl-1H-pyrazol-3-yl)-quinazoline- 30 2,4-diamine (4-Benzothiazol-2-yl-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 31 quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-methoxy-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 32 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-phenyl)-(7H-pyrrolo[2,3-d]pyrimidin-4-yl)-amine 33 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(7H-pyrrolo[2,3-d]pyrimidin-4-yl)-amine 34 (3-Benzothiazol-2-yl-phenyl)-(7H-pyrrolo[2,3-d]pyrimidin-4-yl)-amine 35 (4-Benzothiazol-2-yl-phenyl)-(2-methoxy-7H-pyrrolo[2,3-d]pyrimidin-4-yl)-amine 36 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(2-methoxy-7H-pyrrolo[2,3-d]pyrimidin- 37 4-yl)-amine (3-Benzothiazol-2-yl-phenyl)-(2-methoxy-7H-pyrrolo[2,3-d]pyrimidin-4-yl)-amine 38 (4-Benzothiazol-2-yl-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)-propoxy]- 39 quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-methoxy-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1- 40 yl)-propoxy]-quinazolin-4-yl}-amine (3-Benzothiazol-2-yl-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)-propoxy]- 41 quinazolin-4-yl}-amine (3-Benzothiazol-2-yl-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 42 quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(7H-purin-6-yl)-amine 43 (4-Benzothiazol-2-yl-2-methyl-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 44 propoxy]-quinazolin-4-yl}-amine 2-Benzothiazol-2-yl-5-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 45 quinazolin-4-ylamino}-phenol (5-Benzothiazol-2-yl-2-chloro-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 46 propoxy]-quinazolin-4-yl}-amine (5-Benzothiazol-2-yl-2-methyl-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 47 propoxy]-quinolin-4-yl}-amine (4-Benzothiazol-2-yl-2-trifluoromethoxy-phenyl)-{6-methoxy-7-[3-(4-methyl- 48 piperazin-1-yl)-propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-chloro-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 49 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-fluoro-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 50 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-2-methoxy-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 51 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-2-fluoro-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 52 propoxy]-quinazolin-4-yl}-amine 2-Benzothiazol-2-yl-4-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 53 quinazolin-4-ylamino}-phenol N2-(4-Benzothiazol-2-yl-3-methoxy-phenyl)-N4-(5-methyl-1H-pyrazol-3-yl)-pyrimidine- 54 2,4-diamine N4-(4-Benzothiazol-2-yl-phenyl)-N2-(5-methyl-1H-pyrazol-3-yl)-pyridine-2,4-diamine 55 4-(4-Benzothiazol-2-yl-phenylamino)-pyridine-2-carboxylic acid methylamide 56 (4-Benzothiazol-2-yl-phenyl)-pyridin-4-yl-amine 57 N4-(4-Benzothiazol-2-yl-phenyl)-N2-methyl-pyridine-2,4-diamine 58 5-Benzothiazol-2-yl-2-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 59 quinazolin-4-ylamino}-phenol {6-Methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]-quinazolin-4-yl}-[4- 60 (5-trifluoromethyl-benzothiazol-2-yl)-phenyl]-amine (3-Benzothiazol-2-yl-4-chloro-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin- 61 1-yl)-propoxy]-quinazolin-4-yl}-amine 2-Benzothiazol-2-yl-6-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 62 quinazolin-4-ylamino}-phenol (4-Benzothiazol-2-yl-3-methoxy-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin- 63 1-yl)-propoxy]-quinazolin-4-yl}-methyl-amine (4-Benzothiazol-2-yl-phenyl)-(7-chloro-quinolin-4-yl)-amine 64 (4-Benzothiazol-2-yl-phenyl)-thieno[3,2-d]pyrimidin-4-yl-amine 65 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-(7-chloro-quinolin-4-yl)-amine 66 (4-Benzothiazol-2-yl-3-methoxy-phenyl)-thieno[3,2-d]pyrimidin-4-yl-amine 67 (3-Benzothiazol-2-yl-phenyl)-(7-chloro-quinolin-4-yl)-amine 68 (3-Benzothiazol-2-yl-phenyl)-thieno[3,2-d]pyrimidin-4-yl-amine 69 [4-(5-Chloro-benzothiazol-2-yl)-phenyl]-{6-methoxy-7-[3-(4-methyl-piperazin- 70 1-yl)-propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-methoxy-phenyl)-pyridin-4-yl-amine 71 (3-Benzothiazol-2-yl-phenyl)-pyridin-4-yl-amine 72 (4-Benzothiazol-2-yl-3-chloro-phenyl)-(7-chloro-quinolin-4-yl)-amine 73 (4-Benzothiazol-2-yl-3-chloro-phenyl)-thieno[3,2-d]pyrimidin-4-yl-amine 74 (4-Benzothiazol-2-yl-2-methyl-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)- 75 propoxy]-quinazolin- 2-Benzothiazol-2-yl-5-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)-propoxy]- 76 quinazolin-4-ylamino}-phenol (4-Benzothiazol-2-yl-3-chloro-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)- 77 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-fluoro-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)- 78 propoxy]-quinazolin-4-yl}-amine 5-Benzothiazol-2-yl-2-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)-propoxy]- 79 quinazolin-4-ylamino}-phenol (4-Benzothiazol-2-yl-2-methoxy-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)- 80 propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-2-fluoro-phenyl)-{7-methoxy-6-[3-(4-methyl-piperazin-1-yl)- 81 propoxy]-quinazolin-4-yl}-amine {7-Methoxy-6-[3-(4-methyl-piperazin-1-yl)-propoxy]-quinazolin-4-yl}-[4- 82 (5-trifluoromethyl-benzothiazol-2-yl)-phenyl]-amine [4-(5-Chloro-benzothiazol-2-yl)-phenyl]-{7-methoxy-6-[3-(4-methyl-piperazin- 83 1-yl)-propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-2-fluoro-phenyl)-(7-chloro-quinolin-4-yl)-amine 84 (4-Benzothiazol-2-yl-2-fluoro-phenyl)-thieno[3,2-d]pyrimidin-4-yl-amine 85 N2-(4-Benzothiazol-2-yl-phenyl)-N2-methyl-pyridine-2,4-diamine 86 (4-Benzothiazol-2-yl-phenyl)-(7-chloro-6-methoxy-quinazolin-4-yl)-amine 87 [4-(6-Fluoro-benzothiazol-2-yl)-phenyl]-{6-methoxy-7-[3-(4-methyl-piperazin- 88 1-yl)-propoxy]-quinazolin-4-yl}-amine [4-(6-Chloro-benzothiazol-2-yl)-phenyl]-{6-methoxy-7-[3-(4-methyl-piperazin- 89 1-yl)-propoxy]-quinazolin-4-yl}-amine [4-(6-Chloro-benzothiazol-2-yl)-2-fluoro-phenyl]-{6-methoxy-7-[3-(4-methyl- 90 piperazin-1-yl)-propoxy]-quinazolin-4-yl}-amine (4-Benzothiazol-2-yl-3-methyl-phenyl)-{6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 91 propoxy]-quinazolin-4-yl}-amine [4-(6-Methoxy-benzothiazol-2-yl)-phenyl]-{6-methoxy-7-[3-(4-methyl-piperazin- 92 1-yl)-propoxy]-quinazolin-4-yl}-amine 4-(4-Benzothiazol-2-yl-phenoxy)-6-methoxy-7-[3-(4-methyl-piperazin-1-yl)-propoxy]- 93 quinazoline 4-(4-Benzothiazol-2-yl-2-fluoro-phenoxy)-6-methoxy-7-[3-(4-methyl-piperazin-1-yl)- 94 propoxy]-quinazoline 2-(4-(6-methoxy-7-(3-(pyrrolidin-1-yl)propoxy)quinazolin-4- 95 yloxy)phenyl)benzo[d]thiazole 2-(5-(6-methoxy-7-(3-(pyrrolidin-1-yl)propoxy)quinazolin-4-yloxy)pyridin-2- 96 yl)benzo[d]thiazole
[0132] The compounds of the present invention can form salts with inorganic or organic acids or bases. Examples of pharmaceutically acceptable salts comprise without limitation non-toxic inorganic or organic salts such as acetate derived from acetic acid, aconitate derived from aconitic acid, ascorbate derived from ascorbic acid, benzoate derived from benzoic acid, cinnamate derived from cinnamic acid, citrate derived from citric acid, embonate derived from embonic acid, enantate derived from heptanoic acid, formiate derived from formic acid, fumarate derived from fumaric acid, glutamate derived from glutamic acid, glycolate derived from glycolic acid, chloride derived from hydrochloric acid, bromide derived from hydrobromic acid, lactate derived from lactic acid, maleate derived from maleic acid, malonate derived from malonic acid, mandelate derived from mandelic acid, methanesulfonate derived from methanesulfonic acid, naphtaline-2-sulfonate derived from naphtaline-2-sulfonic acid, nitrate derived from nitric acid, perchlorate derived from perchloric acid, phosphate derived from phosphoric acid, phthalate derived from phthalic acid, salicylate derived from salicylic acid, sorbate derived from sorbic acid, stearate derived from stearic acid, succinate derived from succinic acid, sulphate derived from sulphuric acid, tartrate derived from tartaric acid, toluene-p-sulfate derived from p-toluenesulfonic acid and others.
[0133] Salts of phosphonoxy- and phosphonoxyalkyl groups may be those formed with alkali metal ions e.g. sodium or potassium, or those formed with alkaline earth metal ions e.g. calcium or magnesium, or those formed with zinc ions.
[0134] Such salts of the compounds of the present invention may be anhydrous or solvated. Such salts can be produced by methods known to someone of skill in the art and described in the prior art.
[0135] Other salts like oxalate derived from oxalic acid, which is not considered as pharmaceutically acceptable can be appropriate as intermediates for the production of compounds of the present invention or a pharmaceutically acceptable salt thereof or a prodrug or a stereoisomer thereof.
[0136] The compounds according to the invention and medicaments prepared therewith are generally useful for the treatment of cell proliferation disorders, for the treatment or prophylaxis of immunological diseases and conditions (as for instance inflammatory diseases, neuroimmunological diseases, autoimmune diseases or other).
[0137] The compounds of the present invention are useful for the treatment of diseases which are caused by malignant cell proliferation, such as all forms of solid tumors, leukemias and lymphomas. Therefore the compounds according to the invention and medicaments prepared therewith are generally useful for regulating cell activation, cell proliferation, cell survival, cell differentiation, cell cycle, cell maturation and cell death or to induce systemic changes in metabolism such as changes in sugar, lipid or protein metabolism. They can also be used to support cell generation poiesis, including blood cell growth and generation (prohematopoietic effect) after depletion or destruction of cells, as caused by, for example, toxic agents, radiation, immunotherapy, growth defects, malnutrition, malabsorption, immune dysregulation, anemia and the like or to provide a therapeutic control of tissue generation and degradation, and therapeutic modification of cell and tissue maintenance and blood cell homeostasis.
[0138] These diseases and conditions include but are not limited to cancer as hematological (e.g. leukemia, myeloma), or lymphomas (e.g. Hodgkin's and non-Hodgekin's lymphoma), or solid tumors (for example breast, prostate, liver, bladder, lung, esophageal, stomach, colorectal, genitourinary, gastrointestinal, skin, pancreatic, brain, uterine, colon, head and neck, cervical, and ovarian, melanoma, astrocytoma, small cell lung cancer, glioma, basal and squameous cell carcinoma, sarcomas as Kaposi's sarcoma and osteosarcoma).
[0139] Other aspects of the present invention relate to 2-arylbenzothiazole derivatives of the present invention as new pharmaceutically active agents, especially for the preparation of a pharmaceutical composition for the treatment of diseases which are cured or relieved by the inhibition of one or several kinases and/or phosphatases.
[0140] In another more preferred embodiment of the invention the compounds of the present invention may be used for treating and/or preventing diseases by inhibition of one or or more kinases like: Aurora-A, Aurora-B, EGF-R, ERBB2, PDGFR, FLT3, IGF1-R, VEGF-R2, VEGF-R3, EPHB4, TIE2, FAK and SRC.
[0141] The compounds according to the present invention or a salt or a prodrug or a stereoisomer thereof if desired with appropriate adjuvants and additives for the production of a medicament for the treatment or prevention of a disease characterized by hyperproliferation of keratinocytes and/or T cells, especially inflammatory disorders and immune disorders, preferably selected from the group consisting of Addison's disease, alopecia areata, Ankylosing spondylitis, haemolytic anemia (anemia haemolytica), pernicious anemia (anemia perniciosa), aphthae, aphthous stomatitis, arthritis, arteriosclerotic disorders, osteoarthritis, rheumatoid arthritis, aspermiogenese, asthma bronchiale, auto-immune asthma, auto-immune hemolysis, Bechet's disease, Boeck's disease, inflammatory bowel disease, Burkitt's lymphoma, Crohn's disease, chorioiditis, colitis ulcerosa, Coeliac disease, cryoglobulinemia, dermatitis herpetiformis, dermatomyositis, insulin-dependent type I diabetes, juvenile diabetes, idiopathic diabetes insipidus, insulin-dependent diabetes mellisis, autoimmune demyelinating diseases, Dupuytren's contracture, encephalomyelitis, encephalomyelitis allergica, endophthalmia phacoanaphylactica, enteritis allergica, autoimmune enteropathy syndrome, erythema nodosum leprosum, idiopathic facial paralysis, chronic fatigue syndrome, febris rheumatica, glomerulo nephritis, Goodpasture's syndrome, Graves' disease, Harnman-Rich's disease, Hashimoto's disease, Hashimoto's thyroiditis, sudden hearing loss, sensoneural hearing loss, hepatitis chronica, Hodgkin's disease, haemoglobinuria paroxysmatica, hypogonadism, ileitis regionalis, iritis, leucopenia, leucemia, lupus erythematosus disseminatus, systemic lupus erythematosus, cutaneous lupus erythematosus, lymphogranuloma malignum, mononucleosis infectiosa, myasthenia gravis, traverse myelitis, primary idiopathic myxedema, nephrosis, ophthalmia symphatica, orchitis granulomatosa, pancreatitis, pemphigus, pemphigus vulgaris, polyarteritis nodosa, polyarthritis chronica primaria, polymyositis, polyradiculitis acuta, psoriasis, purpura, pyoderma gangrenosum, Quervain's thyreoiditis, Reiter's syndrome, sarcoidosis, ataxic sclerosis, progressive systemic sclerosis, scleritis, sclerodermia, multiple sclerosis, sclerosis disseminata, acquired spenic atrophy, infertility due to antispermatozoan antibodies, thrombocytopenia, idiopathic thrombocytopenia purpura, thymoma, acute anterior uveitis, vitiligo, AIDS, HIV, SCID and Epstein Barr virus associated diseases such as Sjorgren's syndrome, virus (AIDS or EBV) associated B cell lymphoma, parasitic diseases such as Leishmania , and immunesuppressed disease states such as viral infections following allograft transplantations, AIDS, cancer, chronic active hepatitis diabetes, toxic chock syndrome and food poisoning.
[0142] “Treatment” according to the present invention is intended to mean complete or partial healing of a disease, prevention of a disease, or alleviation of a disease, or stop of progression of a given disease.
[0143] The compounds of the present invention can further be used for diseases that are caused by protozoal infestations in humans and animals.
[0144] The compounds of the present invention can further be used for viral infections or other infections caused for instance by Pneumocystis carinii.
[0145] Furthermore, the invention relates to a method of treatment or prevention of diseases which comprises the administration of an effective amount of compounds of the present invention or a salt or prodrug or a stereoisomer thereof.
[0146] The compounds of the according invention and their pharmacologically acceptable salts can be administered to animals, preferably to mammals, and in particular to humans, dogs and chickens as therapeutics per se, as mixtures with one another or in the form of pharmaceutical preparations which allow enteral or parenteral use and which as active constituent contain an effective dose of at least one compound of the present invention or a salt thereof, in addition to customary pharmaceutically innocuous excipients and additives.
[0147] The production of medicaments containing the compounds according to the present invention and their application can be performed according to well-known pharmaceutical methods.
[0148] While the compounds according to the present invention for use in therapy may be administered in the form of the raw chemical compound, it is preferred to introduce the active ingredient, optionally in the form of a physiologically acceptable salt in a pharmaceutical composition together with one or more adjuvants, excipients, carriers, buffers, diluents, and/or other customary pharmaceutical auxiliaries. Such salts of the compounds may be anhydrous or solvated.
[0149] In a preferred embodiment, the invention provides medicaments comprising compounds according to the present invention, or a salt or a prodrug or a stereoisomer thereof, together with one or more pharmaceutically acceptable carriers thereof, and, optionally, other therapeutic and/or prophylactic ingredients. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not harmful to the recipient thereof.
[0150] A medicament of the invention may be those suitable for oral, rectal, bronchial, nasal, topical, buccal, sub-lingual, transdermal, vaginal or parenteral (including cutaneous, subcutaneous, intramuscular, intraperitoneal, intravenous, intraarterial, intracerebral, intraocular injection or infusion) administration, or those in a form suitable for administration by inhalation or insufflation, including powders and liquid aerosol administration, or by sustained release systems. Suitable examples of sustained release systems include semipermeable matrices of solid hydrophobic polymers containing the compound of the invention, which matrices may be in form of shaped articles, e.g. films or microcapsules.
[0151] For preparing a medicament from a compounds of the present invention and pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavouring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
[0152] In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component. In tablets, the active component is mixed with the carrier having the necessary binding capacity in suitable proportions and compacted in the shape and size desired. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component, with or without carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid forms suitable for oral administration.
[0153] For preparing suppositories, a low melting wax, such as a mixture of fatty acid glyceride or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized moulds, allowed to cool, and thereby to solidify. Compositions suitable for vaginal administration may be presented as pessaries, tampons, creams, gels, pastes, foams or sprays containing in addition to the active ingredient such carriers as are known in the art to be appropriate. Liquid preparations include solutions, suspensions, and emulsions, for example, water or water-propylene glycol solutions. For example, parenteral injection liquid preparations can be formulated as solutions in aqueous polyethylene glycol solution.
[0154] The compounds according to the present invention may thus be formulated for parenteral administration (e.g. by injection, for example bolus injection or continuous infusion) and may be presented in unit dose form in ampoules, pre-filled syringes, small volume infusion or in multi-dose containers with an added preservative. The compositions may take such forms as suspensions, solutions, or emulsions in oily or aqueous vehicles, and may contain formulation agents such as suspending, stabilising and/or dispersing agents. Alternatively, the active ingredient may be in powder form, obtained by aseptic isolation of sterile solid or by lyophilization from solution, for constitution with a suitable vehicle, e.g. sterile, pyrogen-free water, before use.
[0155] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavours, stabilising and thickening agents, as desired. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, or other well known suspending agents.
[0156] Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavours, stabilisers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0157] In one embodiment of the present invention, the medicament is applied topically or systemically or via a combination of the two routes.
[0158] Preferably the medicament is prepared in form of an ointment, a gel, a plaster, an emulsion, a lotion, a foam, a cream of a mixed phase or amphiphilic emulsion system (oil/water-water/oil mixed phase), a liposome, a transfersome, a paste or a powder.
[0159] Ointments and creams may, for example, be formulated with an aqueous or oily base with the addition of suitable thickening and/or gelling agents. Lotions may be formulated with an aqueous or oily base and will in general also contain one or more emulsifying agents, stabilising agents, dispersing agents, suspending agents, thickening agents, or colouring agents.
[0160] Compositions suitable for topical administration in the mouth include lozenges comprising the active agent in a flavoured base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerine or sucrose and acacia; and mouthwashes comprising the active ingredient in a suitable liquid carrier.
[0161] Solutions or suspensions are applied directly to the nasal cavity by conventional means, for example with a dropper, pipette or spray. The compositions may be provided in single or multi-dose form. In the latter case of a dropper or pipette, this may be achieved by the patient administering an appropriate, predetermined volume of the solution or suspension. In the case of a spray, this may be achieved for example by means of a metering atomising spray pump.
[0162] Administration to the respiratory tract may also be achieved by means of an aerosol formulation in which the active ingredient is provided in a pressurised pack with a suitable propellant such as a chlorofluorocarbon (CFC) for example dichlorodifluoromethane, trichlorofluoromethane, or dichlorotetrafluoroethane, carbon dioxide, or other suitable gas. The aerosol may conveniently also contain a surfactant such as lecithin. The dose of drug may be controlled by provision of a metered valve.
[0163] Alternatively the active ingredients may be provided in the form of a dry powder, for example a powder mix of the compound in a suitable powder base such as lactose, starch, starch derivatives such as hydroxypropylmethyl cellulose and polyvinylpyrrolidone (PVP). Conveniently the powder carrier will form a gel in the nasal cavity The powder composition may be presented in unit dose form for example in capsules or cartridges of, e.g., gelatin, or blister packs from which the powder may be administered by means of an inhaler.
[0164] In compositions intended for administration to the respiratory tract, including intranasal compositions, the compound will generally have a small particle size for example of the order of 5 microns or less. Such a particle size may be obtained by means known in the art, for example by micronization.
[0165] When desired, compositions adapted to give sustained release of the active ingredient may be employed.
[0166] The pharmaceutical preparations are preferably in unit dosage forms. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packaged tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form. Tablets or capsules for oral administration and liquids for intravenous administration and continuous infusion are preferred compositions.
[0167] Further details on techniques for formulation and administration may be found in the latest edition of Remington's Pharmaceutical Sciences (Maack Publishing Co. Easton, Pa.).
[0168] Pharmaceutical compositions can also contain two or more compounds of the present invention or their pharmacologically acceptable salts and also other therapeutically active substances.
[0169] Thus, the compounds of the present invention can be used in the form of one compound alone or in combination with other active compounds—for example with medicaments already known for the treatment of the aforementioned diseases, whereby in the latter case a favorable additive, amplifying effect is noticed.
[0170] To prepare the pharmaceutical preparations, pharmaceutically inert inorganic or organic excipients can be used. To prepare pills, tablets, coated tablets and hard gelatin capsules, for example, lactose, corn starch or derivatives thereof, talc, stearic acid or its salts, etc. can be used. Excipients for soft gelatin capsules and suppositories are, for example, fats, waxes, semi-solid and liquid polyols, natural or hardened oils etc. Suitable excipients for the production of solutions and syrups are, for example, water, sucrose, invert sugar, glucose, polyols etc. Suitable excipients for the production of injection solutions are, for example, water, alcohols, glycerol, polyols or vegetable oils.
[0171] The dose can vary within wide limits and is to be suited to the individual conditions in each individual case. For the above uses the appropriate dosage will vary depending on the mode of administration, the particular condition to be treated and the effect desired. In general, however, satisfactory results are achieved at dosage rates of about 1 to 100 mg/kg animal body weight preferably 1 to 50 mg/kg. Suitable dosage rates for larger mammals, for example humans, are of the order of from about 10 mg to 3 g/day, conveniently administered once, in divided doses 2 to 4 times a day, or in sustained release form.
[0172] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples that follow represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments that are disclosed without departing from the spirit and scope of the invention as set out in the appended claims. All references cited are incorporated herein by reference.
EXAMPLES
[0173] Abbreviations: min, minute(s); h, hour(s); r.t., room temperature; TLC, thin layer chromatography; XANTPHOS, 9,9-dimethyl-4,5-bis(diphenylphosphino)xanthene; dba, dibenzylideneacetone; DME, 1,2-dimethoxyethane; DIEA, N,N-diisopropylethylamine; EDC, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide.
[0174] Preparative HPLC-MS: Waters 600 Multisolvent Delivery System with peparative pump heads. 2000 μl or 5000 μl Sample loop. Column, Waters X-Terra RP18, 7 μm, 19×150 mm with X-Terra RP 18 guard cartridge 7 μm, 19×10 mm; used at flow rate 20 ml/min or YMC ODS-A, 120 Å, 40×150 mm with X-Terra RP 18 guard cartridge 7 μm, 19×10 mm; used at flow rate 50 ml/min. Make-up solvent: MeCN—H 2 O—HCO 2 H 80:20:0.05 (v:v:v). Eluent A, H 2 O+0.1% HCO 2 H; eluent B, MeCN. Different linear gradients from 5-100% eluent B, adapted to sample. Injection volume: 500 μl-2000 μl depending on sample.
[0175] Syntheses of Intermediates.
[0176] General Procedure 1:
[0177] Syntheses of 4-chloroquinazolines with alkylamino sidechains: 4-Chloro-6-methoxy-7-[3-(4-methylpiperazin-1-yl)propoxy]quinazoline, 4-Chloro-7-methoxy-6-[3-(4-methyl-piperazin-1-yl)propoxy]quinazoline and 4-Chloro-6-methoxy-7-(3-pyrrolidin-1-yl-propoxy)-quinazoline.
[0178] Step 1. To a solution of methyl vanillate or methyl isovanillate (7.29 g, 40 mmol) in dimethylformamide (25 mL), potassium carbonate (8.29 g, 60 mmol) and benzyl bromide (5.26 mL, 44 mmol) were added. The mixture was heated to 100° C. for 3 h. After cooling to r.t., water was added and the product was extracted several times with ethyl acetate. The combined organic phases were washed with water and brine. After drying over Na 2 SO 4 , the solvent was removed to yield methyl 4-benzyloxy-3-methoxybenzoate or methyl 3-benzyloxy-4-methoxybenzoate, respectively, quantitatively, which was used without further purification.
[0179] Step 2. Crude material of step 1 (40.0 mmol) was converted into methyl 4-benzyloxy-5-methoxy-2-nitrobenzoate or methyl 5-benzyloxy-4-methoxy-2-nitrobenzoate, respectively, in 91-94% yield as described in US 02/0026052 A1, page 51, reference example 15.
[0180] Step 3. In a 1l Schlenk flask filled with argon, product of step 2 (36.6 mmol) and palladium on charcoal (1.17 g, 10% Pd, 1.1 mmol Pd) were combined and tetrahydrofuran (250 mL) was added. The argon was replaced with hydrogen (1 bar), and the mixture was vigorously stirred at r.t. until completion of the reaction. The palladium was separated by filtration through a pad of celite and the solvent was removed to obtain methyl 2-amino-4-hydroxy-5-methoxybenzoate or methyl 2-amino-5-hydroxy-4-methoxybenzoate, respectively, quantitatively, which, again, was used without further purification.
[0181] Step 4. A mixture of formamide (29 mL), ammonium formate (3.41 g, 54 mmol) and crude material of step 3 (36.0 mmol) was heated to 140° C. for 4 h. After cooling to r.t., water (75 mL) was added. After stirring for 1 h, the precipitated 7-hydroxy-6-methoxy-3,4-dihydroquinazolin-4-one or 6-hydroxy-7-methoxy-3,4-dihydroquinazolin-4-one, respectively, was filtered off, washed with water and dried (76-85%).
[0182] Step 5. A mixture of product step 4 (30.5 mmol), acetic anhydride (21.5 mL, 229 mmol) and pyridine (4.9 mL, 61 mmol) was heated to 100° C. for 4 h. After cooling to r.t., ice water (200 mL) was added and the mixture was vigorously stirred for 1 h. The precipitated 7-acetoxy-6-methoxy-3,4-dihydroquinazolin-4-one or 6-acetoxy-7-methoxy-3,4-dihydroquinazolin-4-one, respectively, was filtered off, washed with water and dried (93-96%).
[0183] Step 6. Product step 5 (8.54 mmol) was converted into 4-chloro-7-hydroxy-6-methoxyquinazoline or 4-chloro-6-hydroxy-7-methoxyquinazoline, respectively, (58-95%) by reacting them with thionylchloride (12 mL) and DMF (0.3 mL) at 85° C. for 1.5 h. Excess thionylchloride was removed by distillation. Traces of thionylchloride were removed by aceotropic distillation wit toluene (two times). Alternatively the products step 5 can be converted into the chlorides by reacting them with a mixture of POCl 3 and PCl 5 . The acetyl groups were removed by hydrolysis with ammonium hydroxide (5 mL, 28-30 wt %) in dioxane/water (100 mL/20 mL) at 0° C. to r.t.
[0184] Step 7.
[0185] General Procedure 1:
[0186] Di-tert-butyl azodicarboxylate (0.478 g, 2.08 mmol) was added portionwise to a mixture of product step 6 (1.66 mmol), 3-(4-methylpiperazin-1-yl)-propan-1-ol (synthesis described below, 0.276 g, 1.74 mmol), and triphenylphosphine (0.544 g, 2.08 mmol) in dichloromethane (20 mL) at r.t. If necessary, further alcohol was added. After stirring for 2 h, the solution was concentrated to 10 mL, mounted on silica and chromatographed (gradient, dichloromethane to dichloromethane:methanol=3:2) to obtain the desired ethers (˜73%).
[0187] Synthesis of 4-chloro-6-methoxy-7-[3-(4-methylpiperazin-1-yl)propoxy]quinazoline:
[0188] The compound was synthesised according to general procedure 1 from 4-chloro-7-hydroxy-6-methoxyquinazoline. LC/ESI-MS: m/z=351 [M+H].
[0189] Synthesis of 4-chloro-7-methoxy-6-[3-(4-methylpiperazin-1-yl)propoxy]-quinazoline:
[0190] The compound was synthesised according to general procedure 1 from 4-chloro-6-hydroxy-7-methoxyquinazoline. LC/ESI-MS: m/z=351 [M+H].
[0191] Synthesis of 4-chloro-6-methoxy-7-(3-pyrrolidin-1-yl-propoxy)-quinazoline:
[0192] The compound was synthesised according to general procedure 1 from 4-chloro-7-hydroxy-6-methoxyquinazoline. LC/ESI-MS: m/z=322 [M+H].
[0193] Synthesis of 3-(4-methylpiperazin-1-yl)-propan-1-ol:
[0194] 1-Methylpiperazine (6.99 mL, 63 mol) was dissolved in toluene (30 mL). 3-Bromopropanol (2.62 mL, 30 mmol) was added slowly and the mixture was stirred overnight at r.t. After heating to 80° C. for 2 h and cooling to r.t., the mixture was filtered and the filter cake was thoroughly washed with toluene. After removal of the solvent, the residue was subjected to Kugelrohr distillation (b.p., 180° C./2 mbar) to obtain a colourless oil (4.08 g, 25.8 mmol, 86%). LC/ESI-MS: m/z=159 [M+H].
[0195] Synthesis of 3-morpholin-4-yl-propan-1-ol:
[0196] 3-Morpholin-4-yl-propan-1-ol (b.p., 180° C./1 mbar) was synthesized in analogy to 3-(4-methylpiperazin-1-yl)-propan-1-ol from 3-bromopropanol and morpholine.
[0197] LC/ESI-MS: m/z=146 [M+H].
[0198] Synthesis of 3-Pyrrolidin-1-yl-propan-1-ol:
[0199] 3-Pyrrolidin-1-yl-propan-1-ol (b.p., 230° C./10 mbar) was synthesized in the same manner as 3-(4-methylpiperazin-1-yl)-propan-1-ol from 3-bromopropanol and pyrrolidine. LC/ESI-MS: m/z=130 [M+H].
[0200] Synthesis of 2-(4-Methyl-piperazin-1-yl)-ethanol:
[0201] 2-(4-Methyl-piperazin-1-yl)-ethanol (b.p., 115-135° C./0.1 mbar) was synthesized according to the synthesis of 3-(4-methylpiperazin-1-yl)-propan-1-ol from 2-bromo-ethanol and 1-methylpiperazine. LC/ESI-MS: m/z=145 [M+H].
[0202] Synthesis of 2-morpholin-4-yl-ethanol:
[0203] 2-Morpholin-4-yl-ethanol (b.p., 130-145° C./20 mbar) was synthesized according to the synthesis of 3-(4-methylpiperazin-1-yl)-propan-1-ol from 2-bromo-ethanol and morpholine. LC/ESI-MS: m/z=132 [M+H].
[0204] Synthesis of differently substituted 2- or 4-chloropyrimidines: 2-Chloro-4-(4-methylpiperazin1-yl)pyrimidine, (2-chloropyrimidin-4-yl)-(5-methyl-1H-pyrazol-3-yl)-amine, (2-chloropyrimidin-4-yl)-methylamine, (4-chloropyrimidin-2-yl)-methylamine. Syntheses were performed in analogy to T. Kumagai et al., Bioorg. Med. Chem. 2001, 9, 1349-1355; S. F. Campbell et al., J. Med. Chem. 1987, 30, 1794-1798; US 2004/0132781 A1, [0851].
[0205] A mixture of 2,4-dichloropyrimidine (0.967 g, 6.49 mmol), the respective amine 1-methylpiperazine (0.65 g, 6.49 mmol), 3-amino-5-methylpyrazole (0.63 g, 6.49 mmol) or methylamine hydrochloride (0.44 g, 6.49 mmol), and ethyldiisopropylamine (2.83 mL, 16.22 mmol; 3.96 mL, 22.71 mmol in case of methylamine hydrochloride) in ethanol (13 mL) was stirred at −10° C. for 2 h and then at r.t. overnight. For weaker nucleophiles like aminopyrazoles, the mixture had to be stirred at 50° C. for 4 h additionally to get complete conversion.
[0206] Mixtures were partitioned between H 2 O/brine (3:1; 100 mL) and chloroform (3×70 mL). Combined organic phases were washed once with brine (50 mL) and dried over MgSO 4 .
[0207] 2-Chloro-4-(4-methylpiperazin 1-yl)pyrimidine:
[0208] Removal of solvent yielded a pale-beige solid, which was washed with ethyl acetate/ultrasound to give the desired product as a colourless powder, which was further washed with Et 2 O. Additional product was obtained upon fractional crystallization of the washing solution. A total of 0.741 g (3.48 mmol, 54%) of 2-chloro-4-(4-methylpiperazin1-yl)-pyrimidine was obtained.
[0209] (2-Chloropyrimidin-4-yl)-(5-methylpyrazol-3-yl)amine:
[0210] Upon fractional crystallization from chloroform/diethylether, (2-chloropyrimidin-4-yl)-(5-methylpyrazol-3-yl)amine (0.258 g, 1.23 mmol, 19%) was obtained as colourless crystals.
[0211] (2-Chloropyrimidin-4-yl)-methylamine and (4-chloropyrimidin-2-yl)-methylamine:
[0212] Fractional crystallization from ethyl acetate/diethylether yielded (2-chloropyrimidin-4-yl)-methylamine as the major product within first fractions and enriched (4-chloropyrimidin-2-yl)-methylamine as minor product in the latter fractions, each as colorless powder. A total of 0.396 g (2.57 mmol, 40%) of (2-chloropyrimidin-4-yl)-methylamine and 0.118 g (0.822 mmol, 13%) of (4-chloropyrimidin-2-yl)-methylamine was attained.
[0213] General Procedure 2:
[0214] Synthesis of 3- and 4-(benzothiazol-2-yl)-phenylamines and -phenols from 2-aminothiophenols (According to I. Hutchinson et al., J. Med. Chem. 2001, 44, 1446-1455):
[0215] Differently substituted 2-aminothiophenols (1.1 equiv.) and 3- or 4-aminobenzoic acids/3- or 4-hydroxybenzoic acids (1.0 equiv.), respectively, were placed in a flask and treated with polyphosphoric acid (1.0 g per 1.0 mmol aminobenzoic acid) at 185° C. for 5 h. For aminobenzoic acids additionally substituted with free phenolic OH-groups, 3.0 equiv. of 2-aminothiophenols had to be used.
[0216] Still hot, the mixture was neutralized by pouring it into icy NaOH solution (1 mmol NaOH per 1.0 g polyphosphoric acid, dissolved in 10 mL H 2 O and mixed with ice). A precipitation formed and still remaining polyphosphoric acid (brown-black gummy slurry) was dissolved by further addition of 5% aq. NaOH and ultrasonic treatment. The precipitate was filtered off and washed thoroughly with 5% aq. NaOH and H 2 O. If precipitate was too fine for filtering, a centrifuge was used for sedimentation of the solid. Product was next dissolved in 400 mL DMF/MeOH (1:1) at 60° C., cooled down to r.t. and precipitated by adding H 2 O. Product was filtered off (frit 3 and subsequently, frit 4) and dried in high vacuum.
[0217] If direct precipitation did not succeed properly upon pouring into icy NaOH, the aq. slurry was extracted with CHCl 3 /ethyl acetate 1:1 (3×). Combined org. phases were dried over MgSO 4 and, if necessary, purified using chromatography on silica gel, solvent: petroleum ether/ethyl acetate 10:1 to 1:3.
[0218] General Procedure 3:
[0219] Synthesis of Substituted 3- and 4-(benzothiazol-2-yl)-phenylamines from 2-substituted aminobenzothiazoles (According to I. Hutchinson et al., J. Med. Chem. 2001, 44, 1446-1455):
[0220] Differently substituted 2-amino- or 2-methylbenzothiazoles (3 mmol) were added to a solution of potassium hydroxide (2.5 g) in water (5 mL). The resulting mixture was heated under reflux for 5 h, after which complete solution had occurred. After cooling, the reaction mixture was acidified (to pH 6) by the addition of acetic acid. Water (50 mL) was added, and the resulting mixture was stirred overnight. The solid precipitate was collected and purified by column chromatography (CH 2 Cl 2 ) to give the corresponding bis(2-aminoaryl)disulfide.
[0221] To a solution of the disulfide (1 mmol) in pyridine (5 mL), 4-nitrobenzoyl chloride (2 mmol) or the corresponding derivative was added. The resulting mixture was heated under reflux for 30 min and then poured into water (15 mL). The precipitate was collected, washed with water (20 mL) and purified by column chromatography (CH 2 Cl 2 ).
[0222] The precipitate was reductively cyclized as follows: To a solution of 10 M aq. HCl (10 mL) and ethanol/H 2 O 10:1 (22 mL) was added the disulfide (1.6 mmol) and tin(II) chloride dihydrate (9.8 mmol). The reaction mixture was heated under reflux for 15 h, cooled to 25° C., and poured into water (75 mL). Sodium hydroxide (2 g) was added slowly, and the mixture was stirred for 1 h. The precipitate was collected, washed with water (10 mL) and purified by column chromatography (CH 2 Cl 2 ).
[0223] Synthesis of 2-(4-bromophenyl)-benzothiazole:
[0224] Preparation was performed according to the general procedure 2 described above for 3- and 4-(benzothiazol-2-yl)-phenylamines and -phenols from 2-aminothiophenols and, in this case, 4-bromobenzoic acid. LC/ESI-MS: m/z=290 [M+H].
[0225] Synthesis of 4-benzothiazol-2-yl-phenylamine:
[0226] Preparation was performed according to the general procedure 2 described above and, in this case, 4-aminobenzoic acid. LC/ESI-MS: m/z=227 [M+H].
[0227] Synthesis of 4-benzothiazol-2-yl-2-methyl-phenylamine:
[0228] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-3-methyl-benzoic acid. LC/ESI-MS: m/z=241 [M+H].
[0229] Synthesis of 3-benzothiazol-2-yl-phenylamine:
[0230] Preparation was performed according to the general procedure 2 described above and, in this case, 3-aminobenzoic acid. LC/ESI-MS: m/z=227 [M+H].
[0231] Synthesis of 5-benzothiazol-2-yl-2-chloro-phenylamine:
[0232] Preparation was performed according to the general procedure 2 described above and, in this case, 3-amino-4-chloro-benzoic acid. LC/ESI-MS: m/z=261 [M+H].
[0233] Synthesis of 4-benzothiazol-2-yl-3-methoxy-phenylamine:
[0234] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-2-methoxy-benzoic acid. LC/ESI-MS: m/z=257 [M+H].
[0235] Synthesis of (4-benzothiazol-2-yl-3-methoxy-phenyl)-methyl-amine:
[0236] The compound was obtained as side product within the synthesis of 4-benzothiazol-2-yl-3-methoxy-phenylamine. LC/ESI-MS: m/z=271 [M+H].
[0237] Synthesis of 5-amino-2-benzothiazol-2-yl-phenol:
[0238] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-2-hydroxy-benzoic acid. LC/ESI-MS: m/z=243 [M+H].
[0239] Synthesis of 4-amino-2-benzothiazol-2-yl-phenol:
[0240] Preparation was performed according to the general procedure 2 described above and, in this case, 5-amino-2-hydroxy-benzoic acid. LC/ESI-MS: m/z=243 [M+H].
[0241] Synthesis of 5-benzothiazol-2-yl-2-methyl-phenylamine:
[0242] Preparation was performed according to the general procedure 2 described above and, in this case, 3-amino-4-methyl-benzoic acid. LC/ESI-MS: m/z=241 [M+H].
[0243] Synthesis of 4-benzothiazol-2-yl-2-trifluoromethoxy-phenylamine:
[0244] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-3-trifluoromethoxy-benzoic acid. LC/ESI-MS: m/z=310 [M+H].
[0245] Synthesis of 4-benzothiazol-2-yl-3-chloro-phenylamine:
[0246] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-2-chloro-benzoic acid. LC/ESI-MS: m/z=261 [M+H].
[0247] Synthesis of 4-benzothiazol-2-yl-3-fluoro-phenylamine:
[0248] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-2-fluoro-benzoic acid. LC/ESI-MS: m/z=245 [M+H].
[0249] Synthesis of 4-benzothiazol-2-yl-2-methoxy-phenylamine:
[0250] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-3-methoxy-benzoic acid. LC/ESI-MS: m/z=257 [M+H].
[0251] Synthesis of 4-benzothiazol-2-yl-2-fluoro-phenylamine:
[0252] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-3-fluoro-benzoic acid. LC/ESI-MS: m/z=245 [M+H].
[0253] Synthesis of 2-amino-5-benzothiazol-2-yl-phenol:
[0254] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-3-hydroxy-benzoic acid. LC/ESI-MS: m/z=243 [M+H].
[0255] Synthesis of 4-(5-trifluoromethyl-benzothiazol-2-yl)-phenylamine:
[0256] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-benzoic acid and 2-amino-4-trifluoromethyl-benzenethiol. LC/ESI-MS: m/z=295 [M+H].
[0257] Synthesis of 3-benzothiazol-2-yl-4-chloro-phenylamine:
[0258] Preparation was performed according to the general procedure 2 described above and, in this case, 5-amino-2-chloro-benzoic acid. LC/ESI-MS: m/z=261 [M+H].
[0259] Synthesis of 2-amino-6-benzothiazol-2-yl-phenol:
[0260] Preparation was performed according to the general procedure 2 described above and, in this case, 3-amino-2-hydroxy-benzoic acid. LC/ESI-MS: m/z=243 [M+H].
[0261] Synthesis of 4-(5-chloro-benzothiazol-2-yl)-phenylamine:
[0262] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-benzoic acid and 2-amino-4-chloro-benzenethiol. LC/ESI-MS: m/z=261 [M+H].
[0263] Synthesis of 4-(6-fluoro-benzothiazol-2-yl)-phenylamine:
[0264] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-fluoro-benzothiazol-2-ylamine. LC/ESI-MS: m/z=245 [M+H].
[0265] Synthesis of 4-(6-chloro-benzothiazol-2-yl)-phenylamine:
[0266] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-chloro-benzothiazol-2-ylamine. LC/ESI-MS: m/z=261 [M+H].
[0267] Synthesis of 4-(6-chloro-benzothiazol-2-yl)-2-fluoro-phenylamine:
[0268] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-chloro-benzothiazol-2-ylamine. LC/ESI-MS: m/z=279 [M+H].
[0269] Synthesis of 4-benzothiazol-2-yl-3-methyl-phenylamine:
[0270] Preparation was performed according to the general procedure 2 described above and, in this case, 4-amino-2-methyl-benzoic acid. LC/ESI-MS: m/z=241 [M+H].
[0271] Synthesis of 4-(6-methoxy-benzothiazol-2-yl)-phenylamine:
[0272] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-methoxy-benzothiazol-2-ylamine. LC/ESI-MS: m/z=257 [M+H].
[0273] Synthesis of 2-fluoro-4-(6-fluoro-benzothiazol-2-yl)-phenylamine:
[0274] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 2-amino-6-fluorobenzothiazole. LC/ESI-MS: m/z=263 [M+H].
[0275] Synthesis of 4-(6-bromo-benzothiazol-2-yl)-phenylamine:
[0276] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-bromo-benzothiazol-2-ylamine. LC/ESI-MS: m/z=305 [M+H].
[0277] Synthesis of 4-(6-trifluoromethoxy-benzothiazol-2-yl)-phenylamine:
[0278] Preparation was performed according to the general procedure 3 described above and, in this case, starting from 6-trifluoromethoxy-benzothiazol-2-ylamine. LC/ESI-MS: m/z=311 [M+H].
[0279] Synthesis of 4-benzothiazol-2-yl-phenol:
[0280] Preparation was performed according to the general procedure 2 described above and, in this case, 4-hydroxy-benzoic acid. LC/ESI-MS: m/z=228 [M+H].
[0281] Synthesis of 4-benzothiazol-2-yl-2-fluoro-phenol:
[0282] Preparation was performed according to the general procedure 2 described above and, in this case, 4-hydroxy-3-fluoro-benzoic acid. LC/ESI-MS: m/z=246 [M+H].
[0283] General Procedure 4:
[0284] Reaction of 4-chloroquinazolines without alkylamino sidechains with 3- and 4-(benzothiazol-2-yl)-phenylamines (in Analogy to T. Kumagai et al., Bioorg. Med. Chem. 2001, 9, 1349-1355):
[0285] A mixture of the respective 4-chloroquinazoline (0.221 mmol) and 3- or 4-(benzothiazol-2-yl)-phenylamine (0.221 mmol), respectively, in ethylene glycol (1.5 mL) was heated to 100° C. in a sealed vial for 3 h. In many cases, product precipitated upon cooling of the mixture to r.t. The resulting slurry was rinsed into a frit with ethanol, the filter cake was washed several times with the same solvent and finally with some Et 2 O. If necessary, product was further washed with CHCl 3 /MeOH-ultrasound and Et 2 O/CHCl 3 -ultrasound and separated using a centrifuge.
[0286] General Procedure 5:
[0287] Reaction of 4-chloroquinazolines with alkylamino sidechains with 3- and 4-(benzothiazol-2-yl)-phenylamines
[0288] To a mixture of the respective 4-chloroquinazoline (0.130 mmol) and 3- or 4-(benzothiazol-2-yl)-phenylamine (0.143 mmol), respectively, in ethylene glycol (1.2 mL) was added 4 M HCl in dioxane (2.0 equiv.), and the sealed vial was heated for 3 h to 110° C., or—in case of steric hindrance in the ortho-position of the amino group of 3- or 4-(benzothiazol-2-yl)-phenylamine—to 140° C.
[0289] The reaction mixture was partitioned between satd aq. NaHCO 3 /brine 1:3 (100 mL) and CHCl 3 (100 mL, then 2×50 mL). Combined org. phases were re-extracted once against 50 mL brine and dried over MgSO 4 . If necessary, product was purified by preparative TLC (1 mm silica gel, CH 2 Cl 2 /MeOH 90:10 or prep. HPLC on reversed phase. Product was crystallized from CHCl 3 /Et 2 O or acetone/Et 2 O.
[0290] General Procedure 6:
[0291] Reaction of 4-chloroquinazolines with alkylamino sidechains with 3- and 4-(benzothiazol-2-yl)-phenols (According to K. Kubo et al., J. Med. Chem. 2005, 48, 1359-1366):
[0292] To a cooled solution (0° C.) of substituted 3- or 4-(benzothiazol-2-yl)-phenol (0.11 mmol) in DMSO (1 mL) was added NaH (0.11 mmol) and the mixture stirred at r.t. for 10 min. 4-Chloroquinazoline (0.11 mmol) was then added, and stirring continued at 130° C. for 12 h. Water (5 mL) was added to the reaction mixture, which was further stirred for 5 min, and the product was purified by preparative HPLC.
[0293] General Procedure 7:
[0294] Reaction of 2- or 4-chloropyrimidines with 3- and 4-(benzothiazol-2-yl)-phenylamines (According to T. Kumagai et al., Bioorg. Med. Chem. 2001, 9, 1349-1355):
[0295] A mixture of the respective 2- or 4-chloropyrimidine (0.221 mmol; synthesized as described above) and 3- or 4-(benzothiazol-2-yl)-phenylamine (0.221 mmol), respectively, in ethylene glycol (1.5 mL) was heated to 160° C. in a sealed vial for 3 h.
[0296] If product precipitated upon cooling of the mixture to r.t., the resulting slurry was rinsed into a frit with ethanol, the filter cake was washed several times with the same solvent and finally with some Et 2 O. If necessary, product was further washed with CHCl 3 /acetone-ultrasound and separated using a centrifuge.
[0297] If product stayed dissolved, mixtures were partitioned between satd aq. NaHCO 3 /brine (25+25 mL) and CHCl 3 (3×35 mL). Combined org. phases were dried over MgSO 4 . If necessary, preparative TLC was performed (1 mm silica gel, petroleum ether/CH 2 Cl 2 /MeOH 30:90:20) or prep. HPLC on reversed phase. Product obtained was further washed with CHCl 3 /MeOH-ultrasound and Et 2 O/CHCl 3 -ultrasound and separated using a centrifuge.
[0298] General Procedure 8:
[0299] Palladium-catalyzed reaction of 2-chloro-4-(4-methyl-piperazin-1-yl)-pyrimidine with 3- and 4-(benzothiazol-2-yl)-phenylamine (According to J. Yin et al., Org Lett. 2004, 4, 3481-3484):
[0300] An oven-dried G4 vial was charged subsequently with Pd 2 dba 3 (8.10 mg, 0.009 mmol), XANTPHOS ligand (15.3 mg, 0.027 mmol), pyrimidine (47.0 mg, 0,221 mmol), 3- or 4-(benzothiazol-2-yl)-phenylamine (60.0 mg, 0.265 mmol) and K 3 PO 4 (65.7 mg, 0.309 mmol). The tube was evacuated and purged with argon and dioxane (1.0 mL) was added. The vial was sealed and heated to 100° C. for 21 h.
[0301] Mixtures were filtered through a pipette stuffed with cotton and then directly mounted on a prep. TLC plate (1 mm silica gel), reaction solvent was dried away in a vigorous stream of air, and separation was achieved using petroleum ether/CH 2 Cl 2 /MeOH 30:90:20. Crude product was crystallized from CHCl 3 /Et 2 O to give products as beige powders in 20-38% yield.
[0302] General Procedure 9:
[0303] Reaction of 6-chloropurines with 3- and 4-(benzothiazol-2-yl)-phenylamine:
[0304] A mixture of the respective 6-chloropurine (0.221 mmol) and 3- or 4-(benzothiazol-2-yl)-phenylamine (0.243 mmol), respectively, in ethylene glycol (2.0 mL) was heated to 110° C. in a sealed vial for 3 h. If reaction proceeded too sluggishly, 1.0 equiv 4 M HCl in dioxane was added and stirring continued for additional 3 h at 120° C. Product precipitated upon cooling of the mixture to r.t. Methanol/water 1:1 (40 mL) was added to the mixtures, and the resulting precipitate was filtered off and washed with 5% aq. HCl (3×10 mL) and diethylether (2×10 mL). If necessary, product was further washed with CHCl 3 /MeOH-ultrasound and Et 2 O/CHCl 3 -ultrasound and separated using a centrifuge.
[0305] General Procedure 10:
[0306] Regioselective Twofold 2,4-diamination of 2,4-dichloroquinazolines:
[0307] A mixture of 3- or 4-(benzothiazol-2-yl)-phenylamine (1.0 equiv.), 2,4-dichloroquinazoline (1.0 equiv.) and DIEA (1.0 equiv.) in n-BuOH was stirred at 120° C. over night.
[0308] The respective amine (2.0 equiv.) was added and the mixture was overheated to 140° C. in a sealed vial for 3 h. If amine was used as a hydrochloride, additional DIEA had to be added (0.5 equiv.). For weakly nucleophilic amines like 3-amino-5-methylpyrazole, NaI (1.0 equiv.) was used as additive.
[0309] Synthesis of (55) N 4 -(4-benzothiazol-2-yl-phenyl)-N 2 -(5-methyl-1H-pyrazol-3-yl)-pyridine-2,4-diamine:
[0310] Step 1 (in analogy to S. L. Buchwald et al., J. Org. Chem. 2000, 65, 1158-1174): An oven-dried G24 vial was charged subsequently with Pd(OAc) 2 (44.0 mg, 0.196 mmol), biphenyl-2-yl-di-tert-butyl-phosphine ligand (114 mg, 0.392 mmol), 2-chloro-pyridin-4-ylamine (252 mg, 1.96 mmol), 2-(4-bromophenyl)-benzothiazole (683 mg, 2.35 mmol) and K 3 PO 4 (583 mg, 2.74 mmol). The tube was evacuated and purged with argon and DME (4.0 mL) was added. The vial was sealed and heated to 100° C. for 21 h.
[0311] The mixture was partitioned between half-saturated brine (50 mL, 1:1H 2 O/brine) and CHCl 3 (2×35 mL). Combined org. phases were extracted once with half-saturated brine (50 mL, 1:1H 2 O/brine) and black fluffy precipitate formed was filtered off and discarded. Combined aq. phases were extracted again with CHCl 3 (2×35 mL). Combined org. phases were dried over MgSO 4 , mounted on silica gel and purified by chromatography on using PE/EE 20:1 to 1:2. Product fraction was further purified by prep. TLC (1 mm silica gel, PE/CH 2 Cl 2 /MeOH 70:70:15) and subsequent dissolving in acetone/MeOH and crushing out the product by adding H 2 O. Crude product was treated with Et 2 O and ultrasound, and the suspension was layered with petroleum ether to give two crystal fractions, 10% total yield of (4-benzothiazol-2-yl-phenyl)-(2-chloro-pyridin-4-yl)-amine.
[0312] Step 2: A mixture of product of step 1 (19.0 mg, 0.056 mmol) and 3-amino-5-methylpyrazole (8.20 mg, 0.084 mmol) in ethylene glycol (0.5 mL) was treated with 4 M HCl in dioxane (14 μL, 0.056 mmol) and heated to 160° C. in a sealed G4 vial for 22 h.
[0313] The mixture was partitioned between satd aq. NaHCO 3 /brine 1:1 (50 mL) and CHCl 3 (3×35 mL), combined org. phases were dried over MgSO 4 . Crude material was purified by prep. HPLC. Product fractions were partitioned between satd aq. NaHCO 3 (75 mL added to HPLC phase upon removal of CH 3 CN) and CHCl 3 (3×50 mL), combined org. phases were dried over MgSO 4 , and N 4 -(4-benzothiazol-2-yl-phenyl)-N 2 -(5-methyl-1H-pyrazol-3-yl)-pyridine-2,4-diamine was finally crystallized from CHCl 3 /Et 2 O.
[0314] Synthesis of (58) N 4 -(4-Benzothiazol-2-yl-phenyl)-N 2 -methyl-pyridine-2,4-diamine and (86) N 2 -(4-Benzothiazol-2-yl-phenyl)-N 2 -methyl-pyridine-2,4-diamine:
[0315] Step 1: A mixture of methylamine hydrochloride (149 mg, 2.20 mmol), 2-chloro-4-aminopyridine (257 mg, 2.00 mmol), DIEA (174 μL, 1.00 mmol) and NaI (300 mg, 2.00 mmol) in nBuOH (4 mL) was stirred at 120° C. for 24 h.
[0316] Mixture was partitioned between NaHCO 3 /brine 1:1 (50 mL) and CHCl 3 (3×35 mL). Combined org. phases were washed once with brine (50 mL) and dried over MgSO 4 . The aq. phase still contained some product along with high quantities of DIEA, so water was removed in vacuum and the remaining salt was washed with acetone/CHCl 3 several times. Both organic fractions (first from extraction, second from salt) were purified by prep. TLC (1 mm silica gel each, CH 2 Cl 2 /MeOH 85:15). Product was crystallized from CHCl 3 /Et 2 O and yielded 227 mg (92%) of a beige powder.
[0317] Step 2 (in analogy to S. L. Buchwald et al., J. Org. Chem. 2000, 65, 1158-1174): An oven-dried G4 vial was charged subsequently with Pd 2 dba 3 (36.6 mg, 0.040 mmol), biphenyl-2-yl-di-tert-butyl-phosphine ligand (47.8 mg, 0.160 mmol), product step 1 (98.6 mg, 0.800 mmol, 2-(4-bromophenyl)-benzothiazole (155 mg, 0.880 mmol) and sodium tert-pentoxide (123 mg, 1.12 mmol). The tube was evacuated and purged with argon and toluene (1.6 mL) was added. The vial was sealed and heated to 110° C. for 21 h.
[0318] The mixture was partitioned between half-saturated brine (50 mL, 1:1H 2 O/brine) and CHCl 3 (3×35 mL). Combined org. phases were dried over MgSO 4 and purified by prep HPLC. Two product fractions were collected (constitutional isomers), partitioned between satd aq. NaHCO 3 (20 mL) and CHCl 3 (3×30 mL) to remove any formic acid still present from HPLC and dried again over MgSO 4 . Both fractions were finally purified by prep. TLC (1 mm silica gel, CH 2 Cl 2 /MeOH 80:20), dissolved in a few drops CH 2 Cl 2 and crushed out with Et 2 O to give N 4 -(4-Benzothiazol-2-yl-phenyl)-N 2 -methyl-pyridine-2,4-diamine and N 2 -(4-Benzothiazol-2-yl-phenyl)-N 2 -methyl-pyridine-2,4-diamine, respectively as beige solids (yields around 1% each).
[0319] Synthesis of (56)4-(4-benzothiazol-2-yl-phenylamino)-pyridine-2-carboxylic acid methylamide:
[0320] Step 1: A mixture of methylamine hydrochloride (544 mg, 8.05 mmol) and 4-chloropicolinic acid (296 mg, 2.30 mmol) in DMF (5 mL) was treated with EDC*HC1 (661 mg, 3.45 mmol) and DIEA (2.0 mL, 11.5 mmol) at r.t. for 40 h. was continued over night (LCMS: ST179 — 21h).
[0321] Reaction mixture was partitioned between aq. satd NaHCO 3 (50 mL) and CHCl 3 (3×35 mL). Combined org. phases were washed with aq. satd NH 4 Cl (2×50 mL) and dried over MgSO 4 . The organic phase was purified by chromatography on silica gel using petroleum ether/ethyl acetate 2:1 to pure ethyl acetate. Product was finally purified by prep. HPLC. Product fraction was again partitioned between satd aq. NaHCO 3 (20 mL) and CHCl 3 (3×30 mL) to remove any formic acid still present from HPLC, and dried over MgSO 4 . Resulting oil was dried only under reduced pressure, 25 mbar, as product is volatile at high vacuum.
[0322] Step 2: A mixture of 4-benzothiazol-2-yl-phenylamine (59.7 mg, 0.264 mmol), product step 1 (40.9 mg, 0.240 mmol) and 4.0 M HCl/dioxane (45 μL, 0.180 mmol) in DMF (0.5 mL) was heated to 160° C. for 7 h.
[0323] Slurry was rinsed out into a frit (pore size 4) with EtOH, the filter cake was washed several times with the same solvent and finally with some Et 2 O. Solid was treated with CHCl 3 -ultrasound to remove impurities and 4-(4-benzothiazol-2-yl-phenylamino)-pyridine-2-carboxylic acid methylamide was separated using a centrifuge, resulting in 17.5 mg (20%) of a beige powder.
[0324] Synthesis of (57) (4-benzothiazol-2-yl-phenyl)-pyridin-4-yl-amine:
[0325] When a mixture of 4-benzothiazol-2-yl-phenylamine (79.2 mg, 0.350 mmol) and 4-chloropicolinic acid (45.0 mg, 0.350 mmol) in DMF (0.5 mL) was heated to 160° C. for 3 h, decarboxylation of product formed occurred immediately, but not of starting picolinic acid.
[0326] Mixture was filtered through a pipette stuffed with cotton wool and then purified by prep. TLC (1 mm silica gel), using PE/EE 1:1. (4-Benzothiazol-2-yl-phenyl)-pyridin-4-yl-amine was finally purified by prep. HPLC to give a pale yellow solid (9.10 mg, 8%).
[0327] General Procedure 11:
[0328] Reaction of 4-chloropyridine with Substituted 3- and 4-(benzothiazol-2-yl)-phenylamines:
[0329] A mixture of 4-chloropyridine (40.0 mg, 0.350 mmol) and substituted 3- and 4-(benzothiazol-2-yl)-phenylamines (0.350 mmol) in DMF (2.0 mL) was heated for 3 h at 160° C.
[0330] The mixtures were dissolved in DMSO (2 mL) and separated by prep. HPLC. Product was finally purified by additional prep. TLC (1 mm silica gel, CH 2 Cl 2 /MeOH, 90:10).
[0331] General Procedure 12:
[0332] Reaction of 4,7-dichloroquinoline and 4-chloro-thieno[3,2-d]pyrimidine with Substituted 3- and 4-(benzothiazol-2-yl)-phenylamines:
[0333] A mixture of 4,7-dichloroquinoline or 4-chloro-thieno[3,2-d]pyrimidine (0.242 mmol) and the respective 3- or 4-(benzothiazol-2-yl)-phenylamines (0.220 mmol) and 4.0 M HCl/dioxane (65 μL, 0.440 mmol) in ethylene glycol (1 mL) was heated to 110° C. for 6 h.
[0334] For reactions with 4,7-dichloroquinoline, addition of water resulted in precipitation of product, which was filtered off and washed with water, diethylether, and petroleum ether.
[0335] For reactions with 4-chloro-thieno[3,2-d]pyrimidine, the mixtures were separated by prep. HPLC.
[0336] By following the methods described above, the compounds set out in the following table were prepared.
Com- LCL/EDI-MS: General pound Structure [M + H] m/z = Procedure 1 333 7 2 347 7 3 333 7 4 367 7 5 363 7 6 349 7 7 349 7 8 347 7 9 415 4 10 403 8 11 400 7 12 415 4 13 431 4 14 445 4 15 345 9 16 345 9 17 429 4 18 449 4 19 429 4 20 431 4 21 403 8 22 400 7 23 334 7 24 334 7 25 444 10 26 510 10 27 444 10 28 334 7 29 334 7 30 510 10 31 541 5 32 571 5 33 344 9 34 374 9 35 344 9 36 374 9 37 404 9 38 374 9 39 541 5 40 571 5 41 541 5 42 541 5 43 375 9 44 555 5 45 557 5 46 575 5 47 555 5 48 625 5 49 575 5 50 559 5 51 571 5 52 559 5 53 557 5 54 430 7 55 399 see above 56 361 see above 57 304 see above 58 333 see above 59 557 5 60 609 5 61 575 5 62 557 5 63 585 5 64 388 12 65 361 12 66 418 12 67 391 12 68 388 12 69 361 12 70 575 5 71 334 11 72 304 11 73 422 12 74 395 12 75 555 5 76 557 5 77 575 5 78 559 5 79 557 5 80 571 5 81 559 5 82 609 5 83 575 5 84 406 12 85 379 12 86 333 see above 87 419 4 88 559 5 89 575 5 90 593 5 91 555 5 92 571 5 93 542 6 94 560 6 95 513 6 96 514 6
[0337] Materials and Methods
[0338] In vitro Protein Kinase Assay
[0339] The effect of the 2-arylbenzothiazole derivatives was tested on recombinant, human protein kinases. All protein kinases were expressed in Sf9 insect cells as human recombinant GST-fusion proteins or as His-tagged proteins by means of the baculovirus expression system. Protein kinases were purified by affinity chromatography using either GSH-agarose or Ni-NTH-agarose. The purity and identity of each was checked by SDS-PAGE/silver staining and by western blot analysis with specific antibodies.
[0340] A proprietary protein kinase assay (33 PanQinase® Activity Assay) was used for measuring the kinase activity. All kinase assays were performed in 96-well FlashPlates™ in a 50 μl reaction volume. The assay for all enzymes contained 60 mM HEPES-NaOH, pH 7.5, 3 mM MgCl 2 , 3 mM MnCl 2 , 3 μM Na-orthovanadate, 1.2 mM DTT, 50 μg/ml PEG 20000 and 1 μM [γ- 33 P]-ATP (approx. 5×10 5 cpm per well).
[0341] The reaction cocktails were incubated at 30° C. for 80 minutes. The reaction was stopped with 50 μl of 2% (v/v) H 3 PO 4 , plates were aspirated and washed two times with 200 μl of 0.9% (w/v) NaCl. Incorporation of 33 P i was determined with a microplate scintillation counter. All assays were performed with a BeckmanCoulter/Sagian robotic system.
[0342] Cellular Receptor Tyrosine Kinase Assay
[0343] The effect of 2-arylbenzothiazole derivatives was tested in cellular assays by determining the inhibition of the receptor tyrosine kinases (RTKs) of the growth factor receptors EGF-R, PDGF-R, TIE2, and VEGF-R2. To this end different cell lines expressing the respective growth factor receptor in appropriate amounts were used. 35,000 cells per well were plated in medium containing 10% fetal calf serum (FCS) in 48-well cell culture dishes. After 24 hrs the FCS-containing medium was exchanged against medium without FCS, and subsequently cells were starved in this medium overnight. On the next day test compounds at different concentrations in 100% DMSO were added to the cell culture medium in a 1:100 dilution step resulting in a final DMSO assay concentration of 1%. After 90 min preincubation with test compounds at 37° C., cells were stimulated at room temperature for several min with receptor-specific ligands. Receptor stimulation was followed by cell lysis using a lysis buffer complemented with standard protease and phosphatase inhibitors.
[0344] The phosphorylation status of the various RTKs was quantified in 96-well plates via a sandwich ELISA using receptor-specific capture antibodies and a generic biotinylated anti-phosphotyrosine detection antibody. Finally optical density as measured at 450 nm after addition of avidin-labelled horseradish peroxidase and Tetramethylbenzidine (TMB) as a substrate.
[0345] For each particular concentration of a test compound percental inhibition was calculated relative to maximal phosphorylation in stimulated, untreated cells (“high control”). IC 50 values were calculated based on sigmoidal inhibitor curves covering a concentration range of 9 concentrations of each test compound in half-logarithmic steps.
[0346] Cellular Aurora-B Kinase Assay
[0347] The effect of 2-arylbenzothiazole derivatives was tested in a cellular Aurora-B assay by measuring the effect of the test compounds on the endoreduplication of genomic DNA. Inhibition of Aurora-B results in endoreduplication of genomic DNA, which is detectable in cells as DNA-content higher then 4 n. Intercalation of fluorescent Propidium Iodine (PI) into DNA was used to quantify the DNA content by using a fluorescence activated cell sorter (FACS).
[0348] HT29 colon-carcinoma cells were seeded on day 1 of the experiment at 100,000 cells per well in 6-well cell culture dishes in 3 ml of DMEM medium containing 10% FCS, 100 units/ml Pencillin, 100 mg/ml Streptomycin at 37°, 10% CO 2 . On day 2 test compounds at different concentrations in 100% DMSO were added to the medium in a 1:1000 dilution step resulting in a final DMSO assay concentration of 0.1%. Cells were incubated with test compounds for 3 days. On day 5 the cells were harvested by trypsinization, combined with corresponding supernatants, centrifuged, and resuspended in 80% methanol for fixation and permeabilization at 4° C. overnight. On day 6 fixed cells were centrifuged, rehydrated in PBS/1% FCS for 1 h, and subsequently incubated with RNAse A and PI for 30 min at room temperature.
[0349] Stained cells were analyzed for DNA-content by FACS as follows. For analyses of the cell cycle distribution of the cell population, 5000 single-cell-events of the differently treated cells were aquired by FACS. DNA-intercalated PI was detected by measuring fluorescence emission using a 650 nm pass filter (FL3) upon excitation at 488 nm with an argon laser. Single cell events were plotted in a histogram according to their FL3-A signal. Signal amplification for the first peak of the FL-3 amplitude (FL3-A) was set to about 200 arbitrary units (AU). Using an untreated cell population, gates were defined for each of the different cell cycle phases. The area containing the gaussian-curve-shaped first peak at 200 AU was defined as “cells in G1-phase” containing the double set of chromosomes (2n). The area around the peak at 400 AU was defined as “cells in G2/M-phase” containing the quadruple set of chromosomes (4n). Events in between G1 and G2/M are defined as “cells in S-phase”, those below G1 (subG1) as “apoptotic”. Importantly, all events beyond the G2/M-gate were defined as “endoreduplicated cells” (EndoR). For each concentration of a test compound the percentage of EndoR-population as compared to the whole cell population was determined. For estimation of IC 50 values of Aurora-B inhibition the percentages of EndoR-populations were plotted versus compound concentrations.
[0350] Cellular Aurora-B Kinase Histone H3 Phosphorylation Assay
[0351] The effect of compounds was tested in a cellular Aurora-B assay measuring phosphory-lation of the Aurora B-substrate protein Histone H3 at Serine 10 (H is H3-pS10). Inhibition of Aurora B results in reduction of H is H3-pS 10 which was detected in a specific immuno-assay.
[0352] In the experiment, HT-29 colon-carcinoma cells were seeded on day 1 and on day 2 test compounds at different concentrations were added. Cells were incubated with test compounds for 1 hour. Subsequently, Calyculin A was added for 30 min. For DELFIA®-detection (PerkinElmer) of H is H3-pS 10, lysates were transferred to a microtiterplate and incubated with detecting antibody directed against H is H3-pS10 and Europium-labelled secondary anti-IgG-antibody. Emission at 615 nm was measured upon excitation at 340 nm and the percentage of inhibition was calculated for each concentration of the test compounds relative to controls without inhibitor. Mean values of H is H3-pS10 percentage were plotted versus compound concentration for calculation of IC 50 -values.
[0353] Results
[0354] In vitro Protein Kinase Assay
[0355] The following examples show IC 50 values lower than 500 nM on at least one kinase selected from Aurora-A, Aurora-B, EGF-R, ERBB2, PDGFR, IGF1-R, VEGF-R2, VEGF-R3, EPHB4, TIE2, and SRC or display a beneficial activity profile by inhibiting at least two kinases from at least two different molecular mechanisms of tumor progression with IC 50 values lower than 500 nM: 31, 32, 39, 40, 44, 45, 48, 49, 50, 51, 52, 54, 59, 60, 70, 75, 76, 77, 78, 79, 81, 83, 85, 87, 88, 89, 90, 91, 92, 93, 94, 95.
[0356] The following compounds show IC50 values lower than 10 □M in the Cellular Receptor Tyrosine Kinase Assay and/or the Cellular Aurora-B Kinase Assay: 45, 51, 93, 94, 95.
|
The present invention relates to compounds of the general formula (I) and salts, prodrugs, and stereoisomers thereof,
wherein
Y independently represents S, O, NR 2 , SO, SO 2 ;
A independently represents a fife- or six-membered aromatic carbocycle or heterocycle and wherein R 1 to R 20 in formula (I) represent independently of each other a variety of different substituents comprising alkyl, aryl, aralkyl, alkylaryl, heteroaryl groups and monofunctional moieties.
| 2
|
CROSS-REFERENCE TO A RELATED APPLICATION
[0001] The invention described and claimed hereinbelow is also described in German Priority Document DE 10 2013 105941.4, filed on Jun. 7, 2013. The German Priority Document, the subject matter of which is incorporated herein by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The invention relates to a circular knitting machine with a circular knitting unit fitted with needles and an expander arranged under the circular knitting unit for the tubular knit formed by the circular knitting unit. The expander is rotatably mounted on a central rod arranged coaxially to a knitting machine central axis.
[0003] With the expander the tubular knit is formed into a double-layered web laid flat and is then withdrawn and wound up. In this process the knitted fabric exerts considerable forces on the expander. These forces are transferred to the central rod, which can thus result in fatigue fractures of the central rod. Moreover, the forces also can result in folding and ringing of the knitted fabric during winding, which makes further processing difficult.
[0004] To remedy this problem document DE 12 28 021 has proposed to suspend the expander on the machine on chains. However, this type of suspension of the expander can lead to a relatively substantial lateral displacement of the expander as a result of the forces exerted by the tubular knit. The lateral displacement makes it difficult to uniformly withdraw and wind up the web.
[0005] DE 24 43 067 describes an expander with articulated straps, which are connected to a rigid expander frame by a damper unit. The damper units absorb part of the forces exerted by the tubular knit. This solution, however, is structurally complicated. The damper units suffer fatigue over time and must be regularly replaced.
[0006] DE 31 12 181 also discloses expanders with different adjustment possibilities of individual expander parts relative to one another to enable forces exerted by the knitted fabric to be compensated. These solutions, however, also are very complicated structurally.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes the shortcomings of known arts, such as those mentioned above.
[0008] To that end, the present invention provides a circular knitting machine with an expander, which absorbs forces generated by the tubular knit in a structurally simple manner.
[0009] In an embodiment, the invention provides a circular knitting machine with a circular knitting unit fitted with needles and an expander arranged under the circular knitting unit for the tubular knit (formed by the circular knitting unit). The expander is rotatably mounted on a central rod arranged coaxially to a knitting machine central axis. The expander has a pivoting bearing arranged on the central rod that allows limited swivel movements of the expander relative to the central rod.
[0010] As a result of the pivoting bearing, the expander can move out of the way of the forces exerted by the tubular knit by swivel movements relative to the central rod to relieve the load on the central rod. However, in contrast to the known chain suspension arrangements of expanders, lateral deflection of the expander does not occur and, therefore, the withdrawal and winding up of the web are not detrimentally affected. Ringing or folding in the web can likewise by avoided by the swiveling expander.
[0011] The pivoting bearing is preferably configured as a ball bearing, which allows a uniform movement of the expander in all spatial directions perpendicular to the direction of the longitudinal axis of the central rod. Alternatively, the pivoting bearing is configured as an elastic pivoting bearing. The elastic pivoting bearing is achieved by spring elements or other elastic coupling elements. These elastic bearing elements can absorb forces in the direction of the central rod.
[0012] In a first configuration, the expander is arranged rotatably on the central rod by the pivoting bearing, i.e., pivoting and rotating bearings for the expander are arranged in a unit in the region of the lower end of the central rod.
[0013] If, however, larger swivel radii of the expander are desired, then the central rod CaO be divided into an upper and a lower section and the pivoting bearing can be arranged between the upper and the lower section. The longer the lower section of the central rod is selected to be, the larger the possible swivel radius of the expander and thus the greater its ability to move out of the way of forces generated by the knitted fabric.
[0014] A coupling arrangement with the pivoting bearing can be arranged between the two central rod sections to connect the sections to one another. This coupling arrangement has a holding element and a fastening element, for example, which are connected to one another by spacer screws. In this case, the holding element is connected to one of the sections of the central rod, e.g., the upper section, and the fastening element is connected to the other section. The pivoting bearing is arranged on the fastening element in this case. Moreover, the spacing between the two central rod sections can be adjusted by the spacer screws.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Further features and advantages of the invention will become apparent from the description of embodiments that follows, with reference to the attached figures, wherein:
[0016] FIG. 1 presents a perspective view of an expander with divided central rod, configured according to the invention;
[0017] FIG. 2 presents an enlarged detail view of the connection region of the central rod sections of the expander of FIG. 1 ;
[0018] FIG. 3 presents an exploded drawing of a pivoting bearing on the central rod of the expander of FIG. 1 ;
[0019] FIG. 4 presents a perspective view of a second connection region of the central rod sections of an expander; and
[0020] FIG. 5 presents a perspective view of a third connection region of the central rod sections of an expander.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The following is a detailed description of example embodiments of the invention depicted in the accompanying drawings. The example embodiments are presented in such detail as to clearly communicate the invention and are designed to make such embodiments obvious to a person of ordinary skill in the art. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention, as defined by the appended claims.
[0022] FIG. 1 shows an expander 10 formed according to the invention with two trapezoidal straps 11 , 12 , which are connected to one another at a base 16 . The trapezoidal straps are held at an angle a relative to one another by means of struts 13 , 14 , as shown. The length of the base 16 is adjustable and thus adaptable to a diameter of the tubular knit.
[0023] The base 16 is connected by a strap 17 and a rotating bearing 18 to a lower section 20 . 1 of a central rod 20 . The central rod 20 is fastened to a machine frame of the circular knitting machine. The central rod 20 is oriented coaxially to a central axis of the circular knitting machine in this case.
[0024] A coupling unit 21 and a pivoting bearing 22 , as shown in FIGS. 2 and 3 , respectively, are arranged between the lower section 20 . 1 of the central rod 20 and an upper section 20 . 2 of the central rod 20 . As result of the pivoting bearing 22 , the expander 10 can pivot in relation to the central rod 20 and thus move out of the way of forces that are exerted on it by the tubular knit (not shown) generated by the circular knitting machine. These forces are thus not transferred to the central rod 20 . The central rod 20 is thus subject to a significant relief of load as a result of the pivoting bearing 22 . Moreover, the flat double-layered web generated from the tubular knit by the expander 10 can be withdrawn and wound up free from tension as a result of the limited pivoting ability of the expander 10 .
[0025] Coupling unit 21 is shown in FIG. 2 with a holding element 23 that is connectable to the upper section 20 . 2 of the central rod 20 and, is connected to a ring-shaped fastening element 25 by spacer screws 24 . A pivoting bearing 22 and the lower section 20 . 1 of the central rod 20 are fastened to the underside of the fastening element 25 .
[0026] Pivoting bearing 22 ( FIG. 3 ) consists of a bearing shell 26 , which is screwed to the fastening element 25 , a ball 27 and a spacer ring 28 . The ball 27 is hollow so that the upper end of the lower central rod section 20 . 1 is passed through it. The length of the lower central rod section 20 . 1 determines the swivel radius of the expander 10 .
[0027] FIG. 4 shows a further embodiment of a pivoting bearing 122 , which is arranged between two central rod sections 20 . 1 and 20 . 2 of the expander and is configured as an elastic joint. The upper central rod section 20 . 2 is fastened to a holding element 123 , whereas the lower central rod section 20 . 1 is arranged on a fastening element 125 . The holding element 123 and the fastening element 125 are connected to one another by an elastic element 30 . The elastic element 30 forms the pivoting bearing 122 and can be made, for example, from rubber, polyurethane or another plastic.
[0028] FIG. 5 shows a further elastic pivoting bearing 222 , which is formed from four spring elements 31 arranged between a holding element 223 , on which the upper central rod section 20 . 2 is fastened, and a fastening element for the lower central rod section 20 . 1 . Elastic element 30 and the spring elements 31 of the pivoting bearings 122 and 222 allow a limited swivel movement between the central rod sections 20 . 1 and 20 . 2 and thus, also of an expander 10 ( FIG. 1 ) that is fastened to the lower central rod section 20 . 1 .
[0029] As will be evident to persons skilled in the art, the foregoing detailed description and figures are presented as examples of the invention, and that variations are contemplated that do not depart from the fair scope of the teachings and descriptions set forth in this disclosure. The foregoing is not intended to limit what has been invented, except to the extent that the following claims so limit that.
|
A circular knitting machine has a circular knitting unit fitted with needles and an expander arranged under the circular knitting unit for tubular knit formed by the circular knitting unit. The expander is rotatably mounted on a central rod arranged coaxially to a knitting machine axis. A pivoting bearing is arranged on the central rod to allow limited swivel movements of the expander relative to the central rod.
| 3
|
PRIORITY INFORMATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/384,601 on May 30, 2002.
FIELD OF THE INVENTION
[0002] The field of this invention is a seal for use in temperatures of over 300 degrees Fahrenheit and over 10,000 pounds per square inch (PSI) and more particularly a seal adapted for wireline use where insertion forces are limited.
BACKGROUND OF THE INVENTION
[0003] Currently, in downhole applications, there are different types of seals to handle high temperature and pressure applications. The present limits of service of these designs are roughly about 350 degrees Fahrenheit and about 13,500 PSI. Under more severe temperature or/and pressure conditions, the presently known designs have been tested and have failed to perform reliably.
[0004] Depending on the application, there are different types of seals for high temperatures or/and pressures. In the case of packers set in high temperature applications, U.S. Pat. No. 4,441,721 asbestos fibers impregnated with Inconel wire are used in conjunction with a stack of Belleville washers to hold the set under temperature extremes. Apart from packers or bridge plugs which require seal activation after placement in the proper position, there are other applications involving seals on tools that have to engage a seal bore receptacle downhole and still need to withstand these extremes of temperature and pressure. In many cases, the tool with the seal to land in a seal bore is delivered on wireline. This means that insertion forces are limited because minimal force can be transmitted from the surface through wireline. In these applications, the limited insertion force is a design parameter that has to be counterbalanced with the frictional resistance to insertion created by the interference of the seal in the seal bore. This interference is built into the design of the seal to allow sufficient contact with the seal bore after insertion for proper seal operation. Clearly if the interference is too great the insertion, particularly with a wireline, will become problematic. On the other hand, reducing the interference can result in seal failure under the proposed extreme conditions of pressure and temperature.
[0005] There are other design considerations for seals that engage a seal bore downhole. Clearly, on the trip downhole, the seal is exposed to mechanical contact with well tubulars or other equipment. The materials for the seal must be rugged enough to withstand such mechanical impacts as well as to withstand the temperatures and pressures anticipated in the downhole location.
[0006] These seals also need to control extreme pressure differentials in an uphole and a downhole direction. Such seals may be inserted and removed from several seal bores during their service life. The design has to be flexible enough to allow long service periods under such extreme conditions as well as the resiliency to allow removal and reinsertion without damage to the seal or the surrounding seal bore.
[0007] [0007]FIG. 1 illustrates the current commercially available seal that is promoted for severe duty applications. It illustrates a mirror image arrangement around a central adapter 16 . A pair of chevron packing rings 14 are disposed about the adapter 16 and outside of the rings 14 is a back-up v-ring 12 and outside of v-ring 12 is an end ring 10 to complete one half of the mirror image arrangement shown in FIG. 1. The open portions of the v-shaped rings open toward the central adapter in an effort to position the rings to withstand pressure differentials from opposite directions. The rings are made of materials suitable for the anticipated temperatures. Tests at pressure extremes of over 13,500 PSI and temperatures above 350 degrees Fahrenheit revealed that this design was unsuitable for reliable service.
[0008] In an effort to improve on the performance of the seal shown in FIG. 1, the design of FIG. 2 was tried. It featured a central o-ring 18 surrounded by a pair of center adapters 20 . On either side of the center adapters 20 the arrangement was similar to FIG. 1 except that the orientation of the v-shaped opening were now all away from the central o-ring 18 rather than towards each other as had been the case in the design of FIG. 1. Additionally, there was an alternating pattern of material in the rings 22 and 24 of FIG. 2 as compared to the stacking of rings 14 of a like material as shown in FIG. 1. This design of FIG. 2 showed improved performance in high temperature and pressure conditions but was not to be the final solution. The present invention, an illustrative example of which is discussed in the preferred embodiment below, addresses the temperature and pressure extremes while allowing for insertion using a wireline. It features an internal spring mechanism and a feature that prevents collapse of the spring and the sealing elements under extreme conditions. The opposing members in the assembly are also prevented from engaging each other under extreme conditions. The collapse-preventing feature also has a beneficial aspect of seal centralization as the seal is inserted into the seal bore. Those skilled in the art from a review of the description of the preferred embodiment below and the claims that appear thereafter will readily understand these and other beneficial features of the present invention.
SUMMARY OF THE INVENTION
[0009] A seal for use in temperature and pressure extremes is disclosed. It features springs internal to the sealing members and the ability to seal against pressure differentials from opposed directions. A spacer ring prevents contact from oppositely oriented seal components and at the same time prevents spring and seal collapse under extreme loading conditions. The seal assembly is self-centering in a downhole seal bore and can be used on tools delivered on wireline, where the insertion forces available are at a minimum. The seal can withstand pressure differentials in excess of 13,500 PSI and temperatures above 350 degrees Fahrenheit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a section view of a prior art seal for extreme temperature and pressure conditions;
[0011] [0011]FIG. 2 is an early version of the present invention developed by the inventors;
[0012] [0012]FIG. 3 is a section view of the seal of the present invention in a position before extreme temperature and pressure conditions are applied;
[0013] [0013]FIG. 4 is the view of FIG. 3 shown under fully loaded conditions; and
[0014] [0014]FIG. 5 is a view showing how the seal of the present invention would collapse if the central ring were to be omitted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 3, the seal S of the present invention is shown without the tool that it would be secured to. The seal bore into which the seal S is to be inserted is also omitted on the basis that those skilled in the art are readily familiar with downhole tools and seal bores into which seals such as seal S are inserted. For similar reasons, the surface wireline equipment and the wireline are omitted due to their familiarity to the person skilled in this art. It should be noted that seal S can be used on a subsurface safety valve that can be delivered on wireline. This is only the preferred use and those skilled in the art will recognize that the seal S can be used with a broad variety of tools and delivered downhole in a variety of ways other than a wireline. Seal S is preferably used in applications of sealing in a seal bore downhole under conditions of high pressure and temperature differentials. Seal S can withstand differentials in pressure in either direction in excess of 13,500 PSI and temperatures well in excess of 350 degrees Fahrenheit.
[0016] The components will be described from the downhole end 26 to the uphole end 28 . A female adapter 30 has an uphole oriented notch 32 , which is preferably v-shaped. Located in notch 32 is a chevron shaped ring 34 with a notch 36 oriented in an uphole direction. Mounted in notch 36 is chevron shaped ring 38 with a notch 40 oriented in an uphole direction. Lower seal 42 sits in notch 40 and has an uphole oriented opening 44 in which is disposed one or more generally u-shaped spring rings such as 46 and 48 that are shown stacked on each other with their respective openings oriented uphole. Spring rings 46 and 48 are preferably mounted within opening 44 and in an abutting relation. Inserted into opening 44 and opening 52 of upper seal 54 is ring 50 . Ring 50 has a radial component 56 extending toward the downhole tool (not shown). Located preferably within opening 52 are stacked and abutting spring rings 58 and 60 , which are preferably identical to spring rings 46 and 48 except that they are disposed in a mirror image relation to them. In fact, the upper portion of the seal S above the ring 50 is the mirror image of the previously described components that are located below ring 50 . In the preferred embodiment going uphole or downhole from ring 50 the hardness of the rings going from seal 42 to ring 38 to ring 34 is progressively harder. The same goes for their mirror image counterparts, seal 54 , ring 62 , ring 64 , and female adapter 66 . The preferred material for the female adapters 30 and 66 is Inconel 718 . For ring 64 and its counterpart ring 34 the preferred material is virgin polyetheretherketone. For ring 62 and its counterpart ring 38 the preferred material is a PTFE (Teflon) with 20% polyphenylenesulfide and some carbon. The preferred material for the seals 42 and 54 is a PTFE (Teflon) flourocarbon base with 15% graphite.
[0017] Seals 42 and 54 could have one ore more interior 68 or exterior 70 notches to promote sealing contact with the tool (not shown) and the seal bore (not shown) respectively. These notches promote some flexibility in response to pressure or thermal loads.
[0018] The operation of the seal S under a pressure differential from uphole is illustrated in FIG. 4. Arrow 72 represents such pressure from uphole going around seal 52 because its opening 52 is oriented downhole. The wings 74 and 76 flex toward each other responsive to the pressure differential. The seal 52 is moved with respect to ring 50 . This movement allows the spring rings 58 and 60 to become more nested and to apply a greater spread force against wings 74 and 76 . However, ring 50 also prevents collapse of spring rings 58 and 60 because the described movement has resulted in positioning ring 50 in the openings defines by generally u-shaped spring rings 58 and 60 . For that same reason, wings 74 and 76 are prevented from collapse toward each other. Meanwhile, the pressure represented by arrow 72 enters opening 44 with the result that ring 50 is pushed into spring rings 46 and 48 to not only splay apart the wings 78 and 80 but also to keep such wings from collapsing and permanently deforming due to movement of ring 50 into the openings defined by nested spring rings 46 and 48 . Ring 50 pushes the spring rings 46 and 48 into a more nested relation but at the same time, its presence in their openings prevents collapse of not only spring rings 46 and 48 but also of wings 78 and 80 to their immediate exterior. Another benefit of ring 50 is that it is of the appropriate length to prevent wings 74 and 76 from contacting wings 78 and 80 under maximum loading conditions. Contact at such high temperatures and pressures could fuse the wings together with a seal failure being a possibility. This is illustrated in FIG. 5 where the ring 50 has been eliminated and wings 74 and 76 have contacted wings 78 and 80 . The spring rings in FIG. 5 have all buckled and are permanently deformed. This seal is likely to be in failure mode.
[0019] Another advantage of having the ring 50 is that upon insertion of the downhole end of seal S into a seal bore, ring 50 adds some rigidity to that portion of seal S already inserted into the seal bore to act as a centralizer for the remaining portions of seal S to facilitate its insertion without damage. Radial component 56 also helps in the centralizing function for insertion of seal S into a seal bore (not shown).
[0020] Those skilled in the art will appreciate that while FIG. 4 illustrates a pressure differential from uphole that the response of seal S to a differential pressure from downhole is essentially the mirror image of what was described as the situation in FIG. 4. The design of seal S is unique in high temperature and pressure service and one such feature is the internal spring component. While spring rings having a generally u-shaped cross-section have been illustrated other cross-sectional shapes for the spring rings are contemplated as long as the response is to splay out the wings while exhibiting resiliency to return to a neutral position when the extreme pressure or temperature conditions are removed. The use of a separation ring to keep the wings apart and to prevent their collapse and the collapse of the spring rings inside them allows the seal S to withstand cycles of temperature and pressure extremes and continue to be serviceable. The placement of the components in a nesting relation in conjunction with ring 50 and radial component 56 helps to centralize seal S with respect to the downhole tool to which it is mounted as well as to facilitate its insertion into a seal bore. This is because the downhole end 26 , upon entering the seal bore centralizes the seal S so that the rest of it is simply advanced into the seal bore without damage.
[0021] While the seal S is ideal for high pressure and temperature applications, it can also be serviceable in less severe environments and can be delivered into a seal bore by a variety of conveyances such as coiled tubing, rigid pipe as well as wireline, among others. Its construction makes it easily insertable in a wireline application, when minimal force is available get the seal S into the seal bore.
[0022] The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention.
|
A seal for use in temperature and pressure extremes is disclosed. It features springs internal to the sealing members and the ability to seal against pressure differentials from opposed directions. A spacer ring prevents contact from oppositely oriented seal components and at the same time prevents spring and seal collapse under extreme loading conditions. The seal assembly is self-centering in a downhole seal bore and can be used on tools delivered on wireline, where the insertion forces available are at a minimum. The seal can withstand pressure differentials in excess of 13,500 PSI and temperatures above 350 degrees Fahrenheit.
| 4
|
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to an Fe-Cr-Ni alloy useful for a part of an automatic loom as well as a wear-resistant part of an automatic loom. More particularly, the present invention relates to an Fe-Cr-Ni alloy with improved wear-resistance against yarn.
2. Description of Related Arts
Parts of an automatic loom, which are brought into contact with yarn, include a reed and a heald as described below.
Referring to FIG. 1, a plurality of neck yarn 2 is moved upward or downward according to the information in a Jacquard paper, by means of a Jacquard driving mechanism 1. A plurality of harness cords 3 are connected to the lower ends of the neck cord and pass through a plurality of apertures 5 of a comber board 6. The lower ends of the harness cords 3, which pass through the comber board 6, are secured to a heald 7. The weft (not shown) pass through the apertures 7a of the heald 7. The heald 7 lifts up successively and vertically displaces the weft. As a result, a reed hole is formed between a number of wefts and allows a shuttle, in which warps are mounted, to pass therethrough. Restoring springs 8 are connected to the bottom of the heald 7 at one end thereof and a the fixing bed 9 at the other end.
Referring to FIG. 2, a reed apparatus 10 is located in front of the heald 7 and comprises a reed chamber 11 in the form of a trapezoidal frame and reed wires 12. Warp 16 passes through between the reed blades 12 and then through the apertures 7a of the heald.
Conventionally, the reed 12 and heald 7 are made of a hardsteel sheet or hard-steel wire. The reed 12 and heald 7 are replacable parts liable to wear out due to sliding contact with the yarn. When these parts wear out, minute grooves, referred to as yarn passes, are formed on the parts with the result that such anomalies as fluff and rupture of yarn arise. Operation of an automatic loom will thus be interrupted or its parts must be replaced by new parts, resulting in inconvenience in the operation of the automatic loom. In the worst case, defects are formed on the product.
Furthermore, along with an increase of speed of newer automatic looms, their parts are brought into contact with much longer length of yarn as compared with conventional looms.
Accordingly, fluff and yarn ruptures occur in very short periods of operation that would not occur in a conventional automatic loom. Level of wear-resistance required for parts of an automatic loom have become therefore more stringent than that of conventional parts. In addition, since new textile materials have been developed, the parts of an automatic loom must exhibit wear-resistance against such materials also.
SUMMARY OF INVENTION
Mere increase in hardness of parts of an automatic loom cannot successfully prevent the fluff and yarn rupture due to the formation of yarn passage on such parts.
It is an object of the present invention to provide an Fe-Cr-Ni alloy which has a microstructure capable of improving wear-resistance against yarn.
It is also an object of the present invention to provide a sliding part having highly enhanced wear resistance with respect to yarn.
In accordance with the objects of the present invention, there is provided an Fe-Cr-Ni alloy for use as a part of an automatic loom, which part will be in sliding contact with yarn, characterized in that the Fe-Cr-Ni alloy consists of, by weight percentage, from 13 to 20% of Cr, from 4 to 15% of Ni the balance being Fe and unavoidable impurities, and has a microstructure such that 60% or more, preferably 70% or more based on the matrix is a strain-induced martensite.
In accordance with the objects of the present invention, there is provided a part of an automatic loom, which part will be in sliding contact with yarn and consisting of the Fe-Cr-Ni alloy mentioned above.
BRIEF DISCRIPTION OF THE DRAWINGS
FIG. 1 illustrates as prior art a Jacquard-type opening machine which is shown in Japanese Unexamined Patent Publication No. 4-136,228 and which is operated to form, between the warps, a space for drawing-in the reed.
FIG. 2 illustrates a reed apparatus for beating, used in the apparatus shown in FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
The Fe-Cr-Ni alloy according to the present invention exhibits an exceedingly high wear-resistance against yarn sliding thereon at a high speed, so that the fluff and rupture of yarn can successfully be minimized. Corrosion resistance of the Fe-Cr-Ni alloy is excellent. The inventive alloy has excellent formability to be shaped into parts of an automatic loom.
The alloying components of the Fe-Cr-Ni alloy according to the present invention are first described.
Cr: The parts of an automatic loom are required to have corrosion resistance because the automatic loom is used under various circumstances. For example, parts may come in contact with water which is used in some types of automatic looms. The corrosion resistance of Fe-Cr-Ni can be attained by adjusting the Cr content within an appropriate range. When the Cr content is less than 13%, the corrosion resistance is poor. On the contrary, when the Cr content is more than 20%, the formability of the Fe-Cr-Ni alloy is impaired. The Cr content is therefore from 13 to 20%. A preferred Cr content is from 15 to 19%.
Ni: Ni contributes to improving the corrosion resistance as does Cr. When the Ni content is less than 4%, the corrosion resistance is impaired. In addition, when the Ni content is less than 4%, since Ni is an austenite-former, the austenite phase is formed with difficulty. It then becomes then difficult to induce the required amount of martensite phase by means of working. On the other hand, when the Ni content is more than 15%, since Ni is an austenite-stabilizing element, the required amount of strain-induced martensite becomes difficult to obtain. In addition, the materials costs are increased when the Ni content exceeds 15%. The Ni content is therefore from 4 to 15%. A preferred Ni content is from 5 to 13%. The elements other than those mentioned above, such as C, P and S are detrimental to the corrosion resistance. Such elements other than the above mentioned ones such as Mn, Al and Si are incidental elements which are not particularly effective for attaining the objects of the present invention. These elements are inevitably included in the Fe-Cr-Ni alloy as impurities, when the alloy is produced by melting the ordinary raw-materials. The content of the impurities is preferably not more than 3.5% in total amount.
It was discovered by the present inventors that the wear resistance of an Fe-Cr-Ni alloy with respect to yarn is greatly dependent upon the amount of the strain induced martensite, even though the composition and hardness of the Fe-Cr-Ni alloy remains constant. For example, when an Fe-Ni-Cr alloy (A) having a strain induced martensite of 50 %, an austenite of 50%, and hardness Hv of 500 is compared with an Fe-Cr-Ni alloy (B) having the same composition as alloy (A) and having a strain induced martensite of 60%, an austenite of 40%, and hardness of Hv=500, the wear resistance of (B) is better than that of (A).
Since the desired wear resistance is not attained by a strain induced content of less than 60%, its weight percentage is specified to be 60% or more. A preferred amount of the strain induced martensite is 70% or more. The strain induced martensite herein indicates that a complete austenitic structure is once formed and is then subjected to working to induce the martensitic transformation in order to convert the gamma phase to an alpha phase. The complete austenitic structure means that the essential elements of the present invention, i.e., Fe, Cr and Ni, form an austenitic matrix, and, further, the impurities are present in the form of minority phases such as carbides and sulfides. The minority phases should be present in such a trace amount that the presence exerts an influence upon the measured valued of the strain induced martensite only within a range of measurement error. The amount of strain induced martensite is obtained by applying external density with an intensity of 199000 A/m (i.e., 2.5 kOe) to an Fe-Cr-Ni alloy, measuring the magnetic flux density B (T), multiplying the magnetic flux density with 100 (i.e., the result) and dividing 100B by 1.6 T.
The Fe-Cr-Ni alloy and a part of an automatic loom according to the present invention can be produced by the following process.
The alloying components satisfying the above mentioned range are melted, cast and subsequently subjected to hot-forging or rolling. The wrought product is, if necessary, subjected to solution heat-treatment. Cold-rolling and subsequent annealing are carried out at least once. Finally, the cold-rolling, which induces martensitic transformation, is carried out, while reducing the thickness from to 0.1 down to 0.3 mm. The obtained rolled sheets are blanking worked by means of, for example, a press machine, to provide the shape for parts of an automatic loom. In the case of producing a wire, a process similar to that used in producing a sheet is carried out.
The present invention is hereinafter described by way of an example.
EXAMPLE
The alloys having a composition as shown in Table 1 were melted and cast into ingots. The ingots were then hot-rolled to form 3 mm thick sheets and then solution heat-treated at 1050° C. for 30 minutes. The resultant structure was completely austenitic. The 3 mm thick hot-rolled sheets were cold-rolled at a reduction of from 50 to 90% and then annealed at 1050° C. This cold-rolling and subsequent annealing were in some cases repeated twice. The resultant 0.3 mm thick sheets had hardness of Hv 540 and various amounts of strain induced martensite.
In order to investigate the wear resistance of the obtained materials, samples having a width of 10 mm were taken. Twenty four filaments with 75 denier were suspended from the sample and a tension of 30 gram was applied to the filaments. The filaments were caused to slide on the sample at a speed of 40 cm/minute. The worn of portions of the samples brought into contact with the filaments were observed. The results are shown in Table 1, below.
TABLE 1______________________________________ Chemical Strain Composition Induced State (wt %) Marten- Hardness of Cr Ni Fe site (%) (Hv) Wear______________________________________In- 1 15.8 5.2 Bal 91 554 Extremelyven- Slighttive 2 16.3 6.5 Bal. 85 663 ExtremelyAlloys Slight 3 17.5 7.2 Bal. 73 570 Slight 4 18.2 5.8 Bal. 76 542 Slight 5 18.8 6.1 Bal. 62 557 Slight 6 16.4 6.8 Bal. 77 558 Slight 7 17.3 5.7 Bal. 84 561 SlightCompar- 8 16.0 6.2 Bal. 63 557 Mediumative 9 17.6 5.9 Bal. 48 542 GreatAlloys 10 16.4 6.0 Bal. 55 568 Medium 11 18.4 7.6 Bal. 41 540 Great 12 17.8 6.5 Bal. 50 546 Great______________________________________
Criterion for judging the wear was as follows.
Great: clear yarn marks and fluff were recognized.
Medium: clear yarn marks were recognized.
Slight: some yarn marks were recognized.
Extremely slight: very slight yarn passage was recognized.
As is clear from Table 1, although the hardness of the inventive examples is approximately the same as that of the comparative samples, the wear of the former from yarn is less than that of the latter. The wear resistance is therefore improved by the present invention.
|
An Fe-Cr-Ni alloy used for parts of an automatic loom such as a heald (7) and reed (12) consisting of from 13 to 20% of Cr, from 4 to 15% of Ni, the balance being Fe and unavoidable impurities, and having a microstructure that is 60% or more strain-induced martensite. Wear resistance of the parts is improved, so that neither fluff nor rupture of yarn occurs during loom operation.
| 3
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a National Stage filing of International Application PCT/EP 2009/001780, filed Mar. 12, 2009, entitled “NOVEL THERAPEUTIC AGENTS AGAINST HEPATITIS” claiming priority to German Applications Nos. DE 10 2008 024 010.9 filed May 16, 2008, and DE 10 2008 029 669.4 filed Jun. 24, 2008. The subject application claims priority to PCT/EP 2009/001780, and to German Application Nos. DE 10 2008 024 010.9, and DE 10 2008 029 669.4 and incorporates all by reference herein, in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the use of substances, in particular in the form of inhibitors or repressors, which are capable of regulating the gene activity of a gene associated with the multiplication or replication of hepatitis viruses, in particular hepatitis C viruses, in the field of the diagnosis and therapy of hepatitis, in particular hepatitis type C. The gene associated with the multiplication or replication of hepatitis C viruses is preferably the human interferon-stimulated gene ISG15.
[0003] The present invention furthermore relates to the use of a substance which neutralizes or inhibits or at least reduces the gene activity of a gene associated with the multiplication or replication of hepatitis viruses, in particular hepatitis C viruses, in particular of an inhibitor or repressor, for preparing a medicament or pharmaceutical for the prophylactic and/or curative treatment of hepatitis, in particular hepatitis type C.
[0004] In addition, the present invention relates to the use of an interferon-stimulated gene, in particular ISG15, for identifying and/or providing a pharmaceutical for the prophylactic and/or curative treatment of hepatitis, in particular hepatitis type C, and/or for predicting individual effects of pharmaceuticals and/or for predicting side effects of or the response to pharmaceuticals.
[0005] In addition, the present invention relates to a process for identifying substances, in particular inhibitors and/or repressors, which regulate the gene activity of an interferon-stimulated gene, in particular associated with the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses, and to a process for identifying substances which regulate the activity of the corresponding gene products or of products associated with the gene. Furthermore, the present invention relates to a process for improving the pharmacological properties of these substances.
[0006] Finally, the present invention relates to a pharmaceutical composition comprising at least one pharmacologically active substance, in particular inhibitor or repressor, identified based, on the processes according to the invention, where the substance modulates, in particular inhibits, the gene activity of a gene associated with the multiplication or replication of hepatitis C viruses; moreover, the present invention relates to a pharmaceutical composition, preferably for the prophylactic or therapeutic treatment of hepatitis C disorders, which comprises effective, in particular pharmaceutically effective, amounts of at least one siRNA.
BRIEF SUMMARY OF THE INVENTION
[0007] Chronic infection with the hepatitis C virus (HCV) is, with about 170 million infected people world-wide, a global health problem. At a chronification rate of about 80%, hepatitis type C is one of the main causes of hepatitis, cirrhosis of the liver and liver cell carcinomas.
[0008] The hepatitis C virus belongs to the family of the Flaviviridae and is the only representative of the genus of the hepaci viruses. The hepatitis C virus was initially classified among the so-called NonA-NonB hepatitis viruses until, in 1989, the viral genome was sequenced. To date, six genotypes have been characterized which, for their part, are divided into subtypes. In most cases, infection, with the virus is via transfusion of infected banked blood, in particular in the seventies, or via injuries with syringes, for example among hospital personnel. Further possible ways of transmission are unprotected sexual intercourse and the use of shared syringes among drug addicts. In most cases, acute infection is asymptomatic. In 70 to 80% of the cases, this is followed by a chronic infection of the liver which may progress to cirrhosis of the liver and hepatocellular carcinoma.
[0009] The prior art uses, as currently the most efficient therapy for chronic hepatitis type C, interferon (IFN), in particular α-interferon (synonymously also referred to as interferon-alpha or IFN-α), preferably pegylated IFN-α, if appropriate in combination with the virus static ribavirin. Depending on the genotype and other factors, this therapy results in a cure in only 50 to 90% of the patients. One of the most frequent side effects of this therapy is IFN-induced severe depression which, in addition to a worsening of the quality of life, may lead to a termination of the therapy or even to suicide. As yet, it has not been possible to develop a vaccine against the hepatitis C virus.
[0010] Interferons (IFN) are low-molecular-weight proteins and are classed with the cytokines. A distinction is made between interferons of type I and interferons of type II. The interferons of type I are present in monomeric form and can be divided into superfamilies, their main difference being their origin. From among the interferons of type I, IFN-α and IFN-β are most prevalent. The group of the α-interferons in turn can be divided into a number of subtypes expressed by different genes. They are mainly formed in leucocytes and fibroblasts, whereas IFN-β is produced mainly by endothelial cells and fibroblasts. IFN-λ and IFN-ω also belong to the interferons of type I.
[0011] Expression of the interferons of type I is induced by the recognition of viral, but also bacterial, pathogenic patterns. They are secreted by infected cells and act both parakrine onto neighboring cells and autokrine onto the IFN-producing cell itself. Receptor binding triggers a signal cascade terminating in the induction of interferon-stimulated genes (ISGs).
[0012] The activity of more than 150 ISGs is additionally increased by a modification, and their performance is enhanced. ISG15, an IFN-induced 15 kD protein, has a ubiquitin-like domain and is attached covalently to the target proteins via a set of enzymes (E1=Ube1L, E2=UbcH8 and E3=Herc5), as in ubiquitinylation. In the literature, this process is also referred to as ISGylation, The enzymes E1, E2 and E3 are likewise upregulated by type T interferons, leading to an increased ISGylation and enhancing the interferon response. However, at the same time, there is also an induction of Usp18, the protease which reverses ISGylation, which, in addition to shorter half-lives and with further negative regulation mechanisms, limits the time that IFN is active.
[0013] Further with respect to the interferons, these are, by virtue of their properties and the ability to induce a large number of cellular defense mechanisms and to support the endogenous immune response, used for the therapy of tumors, autoimmune disorders and virus infections (for example HBV and HCV).
[0014] As described above, in the therapy of hepatitis type C disorders or infections, the use of in particular pegylated IFN-α2a or IFN-α2b in combination with the nucleoside analog ribavirin (RBV) has become established. The response to the therapy depends on the HCV genotype, the virus load, the age of the patient, existing liver damage and coinfections. In infections with genotypes 2 and 3, up to 80% of the patients show a sustained decline of the virus after 24 weeks, whereas in infections with genotype 1 only about 50% of the patients respond to the therapy and have a sustained decline of the virus load after 48 weeks, at a body weight-dependent RBV dosage.
[0015] The response to the therapy can be divided into two phases. An early viral response (EVR) depending on the genotype and the medicament dose used in the first phase is followed by a slower but sustained viral response (SVR) in the second phase. Studies have shown that, if, within the first 12 weeks after initiation of the therapy, there is no EVR with a decline of the viral load by at least 2log 10 phases, a sustained response is not to be expected, and the therapy can be terminated. Different expression patterns of the ISGs both in PBMCs (peripheral blood mononuclear cells) and in liver biopsies of patients also allow prognoses to be made about a response to the therapy.
[0016] The abovementioned therapy of the prior art thus has the disadvantages of in some cases severe side effects, in particular with regard to the onset of depression, and the fact that an effective therapeutic success—as described above—is not always ensured.
[0017] Against this background, it is an object of the present invention to provide novel and efficient therapeutic and treatment options for hepatitis disorders, in particular hepatitis C disorders, which, compared to the approaches known from the prior art, are more effective and, at the same time, have reduced side effects.
[0018] In this context, it is the further object of the present invention to provide a process for identifying substances or substances as such which allow a reduction or neutralization of the gene expression or gene activity of genes associated with the multiplication or replication of hepatitis C viruses, in particular ISG15, in order to at least reduce virus multiplication or replication in this way.
[0019] Besides, it is a further object of the present invention to provide a process which allows the identification of specific genes which play a decisive part in the multiplication or replication of hepatitis C viruses, these preferably being human and/or interferon-stimulated genes.
[0020] Finally, one of the objects on which the invention is based is to provide processes, uses and substances of the type mentioned above which avoid the disadvantages of the prior art or else are capable of at least reducing or lessening them.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A shows the inhibition of the HCV replication and the lack of induction of resistant, mutants on. treatment with ISG15-specific siRNA (siISG15) compared to a treatment with siNC, where the HCV copy number has been normalized against the untreated control (MH1) and compared.
[0022] FIG. 1B shows the inhibition of the HCV replication and the lack of induction of resistant mutants on treatment with ISG15-specific siRNA (siISG15) compared to a treatment with siNC, where the HCV/ISG15 copy number has been normalized against the siNC control and compared.
[0023] FIG. 2A shows, by way of a Westernblot, the results of a treatment, carried out on human conl HCV replicon cells, with siRNA directed against ISG15, firstly without additional administration of IFN-α (−IFN-α) and secondly with additional administration of IFN-α (+IFN-α).
[0024] FIG. 2B shows, by way of a Westernblot, the results of a treatment, carried out on murine MH1 HCV replicon cells, with siRNA directed against ISG15, firstly without additional administration of IFN-α (−IFN-α) and secondly with additional administration of IFN-α (+IFN-α).
[0025] FIG. 3 shows a comparison of the replication of hepatitis C viruses in MH1 cells for various passages, where the HCV copy number is based on 100,000 β-aktin molecules (MH1=untreated control, NC=non-silencing control, ISG15=ISG15-specific siRNA). For all passages, when ISG15-specific siRNA is used, a marked decline of the HCV copy number and thus a reduction of virus synthesis and replication can be observed compared to MH1 and NC.
DETAILED DESCRIPTION OF THE INVENTION
[0026] In the context of the present invention, the applicant was, in a completely surprising manner, able to identify, for the first time, a specific gene which is decisive in connection with the multiplication or replication of hepatitis C viruses in a host system, in particular in man. In this context, the applicant has found, in a completely surprising manner, that the interferon-stimulated gene ISG15 is decisive in the abovementioned multiplication or replication of hepatitis C viruses, and that induction or activation of this gene may result in an unwanted increase of the replication of the virus. The gene ISG15 identified with a view to its relevance regarding the multiplication or replication of hepatitis C viruses can thus be used according to the invention as a basis for processes and medicaments for the therapy of a hepatitis C disorder or infection where, in this respect, it is, in accordance with the invention, the aim to inactivate the gene in question.
[0027] Accordingly, the applicant has found, in a completely surprising manner, that the targeted use of an inhibitor or repressor with which the (gene) activity of the gene associated with the multiplication or replication of hepatitis C viruses, in particular ISG15, and thus a modulation of its gene activity leads to a significant reduction of the hepatitis C viral load, which can be attributed substantially to a markedly reduced multiplication or replication of the hepatitis C viruses. In this context, the applicant was—completely surprisingly—able to show in particular that the targeted use of a so-called siRNA specifically adapted to ISG15 or directed against ISG15 results, on its application, in a marked reduction of the gene activity of ISG15 and as a consequence in a significantly reduced synthesis or multiplication or replication of hepatitis C viruses in the host, system. In this manner, the applicant, was able to provide a completely novel therapeutic approach, which in addition has few side effects, and on the basis of which it is possible to treat a hepatitis C disorder effectively.
[0028] It goes without saying that developments, embodiments, advantages and the like which hereinbelow are specified for only one aspect of the invention, to avoid repetition, do, of course, also apply correspondingly to the other aspects of the invention.
[0029] Thus—according to a first aspect of the present invention—the present invention provides the use of an inhibitor and/or repressor of a nucleic acid molecule, in particular gene, associated with the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses, and/or its DNA sequence and/or its assigned RNA sequence and/or its assigned (poly)peptide for preparing a pharmaceutical for the prophylactic and/or therapeutic treatment of hepatitis, in particular hepatitis type C.
[0030] As indicated above, the central idea of the present invention is thus the specific reduction and/or neutralization, in particular inhibition, of the gene activity of such a gene which is associated with the multiplication or replication or synthesis of hepatitis C viruses in particular in the respect that expression and/or activation of the gene which may be induced, for example, owing to the virus infection, leads to an increased replication or multiplication of hepatitis C viruses in the host.
[0031] In this context, the term “inhibitor” and/or “repressor” used in accordance with the invention relates in particular to a substance which reduces and/or neutralizes, in particular inhibits, the gene activity. In other words, the inhibitor or the repressor is a compound which neutralizes or at least reduces the gene activity, where the respective pharmacological activity of the inhibitor or repressor may be both on the level of the gene, i.e. for example by direct, interaction with the gene or with promoters and/or enhancers assigned thereto, and on the level of the gene product(s), such as transcription products (for example mRNA) and/or translation products (for example proteins). In addition, the pharmacological activity or the gene activity—reducing and/or—neutralizing, in particular—inhibiting activity of the inhibitor or repressor may act on the level of gene-regulated mediators or factors and/or on the level of gene-regulating mediators or factors. Thus, the inhibitor or repressor used according to the invention may result in a reduction of the expression or gene activity, for example and in a non-limiting manner by direct or indirect interaction with the DNA sequence or the DNA and/or its assigned RNA sequence or mRNA and/or by direct or indirect modulation or interaction with the gene product in the form of the (poly)peptide encoded by the gene or by the DNA sequence. The inhibitor or repressor is in particular a substance having antiviral properties against, hepatitis viruses, in particular hepatitis C viruses.
[0032] In other words, the present invention aims essentially for a targeted, suppression of the gene expression or the gene activity of genes associated with the multiplication or replication or synthesis of hepatitis C viruses, in particular ISG15, which may, in a general manner, also be referred to as gene-knockdown or as gene-silencing.
[0033] With regard to the term “gene” used in accordance with the invention, in this respect the corresponding nucleic acid molecule or the corresponding DNA sequence is also included. However, the present invention likewise relates, as mentioned above, to the RNA sequence assigned to the gene, in particular mRNA, which, so to speak, acts as post-transcriptional product and, so to speak, may be complementary to the cociogenic strand of the DNA of the gene. Likewise, in the context of the present invention, it is also possible to use the (poly)peptide encoded by the nucleic acid or the gene, in particular as defined above,—and thus, as it were, the translation product—or be used as target molecule or target. The term “nucleic acid molecule” is synonymous with the term “polynucleic acid” or “polynucleic acid molecules” and may refer both to DNA and to RNA. In this context, the term “DNA sequence” or “RNA sequence” refers not only to the complete DNA assigned to or corresponding to the gene, but also to corresponding sections of the gene, or not only to complete RNA synthesized in particular in the context of transcription, but also to RNA sections or RNA fragments.
[0034] With regard to the gene taken into consideration in the context of the use according to the invention, this is preferably a human gene.
[0035] The gene taken into consideration in the context of the use according to the invention may in particular be an interferon-stimulated gene (ISG). In this respect, the gene may be a gene stimulated by interferons of type 1, preferably α-interferon and/or β-interferon. As described above, this is in particular a gene which can be induced or activated as a result of an increased interferon concentration, such that its expression is increased in particular under the control of interferon—caused, for example, by an infection with hepatitis C viruses.
[0036] In this respect, the applicant has found, in a completely surprising manner, that, the gene ISG15 forms a gene responsible with regard to the multiplication or replication of hepatitis C viruses or associated therewith. This is likewise an interferon-stimulated gene. The gene in question is in particular ISG15, in particular having the transcript ID (Locus) NM — 005101 or in particular in accordance with sequence protocol I and/or in particular in accordance with SEQUENCE LISTING. In this respect, the applicant has found, in a completely surprising manner, that ISG15, which is also referred to as Homo sapiens ISG15 Ubiquitin-like Modifier, is a particularly effective target with regard to the use according to the invention in the context of the therapy of hepatitis type C, the inactivation or suppression of which leads to a significant reduction of hepatitis C viruses in the host system.
[0037] The sequence protocol I mentioned above and the SEQUENCE LISTING listed above refer to the DNA sequence of the gene ISG15. Here, sequence protocol I is synonymous with or has the same meaning as the corresponding SEQUENCE LISTING. The essential difference between the sequence protocols is that sequence protocol I is based on a scientifically standardized notation or representation, whereas the SEQUENCE LISTING is based, on a notation or representation standardized according to patent law and generated using the software PatentIN Version 3.3. Thus, with respect to the DNA or with respect to the gene, the difference is purely formal in the presentation, but not in the content.
[0038] With regard to the inhibitor or repressor used in the context of the use according to the invention it should in this regard be a substance which reduces or neutralizes, in particular inhibits, the activity of the gene, in particular for ISG15.
[0039] In the context of the present invention, it is particularly advantageous for the inhibitor or the repressor to be a substance which interacts with the gene, in particular with ISG15, or with its DNA sequence and/or with its assigned RNA sequence and/or with its assigned (poly)peptide. In this respect, it is particularly advantageous for the substance to reduce and/or neutralize, in particular inhibit, the activity of the gene, in particular for ISG15, and/or its DNA sequence and/or its assigned RNA sequence and/or its assigned (poly)peptide.
[0040] In this context, the term “inhibitor” or “repressor” is to be understood in a very broad sense; it may in particular be a substance which interacts directly and/or indirectly, for example via metabolic cascades or signal transductions, with the appropriate target, in particular with ISG15, reducing or neutralizing, in particular inhibiting, its gene activity in the process. Here, the modulation of the gene, in particular of ISG15, or of the products (for example transcription and/or translation products) assigned to the gene or ISG15, may also be caused in the form of precursor substances which, for example, are converted only in the cell or host system into the actual interacting substance, for example via specific metabolic processes.
[0041] As discussed below, the direct and/or indirect interaction of the substance with the target structure, in particular with the gene, such as ISG15, may be realized on many levels:
[0042] According to a first preferred embodiment according to the invention, the interacting substance or the inhibitor and/or repressor may interact with the promoter and/or enhancer of the gene, in particular of ISG15, such that binding of in particular endogenous transcription factors, in particular activators, to the promoter and/or enhancer is prevented or at least inhibited.
[0043] However, it is likewise also possible for the substance or the inhibitor and/or repressor to interact with an in particular endogenous transcription factor, in particular activator, such that binding of the transcription factor, in particular activator, to the promoter and/or enhancer of the gene, in particular for ISG15, is prevented or at least inhibited.
[0044] However, it is likewise also possible for the substance or the inhibitor and/or repressor to interact with an in particular endogenous transcription factor, in particular activator, such that binding of the transcription factor, in particular activator, to the promoter and/or enhancer of the gene, in particular for ISG15, is prevented or at least inhibited. In this context, the inhibitor and/or repressor may interact with in particular endogenous mediators and/or factors regulated by the gene, in particular ISG15-regulated mediators and/or factors, and/or with in particular endogenous mediators and/or factors regulating the gene, in particular ISG-regulating mediators and/or factors, in particular such that the activity of the gene, in particular of ISG15, and/or its DNA sequence and/or its assigned RNA sequence and/or its assigned (poly)peptide is reduced and/or neutralized, in particular inhibited.
[0045] However, it is likewise also possible for the substance or the inhibitor and/or repressor to react with the endogenous transcription activators themselves, thus causing an inactivation of the transcription factor or activator per se, to reduce or neutralize, in particular inhibit, the gene activity, in particular for ISG15, in this manner.
[0046] The substance in the form of an inhibitor and/or repressor used in the context of the use according to the invention may, firstly, be a substance discovered on the basis of the process according to the invention, illustrated below, for identifying such substances.
[0047] According to an embodiment which is particularly preferred in accordance with the invention, the inhibitor and/or repressor may, secondly, be an RNA sequence which interacts preferably with the RNA sequence, in particular mRNA sequence, assigned, to the gene, in particular ISG15. According to this embodiment of the present invention, the inhibitor or repressor should be an RNA or RNA sequence which is in particular complementary to the RNA or mRNA or RNA sequence or mRNA sequence assigned to the gene.
[0048] In this connection, in the context of the present invention, it is particularly advantageous for the inhibitor and/or repressor to be an RNA sequence in the form of an oligomer, in particular having 15 to 20 bp (base pairs), preferably 18 to 25 bp, preferably 21 to 23 bp.
[0049] In the context of the present invention, the RNA sequence interacting with the RNA sequence assigned to the gene, in particular ISG15, is preferably a single-strand RNA, which, in this respect, should, in accordance with a particularly preferred embodiment, be an antisense strand in particular with respect to the RNA, in particular mRNA, assigned to the gene.
[0050] However, it is likewise also possible for the RNA sequence used according to the invention and interacting with the RNA sequence assigned, to the gene, in particular ISG15, to be a double-strand RNA which, in particular in the context of further modifications or metabolic processes, may be converted into or modified to a single-strand RNA, in particular in the form of an antisense strand, as defined above.
[0051] In accordance with a particularly preferred embodiment according to the invention, the inhibitor and/or repressor described above is an siRNA (small interfering RNA), where the siRNA is directed in particular against ISG15, in particular against ISG15-specific mRNA or against mRNA assigned to ISG15. In other words, the nature of the siRNA should be such that an interaction with the mRNA, in particular as defined above, is possible and, as a consequence, leads to the deactivation or to the degradation of the corresponding RNA. For example, the siRNA may be complementary to the mRNA or to sections of the mRNA. In this context, the applicant has found, in a completely surprising manner, that such an siRNA leads to particularly good results with regard to a reduction or neutralization of the gene activity of the gene, in particular ISG15, associated with the multiplication or replication of hepatitis C viruses.
[0052] The siRNA used in the context of the use according to the invention is, in accordance with a very particularly preferred embodiment, an siRNA which is directed against ISG15 and which can be obtained from Qiagen, Hilden, Germany, under the product number or order number SI00072337 (human) or SI01007531 (murine).
[0053] Without wishing to be bound to this theory, the mode of action of the specific ISG15-specific siRNA can be understood such that initially an siRNA/protein complex is formed in the cell or host system, which complex is also referred to as RNA-induced silencing complex (RISC), where a protein complex binds the antisense strand of the siRNA and cuts the complementary mRNA. In this context, the RISC complex has RNA helicase and RNA nuclease activities. In the interaction with the mRNA which, so to speak, represents the transcription product of the gene associated with the multiplication or replication of hepatitis C viruses, in particular ISG15, these properties lead to its unwinding and cleavage. As a consequence, the mRNA is degraded, which leads to a reduction of the translation of this mRNA and thus to gene-silencing or gene-knockout on the post-transcriptional level and thus to gene inactivation.
[0054] According to the invention, it may also be intended for the inhibitor and/or repressor to be an inhibitor or repressor which represents in particular the antisense strand of an siRNA. In the context of the present, invention, it may likewise be intended for the inhibitor or repressor to represent a complex of an antisense strand of the siRNA and at least one protein component, where this complex may in particular be an RISC complex (RISC=RNA-induced silencing complex).
[0055] A central concept of the present invention according to this aspect of the invention using an siRNA consists in the introduction of in particular synthetically prepared siRNA having a specificity for mRNA as transcription product, in particular of ISG15, into the cell or host system, which leads to a degradation of the mRNA of the target gene, i.e. in particular ISG15, which in turn leads to a reduction of the gene products and thus to gene-silencing or gene-knockout. The principle on which, according to this embodiment, the invention is based may also be referred to as RNA interference, on the basis of which the expression of certain (target) genes, in the present case in particular ISG15, is reduced. This is a result of in particular the interaction of siRNA directed specifically against a gene with the mRNA of the gene with the consequence of a degradation of the mRNA, which corresponds to a (gene) inactivation.
[0056] The application or the introduction of the siRNA in question into the cell or host system is known per se to the person skilled in the art so that this requires no further explanations. For example, the introduction or transfection may also take place via polyethyleneimine complexation (PEI complexation).
[0057] On application, the inhibitor or repressor employed according to the use according to the present invention should be administered in pharmaceutically effective amounts. In addition, the inhibitor or the repressor should be administered systemically, for example intravenously. The appropriate measures, too, are known as such to the person skilled in the art, so that this requires no further explanations.
[0058] In the context of the use according to the invention, it may likewise be intended for the inhibitor or repressor, in particular as described above, to be administered together with at least one interferon, in particular α-interferon, preferably pegylated α-interferon. In this context, a combination of the ISG15-specific siRNA described above or the siRNA directed against ISG15 with an interferon is of particular advantage. This is because the applicant observed—as shown below by the working examples—in a completely surprising manner a synergistic effect in the context of the combination, described above, of, firstly, inhibitor and/or repressor and, secondly, interferon with regard to the neutralization or reduction of multiplication or replication of hepatitis C viruses in the affected host systems or cell systems. Likewise, it is possible for the inhibitor and/or repressor to be administered together with and/or in combination with at least one substance having antiviral properties against hepatitis viruses, in particular hepatitis C viruses.
[0059] Altogether, in the context of the use according to the invention according to the present aspect of the invention, a novel way of treating a hepatitis C infection or hepatitis C disorders is provided, which is based on a completely novel approach, namely the targeted inactivation of a gene associated with the multiplication or replication of hepatitis C viruses, in particular ISG15.
[0060] The present invention furthermore provides—according to a second aspect of the present invention—the use of at least one substance, in particular an inhibitor and/or repressor, for preparing a medicament or pharmaceutical for the prophylactic and/or therapeutic treatment of hepatitis, in particular hepatitis type C, where the substance regulates, in particular at least reduces or inhibits, the gene activity and/or gene expression of at least one interferon-stimulated gene, in particular of ISG15.
[0061] For further explanations in respect of the use according to the invention according to the second aspect of the present invention, reference may be made to the explanations given for the previous aspect, which, in this respect, apply correspondingly.
[0062] In addition, the present invention furthermore provides—according to a third aspect of the present invention—a use of at least one interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, and/or its DNA sequence and/or its assigned RNA sequence and/or at least one (poly)peptide encoded by the nucleic acid for identifying and/or providing a pharmaceutical for the prophylactic and/or curative treatment of hepatitis, in particular hepatitis type C, and/or for predicting individual effects of the pharmaceutical and/or side effects of the pharmaceutical.
[0063] With regard to the use in accordance with this aspect according to the invention, the gene associated with the multiplication or replication of hepatitis C viruses, in particular ISG15, can in a way be used as starting object for identifying or providing pharmaceuticals with respect to a hepatitis C infection or disorder. Here, the pharmaceuticals may be of a nature such that—as indicated above—they interact directly or indirectly with the gene defined above or the RNA, in particular mRNA, assigned thereto, and/or the corresponding (poly)peptide, in this manner leading, in particular via reduction or neutralization, in particular inhibition, of the gene activity, to a reduction or neutralization of the multiplication or replication of hepatitis C viruses and thus to amelioration or cure of the hepatitis C disorder. Accordingly, these may be substances having a gene-regulatory action.
[0064] The person skilled in the art is essentially familiar with the principles with respect to the specific area of application of the use according to the invention according to this aspect of the invention, so that this does not require any further explanations.
[0065] The present invention furthermore provides—in accordance with a fourth aspect of the present invention—a process for identifying an inhibitor and/or repressor of an interferon-stimulated nucleic acid molecule, in particular gene, preferably of ISG15, and/or its DNA sequence and/or its assigned RNA sequence, which comprises the following steps:
(a) bringing the nucleic acid molecule into contact with at least one test substance under conditions allowing an interaction, in particular binding, of the test substance(s) with the nucleic acid molecule; and (b) detection and/or analysis of whether the test substance(s) limits or neutralizes the gene activity and/or expression of the nucleic acid molecule and/or of whether the test substance(s) limits or neutralizes multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses.
[0068] The process according to the invention may be carried out, for example, in vitro, where in a way an interaction of the test substance with the nucleic acid molecule or the gene is studied and, if an interaction is present, a resulting reduced gene activity as a consequence of this interaction may be inferred. The process according to the invention may likewise be carried out in an appropriate host system, where the host should be a carrier of the gene associated with the multiplication or replication of hepatitis C viruses, in particular ISG15, and advantageously also have a corresponding expression system. The interaction or the modulated gene activity can be demonstrated using processes known per se to the person skilled in the art.
[0069] In this context, the present invention—according to a fifth aspect of the present invention—relates to a process for identifying an inhibitor and/or repressor of a (poly)peptide encoded by an interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, and/or by its DNA sequence and/or by its assigned RNA sequence, which comprises the following steps:
(a) bringing the (poly)peptide into contact with at least one test substance under conditions allowing an interaction, in particular binding, of the test substance(s) with the (poly)peptide; and (b) detection and/or analysis of whether the test substance(s) limits or neutralizes the activity of the (poly)peptide and/or of whether the test substance(s) limits or neutralizes the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses.
[0072] According to this aspect, the process according to the invention is thus focused on modulating the gene product, in particular in the form of a protein or (poly)peptide. The process can be carried out in a manner known per se to the person skilled in the art, both in vitro and in vivo, in a host system, where in the latter case the host should preferably carry the nucleic acid coding for the (poly)peptide to be examined. However, an interaction may likewise also be carried out in vitro using isolated (poly)peptides.
[0073] In addition, the present invention likewise relates to a process for identifying a substance which interacts with an in particular endogenous mediator and/or factor which is regulated by an interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, or which regulates an interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, where the process comprises the following steps:
(a) bringing the mediator and/or factor into contact with at least one test substance under conditions allowing an interaction, in particular binding, of the test substance(s) with the mediator and/or factor; and (b) detection and/or analysis of whether the test substance(s) modulates the activity of the mediator and/or factor and/or of whether the test substance (s) limits or neutralizes the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses.
[0076] According to the process mentioned above, the interacting substance is preferably an inhibitor and/or repressor of the mediator and/or factor, if this is associated with an activation of the interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15. If the mediator and/or factor itself is associated with an inactivation or repression of the interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, the interacting substance is, with respect to the mediator and/or factor, an activator—however, with regard to the interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15, based on the above definition, such a substance is likewise an inhibitor or repressor, since in this case, too, the final result is an inactivation or repression of the interferon-stimulated nucleic acid molecule, in particular gene, preferably ISG15.
[0077] The processes according to the invention in accordance with the fourth and fifth aspect of the present invention can be carried out such that a plurality of test substances are used and the following steps are carried out:
(a) testing various test substances in various reaction vessels, where the test substances which do not limit or neutralize the gene activity and/or expression and/or activity of the nucleic acid molecule (DNA or RNA, in particular mRNA) and/or which do not limit or neutralize the activity of the (poly)peptide and/or which do not limit or neutralize the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses and/or which do not interact with the mediator and/or factor, are no longer taken into consideration in the further test process; (b) distribution of test substances from those reaction vessels where, in step (a), a reduction or neutralization of the gene activity and/or expression and/or activity of the nucleic acid molecule has been determined and/or a reduction or neutralization of the activity of the (poly)peptide has been determined and/or a reduction or neutralization of the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses has been determined and/or an interaction with the mediator and/or factor has been determined, to new reaction vessels and repetition of step (a) with the new reaction vessels; and (c) repetition of step (b) until a single test substance has been identified to which the reduction or neutralization of the gene activity and/or expression of the nucleic acid molecule and/or the reduction or neutralization of the activity of the (poly)peptide and/or the reduction or neutralization of the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses, can be assigned and/or to which the interaction with the mediator and/or factor can be assigned.
[0081] Here, it is likewise possible to carry out the processes according to the fourth and the fifth aspect of the present invention such that the test substance(s), the nucleic acid molecule (DMA or RNA, in particular mRNA) and/or the (poly)peptide are coupled to a readout system and/or that a readout system is added to the test batch and/or that the readout system affords, after binding of the test substance (s) to the nucleic acid molecule and/or the (poly)peptide, a detectable signal.
[0082] In the context of the processes mentioned above, the test substances may be low-molecular-weight substances, peptides, aptamers, antibodies, DNA, RNA, in particular siRNA, and/or fragments or derivatives thereof.
[0083] As explained above, the processes mentioned above can be carried out, for example, in a host or host system, where the host or the host system preferably comprises the genes defined above and also has a corresponding expression system. Such hosts are known per se to the person skilled in the art, or, against the background of the present invention, the person skilled in the art is at any time able to select specific host systems, so that this does not require any further explanations. The processes according to the invention can likewise be carried out in the form of high-throughput processes and/or in a computer-assisted manner.
[0084] For further details with respect to the processes according to the invention in accordance with the fourth and the fifth aspect of the present invention, reference may be made to the explanations given for the other aspects of subject matters of the present invention, which, in this respect, apply correspondingly.
[0085] In addition, the present invention furthermore provides—according to a sixth aspect of the present invention—a process for improving the pharmacological properties of the test substances identified by the process according to the fourth and/or fifth aspect of the present invention, where
(a) the binding site of the test substance to the nucleic acid molecule (DNA or RNA, in particular mRNA) or to the (poly)peptide and, if appropriate, the binding site of the nucleic acid molecule or the (poly)peptide to the test substance are identified; (b) the binding site of the test substance and the nucleic acid molecule or the (poly)peptide is modified by molecular modeling; and (c) the test substance is modified such that its binding specificity or binding affinity or binding avidity for the nucleic acid molecule or the (poly)peptide is increased.
[0089] In this respect, the binding site in step (a) can be identified by site-specific mutagenesis, the relevant processes being known per se to the person skilled in the art.
[0090] In addition, the present invention furthermore provides—in accordance with a seventh aspect of the present invention—a process for modifying a test substance identified or improved by the processes according to the fourth and/or fifth and/or sixth aspect of the present invention, where the test substance as lead structure is modified further to achieve
(i) a modified active center, a modified activity spectrum and/or a modified organ specificity and/or (ii) an improved activity and/or (iii) a reduced toxicity (an improved therapeutic index) and/or (iv) reduced side effects and/or (v) onset of the therapeutical activity at a different time and/or different length of therapeutic activity and/or (vi) changed pharmacokinetic parameters (in particular bioabsorption, distribution, metabolism and/or excretion) and/or (vii) modified physicochemical parameters, in particular solubility, hygroscopic properties, color, taste, smell, stability and/or state, and/or (viii) improved general specificity, organ/tissue specificity, and/or (ix) optimized administration form and/or route, in particular by
(a) esterification of carboxyl groups and/or (b) esterification of hydroxyl groups with carboxylic acids and/or (c) esterification of hydroxyl groups, in particular to phosphates, pyrophosphates or sulfates and/or hemisuccinates and/or (d) formation of pharmaceutically acceptable salts and/or (e) formation of pharmaceutically acceptable complexes and/or (f) synthesis of pharmacologically active polymers and/or (g) introduction of hydrophilic groups and/or (h) introduction and/or exchange of substituents in aromatics and/or side chains and/or modification of the substituent pattern and/or (i) modification by introduction of isosteric and/or bioisosteric groups and/or (j) synthesis of homologous compounds and/or (k) introduction of branched side chains and/or (l) conversion of alkyl substituents into cyclic analogs and/or (m) derivitization of hydroxyl groups to ketals and/or acetals and/or (n) N-acetylation to amides and/or phenylcarbamates and/or (o) synthesis of Mannich bases and/or imines and/or (p) conversion of ketones and/or aldehydes into Schiff bases, oximes, acetals, ketals, enol esters, oxazolidines, thiozolidines or combinations thereof.
[0116] Here, it is possible in the context of the process according to the invention for the identified, improved or modified test substance, in particular the inhibitor and/or repressor of the gene(s) mentioned above, to be further improved pharmacologically by peptidomimetics.
[0117] For further explanations in respect to the processes according to the invention in accordance with this aspect of the present invention, reference may be made to the explanations for the above aspects of the present invention, which apply correspondingly.
[0118] Additionally, the present invention furthermore provides—according to an eighth aspect of the present invention—a process for identifying and/or determining at least one nucleic acid, molecule, in particular gene, preferably human and/or interferon-stimulated gene, associated with the replication of hepatitis viruses, in particular hepatitis C viruses, where the process comprises the following steps:
(a) generation of a gene expression and/or gene activity profile of a large number of subjects of a collective of subjects, where (i) the subjects of a first group of the collective of subjects are infected by hepatitis viruses, in particular hepatitis C viruses, and (ii) the subjects of a second group of the collective of subjects do not have such an infection; (b) analysis and comparison or aligning of the respective gene expression and/or gene activity profiles of (i) subjects of the first group and (ii) subjects of the second group and (c) identification of at least one nucleic acid molecule, in particular at least one gene, which, in (i) the subjects of the first group, compared to (ii) the subjects of the second group, has increased gene expression and/or gene activity.
[0122] The process may, subsequent to step (c), comprise the following step (d):
(d) assignment of the nucleic acid molecule, in particular gene, identified in step (c), as a nucleic acid molecule, in particular gene, associated with the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses.
[0124] The process according to the invention according to this aspect of the present invention can be employed, for example, by a differential expression using DNA chips. Here, the procedure adopted may be such, for example, that initially RNA is isolated from the blood of a subject to be examined, and this isolate is added onto specific gene chips and, in evaluation or analysis processes known per se to the person skilled in the art, the degree of expression of certain genes is determined for subjects having a hepatitis C infection in comparison to subjects without hepatitis C infection, and a gene, in particular an interferon-stimulated gene, having an increased degree of expression is assigned the properties of a gene associated with the multiplication or replication of hepatitis C viruses, in particular a gene promoting the multiplication or replication of hepatitis C viruses.
[0125] In this manner, it is possible to identify further genes, in particular interferon-stimulated genes, which are associated with the multiplication or replication of hepatitis C viruses in a hepatitis C infection or hepatitis C disorder.
[0126] The present invention furthermore relates—according to a ninth aspect of the present invention—to a pharmaceutical composition, preferably for the prophylactic or therapeutic treatment of hepatitis C disorders, comprising effective, in particular pharmaceutically effective, amounts of at least one pharmacologically active substance, in particular an inhibitor and/or repressor, for a nucleic acid molecule, in particular gene, associated with the multiplication and/or replication of hepatitis viruses, in particular hepatitis C viruses, preferably ISG15, and/or for its DNA sequence and/or for its assigned RNA sequence, in particular for its assigned mRNA sequence, and/or for its assigned (poly)peptide, the substance being obtainable by the process according to the fourth and/or fifth and/or sixth aspect of the present invention.
[0127] For further relevant details in respect of the pharmacologically active substance according to the invention, reference may be made to the other explanations of the further aspects of the present invention, which apply correspondingly in this context.
[0128] In addition, the present invention furthermore provides—in accordance with a tenth aspect of the present invention—a pharmaceutical composition, preferably for the prophylactic or therapeutic treatment of hepatitis C disorders, comprising effective, in particular pharmaceutically effective, amounts of at least one siRNA, where the siRNA regulates, in particular reduces or at least inhibits, the gene activity and/or gene expression of at least one interferon-stimulated gene, in particular of ISG15.
[0129] The siRNA used in the context of the pharmaceutical composition according to the invention is, according to a very particularly preferred embodiment, an siRNA which is directed against ISG15 and which can be obtained from Qiagen, Hilden, Germany, under the product, number or order number SI00072387.
[0130] For further details with respect to the pharmaceutical composition according to the invention in accordance with this inventive aspect of the present invention, reference may be made to the explanations given for the other above-mentioned aspects of the present invention, which, in this context, apply correspondingly.
[0131] Further developments, modifications and variations of the present invention will be directly evident and achievable for the person skilled in the art reading the description without departing from the scope of the present invention.
[0132] The present invention is illustrated by means of the following working examples which do not, however, restrict the present invention in any way.
WORKING EXAMPLES
Methods and Test Results:
[0133] 1. Isolation of Total RNA
[0134] For the extraction of total RNA, the cells were covered with 500 μl of Trizol. Using a scraper made of plastic, the adhering cells were detached from the base and transferred into a reaction vessel, 0.1 ml of chloroform/1 ml of Trizol was added and mixed in by shaking. Centrifugation at 12,000 g and at 2 to 8° C. for 15 min resulted in phase separation of the phenol/chloroform mixture. The aqueous phase was removed and the dissolved RNA was precipitated using 0.5 ml of isopropanol/1 ml of Trizol. The pellet was then washed with 75% ethanol, dried under reduced pressure and then dissolved in RNase-free water. The RNA was subsequently purified using the “RNeasy Mini” kit (Qiagen, Hilden, Germany) in accordance with the instructions of the manufacturer and stored at −20° C. until further analysis.
[0135] 2. Quantitative Real-Time PCR:
[0136] Reverse transcription of RNA followed by a polymerase chain reaction (RT-PCR) is a sensitive method for the quantification of specific mRNAs. In a one-step RT-PCR process (one-step RT-PCR), using specific primers, initially, the mRNA of the wanted gene is transcribed into complementary DNA (cDNA) which in turn affords the template or the basis for the PCR that follows.
[0137] To be able to make quantitative statements with regard to the amount of mRNA employed, the LightCycler Rotor-Gene 2000 from Corbett (Mortlake, Australia) was used. Via a fluorimeter component, the LightCycler measures the fluorescence of the fluorophore after binding to double-stranded DNA. Use was made of the QuantiTect SYBR Green RT-PCR Kit from QIAGEN; a 25-μl batch was, using a pipette, composed as follows: 5.25 μl of H 2 O (RNase-free), 12.5 μl of SYBR Green RT-PCR Master Mix, 0.25 μl of QuantiTect RT-Mix, 2.5 μl of each primer (0.5 mM) and 2 μl of total RNA (100 ng to 200 ng). The LightCycler program used started with a 30-minute RT step at 55° C., followed by a 15-minute heat deactivation of the RT polymerase and a subsequent conventional PCR scheme, i.e. per cycle 5 s of denaturation at 95° C., 10 s of annealing temperature (55° C.) and 30 s of elongation at 72° C. Product formation was determined after each replication cycle via the increase in fluorescence. After on average 40 replication cycles, the melting curves of the products formed were measured to check the specificity of the PCR reaction. Owing to the melting properties of DNA, the fluorescence decreases with increasing temperature. The maximum change in fluorescence per temperature increase yields a maximum in the melting curve characteristic for each PCR product. The copy numbers, calculated by the LightCycler, of the measured genes were aligned with the housekeeping gene β-aktin and analyzed.
[0138] 3. Suppression of the Gene Expression of ISG15 by siRNA:
[0139] The expression of ISG15 was switched off on the cell culture level in the HCV replicon system to examine the direct effect on HCV replication. Suppression of gene expression, also referred to as gene-knockdown or gene-knockout, is carried out using siRNA, via a cellular mechanism of processing. The dicer enzyme complex cleaves cell-atypical dsRNA into 21- to 23-bp-oligomers, the so-called small interfering RNAs (siRNA). The siRNA and a protein complex may form the RNA-induced silencing complex (RISC); this binds the antisense strand of the siRNA and cuts the complementary mRNA. The degration of the mRNA results in a reduction of the translation of these mRNAs and thus a gene-silencing on the post-transcriptional level.
[0140] A con1 replicon system based on the human hepatoma cell line HuH-7 and the murine MH1 cells, which likewise contain an HCV replicon, were, in a 96-well plate format, transfected with siRNAs directed against ISG15 (Qiagen) (human: order No. SI00072387, murine: order No. SI01007531). The effect of the gene suppression on the HCV replication was then examined.
[0141] To this end, in a reverse transfection batch, initially 12.5 ng of the siRNAs (5 nM) were dissolved in 3 μl of suspension buffer and, using a pipette, initially charged in the wells of the well plate. In a further batch, in each case 2.5 ng of the siRNAs were used for simultaneous silencing of further genes (not shown in the graphics). The control used was a non-codogenic siRNA. Per batch, 0.75 μl of the transfection reagent Hi-PerFect™ (Qiagen, Hilden, Germany) was then transferred into 24.25 μl of serum-free culture medium, and reagent and medium were mixed and added to the siRNAs initially charged. The transfection batch was then incubated at room temperature for 10 minutes. 1.10 4 cells were then added to the transfection batches, the volume was made up to 200 μl with culture medium and the cells were incubated at 37° C., 5% CO 2 and saturated atmospheric humidity for 12 hours. The RNA was extracted as already described, and the decrease of the gene expression of ISG15 and the HCV replication were examined by quantitative RT-PCR and Westernblot.
[0142] 4. Inhibition of HCV Replication during Extended Testing over 3 Months—Lack of Induction of Resistant Mutants:
[0143] Murine MH1 HCV replicon cells were cultivated over 19 cell passages with non-coding siRNA or siRNA directed against ISG15. The HCV copy number/100,000 copies of β-aktin was determined for cell passages 1, 7, 11, 15 and 19 and in each case compared to the untreated control (100%). Since, during the entire duration of the experiment, the siRNA directed, against ISG15 maintained its anti-HCV activity, it has to be assumed that no mutants resistant to this batch nave been formed or were selected. FIG. 1A and FIG. 1B illustrate the results obtained (with siNC=non-silencing control, siISG15=ISG15—specific siRNA). In FIG. 1A , the HCV copy number has been normalized and compared with the untreated control (MH1), and in FIG. 1B the HCV/ISG15 copy number has been normalized and compared with the siNC control. FIG. 1A and FIG. 1B show the marked decrease of the HCV copy number on treatment with ISG15-specific siRNA (siISG15). As a consequence, the multiplication and replication under the action of siISG15 is reduced, too.
[0144] 5. Inhibition of HCV NS5A Protein Expression by siRNA Knockdown of ISG15-synergism with IFN-α:
[0145] The murine MH1 and the human con1 HCV replicon cells were sowed in 6-well plates and incubated at 37° C. and an atmospheric CO 2 content of 5% to a confluence of 30 to 40%. Transfection with 5 nM siRNA (siNC=non-silencing control, siISG15=ISG15-specific human and murine siRNA) was carried out with “HiPerFect™ Transfection Reagent” (Qiagen, Hilden, Germany). After 8 h of incubation (37° C., 5% CO 2 ), the cells were washed and taken up again in culture medium and medium to which IFN-α had been added and incubated for a further 64 h. Subsequently, the cells were lyzed and a protein extraction was carried out. Using Westernblot, it was possible to detect the viral protein NS5A and the housekeeping gene β-aktin.
[0146] In the context of a Westernblot, FIG. 2A and FIG. 2B show that treatment with siRNA directed against ISG15 leads to a marked suppression of the HCV NS5A protein both in murine and in human HCV replicon systems. Furthermore, FIG. 2A and FIG. 2B show that synergism with IFN-α exists, since the additional administration of IFN-α (cf. FIG. 2A and FIG. 2B : +IFN-α) results in a significant reduction of NS5A synthesis compared to the batch which had not been treated with IFN-α (cf. FIG. 2A and FIG. 2B : −IFN-α).
[0147] FIG. 1A shows the inhibition of the HCV replication and the lack of induction of resistant, mutants on treatment with ISG15-specific siRNA (siISG15) compared to a treatment with siNC, where the HCV copy number has been normalized against the untreated control (MH1) and compared.
[0148] FIG. 1B shows the inhibition of the HCV replication and the lack of induction of resistant mutants on treatment with ISG15-specific siRNA (siISG15) compared to a treatment with siNC, where the HCV/ISG15 copy number has been normalized against the siNC control and compared.
[0149] FIG. 2A shows, by way of a Westernblot, the results of a treatment, carried out on human con1 HCV replicon cells, with siRNA directed against ISG15, firstly without additional administration of IFN-α (−IFN-α) and secondly with additional administration of IFN-α (+IFN-α).
[0150] FIG. 2B shows, by way of a Westernblot, the results of a treatment, carried out on murine MH1 HCV replicon cells, with siRNA directed against ISG15, firstly without additional administration of IFN-α (−IFN-α) and secondly with additional administration of IFN-α (+IFN-α).
[0151] FIG. 3 shows a comparison of the replication of hepatitis C viruses in MH1 cells for various passages, where the HCV copy number is based on 100,000 β-aktin molecules (MH1=untreated control, NC=non-silencing control, ISG15=ISG15-specific siRNA), For all passages, when ISG15-specific siRNA is used, a marked decline of the HCV copy number and thus a reduction of virus synthesis and replication can be observed compared to MH1 and NC.
|
This invention relates to the treatment of hepatitis infections or hepatitis diseases, in particular hepatitis C. The invention more particularly relates to the use of an inhibitor and/or repressor of a nucleic acid molecule, especially gene, which is related to the proliferation and/or replication of hepatitis viruses, in particular hepatitis C viruses, in order to produce a medicament for preventing and/or curing hepatitis, in particular hepatitis C, as well as a pharmaceutical composition, preferably for preventing or treating hepatitis C diseases, said composition containing the repressor and/or inhibitor.
| 2
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation-in-part of currently pending U.S. Ser. No. 11/473,880 filed Jun. 23, 2006 entitled, “Ruminant Feedstock Dietary Supplement”, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to a control release formulation that is supplemented with a rumen-bypass protected biologically active content. More specifically, in preferred embodiments this invention relates to ruminant feedstocks for domesticated ruminants which are capable of delivering undegraded essential aminoacids such as lysine and methionine to the post-rumen digestive system of ruminants such as dairy cattle.
BACKGROUND OF THE INVENTION
[0003] Publications cited in the present specification are incorporated by reference.
[0004] When a feedstock for ruminants has a content of biologically active constituent, a substantial amount of the said constituent (e.g., protein, aminoacids, and the like) is degraded to ammonia or carbon dioxide gas by microorganisms in the rumen. This prevents effective utilization of the administered biologically active constituent in the feedstock.
[0005] When special nutrients or medicaments are administered to ruminants, it is essential to protect these ingredients from decomposition in the rumen. The objective is to pass the said ingredients through the rumen to the omasum, and subsequently to the abomasum and absorption by the small intestine.
[0006] There are ongoing research and development activities which are seeking to achieve ruminant feedstock supplements which have the desired rumen-bypass properties. Rumen-bypass formulations are reported in numerous publications such as U.S. Pat. Nos. 4,842,863; 4,948,589; 5,023,091; 5,064,665; 5,093,128; 5,571,527; 5,633,004; 5,635,198; 6,203,829 and 6,306,427. There is further disclosure in WO2004/080197-A2 (PCT) and references cited therein.
[0007] Special effort has been directed to achieving rumen-bypass protection for essential aminoacids which supplement feedstocks for milk-producing ruminants.
[0008] It is known that lysine and methionine are important for milk production in dairy cattle. Journal of Dairy Science, 70, 789 (1987) reports that rumen-protected lysine increased feed intake, milk yield and 4% fat-corrected milk production in dairy cows; rumen-protected methionine and lysine increased production of milk protein in dairy cows.
[0009] Similar results are reported in Journal of Dairy Science, 72, 1484 (1989); 72, 1800 (1989); 73, 135 (1990); and 74, 2997 (1991). Data also indicated that added fat increased the percentage and yield of long-chain fatty acids in cow milk. Adding ruminally-protected aminoacids to fat-supplemented diets appeared to alleviate the milk protein depression observed with added lipids in feedstock.
[0010] Because of the significant economic consequences of rumen-bypass undegraded dietary nutrient transport, there is continuing interest in the development of superior rumen-bypass feedstock supplements to promote these prospective advantages.
[0011] Accordingly, it is an object of this invention to provide ruminant feedstocks which are supplemented with a rumen-protected biologically active content for advancing ruminant husbandry and for providing value added meat and dairy products for human consumption.
[0012] It is another object of this invention to provide rumen-bypass dietary supplements to stabilize and maintain the health of ruminants, and to improve the lactational performances of dairy ruminants.
[0013] It is yet another object of this invention to provide rumen-bypass dietary supplements which deliver post-rumen undegraded aminoacids in milk-producing dairy cattle for increased milk yield and increased production of milk protein.
[0014] It is a further object of this invention to provide an efficient process for producing a rumen-bypass dietary supplement in compacted particulate form, which supplement has the capability of passing between about 20-99 percent of its rumen-protected biologically active content to the post-rumen digestive system of ruminants.
[0015] Other objects and advantages of the present invention shall become apparent from the accompanying description and example data.
SUMMARY OF THE INVENTION
[0016] The present invention discloses a control release formulation (e.g., a rumen-bypass dietary supplement) in compacted form. In one embodiment, the control release formulation (or supplement) has the capability to transport a fatty acid salt (e.g., a fatty acid calcium salt) and one or more rumen-protected undegraded biologically active agents (e.g., an aminoacid) to the post-ruminal digestive system of a ruminant. In accordance with the present invention, the rumen-bypass dietary supplement comprises: (a) a fatty acid salt; (b) one or more biologically active agents; (c) a free alkali metal salt and/or a free alkaline earth metal salt; and (d) a binder. In one embodiment, under ruminant feeding conditions the dietary supplement has the capability to transport between about 20-99 percent of one or more rumen-protected undegraded biologically active agents (e.g., an aminoacid) to the post-rumen digestive system of a ruminant.
[0017] In another embodiment, the present invention provides a process for producing a rumen-bypass dietary supplement comprising: (1) blending a fatty acid salt (e.g., an alkaline earth metal salt) and one or more biologically active agents to form solid central core particles; (2) compacting the core particles to form pellets; (3) optionally coating the pellets with a liquid carboxylate salt-forming fatty acid constituent and/or a liquid carboxylate salt; and (4) optionally applying one or more additional coatings to the pellets with a constituent comprising a basic inorganic alkaline earth metal compound to create an in situ reactive carboxylate salt-forming matrix.
DETAILED DESCRIPTION OF THE INVENTION
[0018] One or more objects of the present invention are accomplished by the provision of a control release formulation (e.g., a rumen-bypass dietary supplement) in compacted form comprising:
[0019] (a) a fatty acid salt, for example, a C 4 -C 24 fatty acid alkaline earth metal salt;
[0020] (b) one or more biologically active agents, for example, an amino acid, vitamin, mineral, trace elements, enzyme, protein, non-protein nitrogen compound, medicaments, or mixtures thereof;
[0021] (c) a free alkali, for example, hydroxide and/or carbonates of alkali metals, and/or alkaline earth metals;
[0022] (d) a binder, for example, a C 4 -C 24 fatty acid carboxylate-salt forming constituent; and
[0023] (e) optionally one or more additional coatings.
[0024] Other constituents may be included in the compacted formulation including, but not limited to, inorganic acidic salts, clays and other inorganic and organic-based compounds, either dispersed throughout or applied to the exterior of the compacted materials.
[0025] In one embodiment, the control release formulation of the present invention can be in compacted particulate form wherein the particles have average dimensions between about 2-5 millimeters, and a density between about 1-1.3 grams per cubic centimeter. In another embodiment, under ruminant feeding conditions control release formulation of the present invention has the capability to transport between 20-99 percent of one or more rumen-protected undegraded biologically active agents (e.g., an aminoacid) to the post-rumen digestive system of a ruminant.
[0026] Standard procedures and equipment are employed to blend ingredients, compact ingredients, and apply coatings as appropriate. Granules or pellets are coated by conventional means such as pan coating, fluidized coating, centrifugal fluidized coating, and the like.
[0027] A present invention dietary supplement can be in the form of spherical, elliptical or cylindrical pellets which are in compacted form. Production of compressed solids can be facilitated with commercially available pellet mills and extruders, supplied by companies such as Sprout-Matador (Muncy, Pa.) and Roskamp Champion (Waterloo, Iowa).
[0028] In a preferred embodiment this invention provides a rumen-bypass dietary supplement in compacted particulate form comprising:
[0029] (a) between about 50-90 weight percent of C 4 -C 24 fatty acid alkaline earth metal salt;
[0030] (b) between about 5-50 weight percent of one or more biologically active agents;
[0031] (c) between about 0.2-5 weight percent of a free alkali salt and/or an alkaline earth metal salt; and
[0032] (d) between about 0.5-20 weight percent of a C 4 -C 24 fatty acid carboxylate-salt forming fatty acid; and
[0033] (e) optionally one or more coatings.
[0034] The central core of a typical control release formulation or dietary supplement particle (e.g., in pellet form) comprises a blend of one or more biological active agents (e.g., an aminoacid), a fatty acid salt (e.g., a fatty acid calcium and/or magnesium salt), a free alkali metal salt and/or an alkaline earth metal salt and a binder. In an optional embodiment, of the present invention, one or more additional or external coatings can be applied to the central core of the control release formulation. For example, a liquid fatty acid coating can be applied to the surface of the central core, and the separate application of a basic inorganic reagent such as calcium hydroxide can be added to the same central core surface. Either coating can be applied first and the liquid fatty acid and the basic inorganic reagent may be combined together to form the reactive matrix for subsequent application on the surface of the pellet. The super-imposed coatings may constitute a reactive matrix, and the in-situ matrix can transform into an interlocking network of multi-valent fatty acid salts. The resultant periphery of the pellet structure is a bonded hard lamina which imparts superior rumen-bypass properties to an invention dietary supplement for incorporation in ruminant feedstocks. In addition, the liquid fatty acid and the basic inorganic reagent may be combined together to form the reactive matrix for subsequent application on the surface of the pellet.
[0035] As another optional modification, the hereinabove described central core of a typical control release formulation or dietary supplement particle (e.g., in pellet form) can be encapsulated with an outer coating for additional rumen-bypass capability. Suitable coating substrates include waxes and polymers which can form a continuous film that functions as a semi-permeable barrier to a ruminal medium. This type of coating subsequently is capable of being at least partially disintegrated in the strongly acidic condition of the gastric fluid in the abomasum of ruminants.
[0036] Useful coating materials include carnauba wax, beeswax, polyvinylpyrrolidone, polyacrylamide, poly(styrene/2-vinylpyridine), polyvinyl acetate, shellac, zein, benzylaminomethylcellulose, ethylcellulose, cellulose acetate, and the like, and coating materials disclosed in U.S. Pat. Nos. 4,194,013; 4,384,004; 4,887,621; and 4,996,067.
[0037] The control release formulation of the present invention comprises a fatty acid salt. In one embodiment, the fatty acid salt can be a C 4 -C 24 fatty acid calcium and/or magnesium salt. The fatty acid salt of the control release formulation of the present invention may comprise from about 25 to about 99 weight percent, from about 50 to about 90 weight percent, or from about 60 to about 75 weight percent, of a fatty acid salt. In another embodiment, the fatty acid salt can be C 12 -C 22 fatty acid calcium and/or magnesium salt.
[0038] The control release formulation of the present invention comprises one or more biologically active agents. The one or more biologically active agents of the control release formulation may comprise from about 1 to about 75 weight percent, from 5 to about 50 weight percent, or from about 10 to about 40 weight percent, of one or more biologically active agents. In one embodiment, one or more biologically active agents can be one or more amino acids, vitamins, minerals, trace elements, enzymes, proteins, non-protein nitrogen compounds, medicaments, or mixtures thereof.
[0039] When the one or more biologically active agents is an aminoacid, the essential aminoacids are of special interest. Preferred aminoacids include alanine, glycine, lysine, methionine, methionine hydroxy analog, tryptophan, arginine, threonine, valine, leucine, isoleucine, histidine, phenylalanine, glutamine and glutamic acid.
[0040] For lactating dairy cattle feedstocks, a preferred control release formulation or dietary supplement is one that delivers high levels of post-rumen contents of C 12 -C 22 fatty acids and one or more of lysine, methionine, methionine hydroxy analog and tryptophan.
[0041] In one embodiment, the control release formulation (e.g., a dietary supplement) of the present invention can have a varied combination of biologically active ingredients, for example, the formulation may contain from about 1-75 weight percent of an aminoacid and/or from about 0.1-30 weight percent of one or more active ingredients selected from vitamins, trace elements, proteins, non-protein nitrogen compounds, medicaments, enzymes, inorganic acidic salts, clays, and the like.
[0042] Vitamins either singly or in combination include thiamine HCl, riboflavin, pyridoxine HCl, niacin, biotin, folic acid, ascorbic acid, vitamin B 12 , vitamin A acetate, vitamin K, vitamin D, vitamin E, and the like.
[0043] Trace elements include compounds of cobalt, copper, manganese, iron, zinc, tin, iodine, vanadium, selenium, and the like.
[0044] Protein ingredients are obtained from sources such as dried blood or meat meal, cottonseed meal, soy meal, dehydrated alfalfa, dried and sterilized animal and poultry manure, fish meal, powdered eggs, canola meal, and the like.
[0045] Protein equivalent ingredients include urea, biuret, ammonium phosphate, and the like.
[0046] Medicament ingredients either singly or in combination include promazine hydrochloride, chlorotetracycline, sulfamethazine, monensin, poloxalene, and the like. Oxytetracycline is a preferred antibiotic for cattle prophylaxis.
[0047] Enzymes of choice include lipolytic proteins which aid feed digestibility, e.g., by hydrolysis of fatty acid glycerides to free fatty acid and glycerol.
[0048] As illustrated in the Examples, this invention further provides a process for producing the range of rumen-bypass dietary supplements described hereinabove.
[0049] As disclosed hereinabove, the core compacted particle comprises a blend of one or more biologically active agents (e.g., an amino acid) and a fatty acid salt (e.g., a calcium and/or magnesium salt). The inventors have surprisingly found that by using a binder or reactant in the formation of the core compacted particle, superior rumen-bypass can be achieved. As such, in one embodiment, the use of a binder or reactant can be used in the process for producing the control release formulation (or the rumen-bypass dietary supplement) of the present invention. The binder can be, but is not limited to, a carboxylate salt-forming C 4 -C 24 fatty acids. In the practice of this embodiment, an excess of free alkali is typically used in the formation of the fatty acid calcium and/or magnesium salt. The free alkali can be a hydroxide and/or carbonate of an alkali metal salt or alkaline earth metal salt (e.g., Ca(OH) 2 or Mg(OH) 2 ). Typically, the free alkali comprises from about 0.2 to about 10 weight percent of the total weight of the fatty acid salt. In another embodiment, the free alkali content is between about 0.2 and about 5 weight percent, or from about 0.2 to about 2 weight percent, of the total weight of the fatty acid salt used. While not wishing to be bound by theory, it is believed that by using an excess of a free alkali (e.g., Ca(OH) 2 or Mg(OH) 2 ), the excess free alkali (e.g., Ca(OH) 2 or Mg(OH) 2 ) is available for reaction, and can act as a reactant and interact with the binder or reactant in-situ to form a fatty acid salt encapsulate in and throughout the pellet (e.g., a Ca- or Mg-fatty acid salt encapsulate). Other sources of OH, Ca 2+ and Mg 2+ may be used, such as NaOH, KOH and other monovalent alkali metals alone and/or in the presence of metal salts such as CaCl 2 and MgSO 4 , among others, as well as reaction products of CaO and H 2 O to yield Ca(OH) 2 and the reaction products of MgO and H 2 O to yield Mg(OH) 2 . Thus, for example, this excess of Ca(OH) 2 and/or Mg(OH) 2 can act as a reactant and interact with the binder or reactant in-situ to form a Ca- and/or Mg-fatty acid salt encapsulate. In some embodiments, the use of excess free alkali and excess binder or reactant can result in the formation of a fatty acid salt coating on the compacted control release formulation of the present invention. In general, any known binder or reactant can be used in the practice of this invention. Typically, the reactant or binder is a free fatty acid or a carboxylate salt-forming C 4 -C 24 fatty acids. Fatty acids useful for the practice of this invention include, but are not limited to, palm fatty acid distillate (PFAD), the individual or combination fatty acids found therein such as, palmitic acid, stearic acid, oleic acid, linoleic acid, and the like, and/or other fatty acid-containing mixtures. Such mixtures may comprise, but are not limited to, non-free fatty acid ether extractable fats and other materials, such as the mono-, di- and tri-gylceride forms of said groups. A free fatty acid content of from about 0.5% by weight to about 20% by weight of the core compacted particle can be used, and can include non-free fatty acid ether extractable fats and other materials. In yet another embodiment, the free fatty acid content can be from about 0.5% by weight to about 10% by weight of the core compacted particle, and can include non-free fatty acid ether extractable fats and other materials.
[0050] A volume of core particles as described can be compacted into pellets by conventional means such as extrusion. Any known pelletizer can be used, for example, any known pellet mill. The core particles are pressed into pellets by extrusion through a die. In the invention process elaborated above, either of the coatings can be the first applied to the pellets, or pre-mixed before application. As an optional step, the pellets then can be encapsulated with a final outer coating of wax or polymeric material to form a further semi-permeable barrier to a ruminal fluid.
[0051] The following Examples are further illustrative of the present invention. The components and specific ingredients are presented as being typical, and various modifications can be derived in view of the foregoing disclosure within the scope of the invention.
Example I
[0052] Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA) and L-lysine*HCl powder (as specified in Table 1) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. After mixing, the feed was fed to a CPM Master Model 1000 pellet mill via an auger feeder-conditioning chamber and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower. Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Megalac®-L-lysine*HCl-based pellets (see Table 1); if the Megalac®-L-lysine*HCl-based pellet is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the non-pelleted blend, thus demonstrating the control release properties of the pellets. While it is desirable for enhancing rumen bypass L-lysine in this example, the control release formulation in terms of fatty acid reactant type and levels, hydroxide and/or carbonate of an alkali metal type and levels and the compaction extrusion process, among other factors, can be tailored accordingly to control, for example, fatty acid salt formation (degree of reaction), degree of compaction of the resultant extruded pellet, cohesiveness of the pellet, among other physical and chemical properties, which dictate the control release characteristics of the core materials.
[0053] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 1 (Table 1)=15%.
[0054] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 1 (Table 1)=21%.
[0055] Experiment 1 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example II
[0056] Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl powder and additive (as specified in Table 1) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Liquid stearic acid (Acros Organics N.V., Fair Lawn, N.J.) was then added to the dry blend and blended for 2 minutes. The stearic acid used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 100%, respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower. Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Megalac®-L-lysine*HCl-additive-based pellets (see Table 1); if the Megalac®-L-lysine*HCl-additive-based pellet is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the non-pelleted blend, thus demonstrating the control release properties of the pellets. While it is desirable for enhancing rumen bypass L-lysine in this example, the control release formulation in terms of fatty acid reactant type and levels, hydroxide and/or carbonate of an alkali metal type and levels and the compaction extrusion process, among other factors, can be tailored accordingly to control, for example, fatty acid salt formation (degree of reaction), degree of compaction of the resultant extruded pellet, cohesiveness of the pellet, among other physical and chemical properties, which dictate the control release characteristics of the core materials.
[0057] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 2 (Table 1)=38%.
[0058] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 2 (Table 1)=46%.
[0059] Experiment 2 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example III
[0060] Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl powder/granules and additive (as specified in Table 1) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Palm fatty acid distillate (PFAD) liquid (PT Bukit Kapur Reksa, Indonesia) was then added to the dry blend and blended for 2 minutes. The PFAD used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 81% (based on palmitic), respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower. Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Megalac®-L-lysine*HCl-additive-based pellets (see Table 1); if the Megalac®-L-lysine*HCl-additive-based pellet is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the non-pelleted blend, thus demonstrating the control release properties of the pellets. While it is desirable for enhancing rumen bypass L-lysine in this example, the control release formulation in terms of fatty acid reactant type and levels, hydroxide and/or carbonate of an alkali metal type and levels and the compaction extrusion process, among other factors, can be tailored accordingly to control, for example, fatty acid salt formation (degree of reaction), degree of compaction of the resultant extruded pellet, cohesiveness of the pellet, among other physical and chemical properties, which dictate the control release characteristics of the core materials.
[0061] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 3 (Table 1)=29%.
[0062] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 3 (Table 1)=43%.
[0063] Experiment 3 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example IV
[0064] Calcium stearate flakes (Baerlocher USA, Cincinnati, Ohio), L-lysine*HCl granules and additive (as specified in Table 1) were batched and blended. The calcium stearate used had a fat (petroleum ether extract) %, free fatty acid % and Ca(OH) 2 % of ca. 0.3%, ca. 0.3% and ca. 0.1%, respectively. Liquid stearic acid (Acros Organics N.V., Fair Lawn, N.J.) was then added to the dry blend and blended for 2 minutes. The stearic acid used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 100%, respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower. Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Ca-stearate-L-lysine*HCl-additive-based pellets (see Table 1); if the Ca-stearate-L-lysine*HCl-additive-based pellet is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the non-pelleted blend, thus demonstrating the control release properties of the pellets. While it is desirable for enhancing rumen bypass L-lysine in this example, the control release formulation in terms of fatty acid reactant type and levels, hydroxide and/or carbonate of an alkali metal type and levels and the compaction extrusion process, among other factors, can be tailored accordingly to control, for example, fatty acid salt formation (degree of reaction), degree of compaction of the resultant extruded pellet, cohesiveness of the pellet, among other physical and chemical properties, which dictate the control release characteristics of the core materials.
[0065] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 4 (Table 1)=4%.
[0066] In-sacco Bypass (ISB). Not completed due to the low solubility leaching result.
[0067] Experiment 4 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example V
[0068] Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl powder/granules and additive (as specified in Table 1) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Liquid soy oil (Spectrum Organic Products, LLC, Petaluma, Calif.) was then added to the dry blend and blended for 2 minutes. The soy oil used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 0.5%, respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower. Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Megalac®-L-lysine*HCl-additive-based pellets (see Table 1); if the Megalac®-L-lysine*HCl-additive-based pellet is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the non-pelleted blend, thus demonstrating the control release properties of the pellets. While it is desirable for enhancing rumen bypass L-lysine in this example, the control release formulation in terms of fatty acid reactant type and levels, hydroxide and/or carbonate of an alkali metal type and levels and the compaction extrusion process, among other factors, can be tailored accordingly to control, for example, fatty acid salt formation (degree of reaction), degree of compaction of the resultant extruded pellet, cohesiveness of the pellet, among other physical and chemical properties, which dictate the control release characteristics of the core materials.
[0069] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 5 (Table 1)=9%.
[0070] In-sacco Bypass (ISB). Not completed due to the low solubility leaching result.
[0071] Experiment 5 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example VI
[0072] Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl powder/granules and liquid PFAD additive (as specified in Table 1) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. The PFAD (PT Bukit Kapur Reksa, Indonesia) used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 81% (based on palmitic), respectively. The resultant mash was not pelletized.
[0073] Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from Megalac®-L-lysine*HCl-additive-based mash (see Table 1).
[0074] Characterization—Solubility Leaching. The mash was exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the mash was removed, collected on a filter paper, washed with water and then dried. Mash “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of mash “after exposure”)]/(Weight of mash “before exposure”)]×100. SIF for Experiment 6 (Table 1)<1%.
[0075] In-sacco Bypass (ISB). Not completed due to the low solubility leaching result.
[0076] Experiment 6 of Table 1 includes some additional formulation details, processing details, experimental details and efficacy/characterization results. Experiment 6 serves as a representative example for the non-pelleted forms of the formulations described herein.
[0000]
TABLE 1
Pellet and mash formulation details, efficacy and characterization results.
% Bypass
End
% Bypass
(In-sacco
Liquid
Feed
Pellet
(In-house
Bypass
Ca-fatty
Free
L-lysine*HCl
Reactant
Temp.
Temp.
leaching,
ISB
Experiment
Die Size
L/D
acid, %
Ca(OH) 2
%
Additive, %
Compacted
(F.)
(F.)
SIF (24 h))
(12 h))
1
5/32″ ×
7.3
Megalac ®,
Yes
20
None
Yes, Pellet
100
125
15
21
⅞″
80
2
3/16″ ×
5.3
Megalac ®,
Yes
20
Stearic
Yes, Pellet
140
130
38
46
1″
77
Acid, 3
3
3/16″ ×
8.0
Megalac ®,
Yes
20
PFAD, 3
Yes, Pellet
125
160
29
43
1½″
77
4
3/16″ ×
5.3
Calcium
No
20
Stearic
Yes, Pellet
125
112
4
x
1″
Stearate, 77
Acid, 3
5
3/16″ ×
8.0
Megalac ®,
Yes
20
Soy Oil, 3
Yes, Pellet
130
147
9
x
1½″
77
6
NA
NA
Megalac ®,
Yes
20
PFAD, 3
No, Mash
100
NA
<1
x
77
Example VII
[0077] Pellet preparation. Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl granules and additive (as specified in Table 2) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Liquid stearic acid (Acros Organics N.V., Fair Lawn, N.J.) was then added to the dry blend and blended for 2 minutes. The stearic acid used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 100%, respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower.
[0078] Coating preparation. Stearic acid coating. A stearic acid liquid at ca. 220° F. was spray applied onto the abovementioned pellets (ca. 100° F.) as they tumbled in a candy coater until an ca. 10% (by weight) coating was applied.
[0079] Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from the uncoated Megalac®-L-lysine*HCl-additive-based pellets and the stearic acid-coated pellets (see Table 2); if the stearic acid coating is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the uncoated pellet.
[0080] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 7 and Experiment 8 (Table 2)=28% and 40%, respectively.
[0081] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 7 and Experiment 8 (Table 2)=55% and 66%, respectively.
[0082] Experiment 7 and Experiment 8 of Table 2 include some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example VIII
[0083] Pellet preparation. Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl granules and additive (as specified in Table 2) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Palm fatty acid distillate (PFAD) liquid was then added to the dry blend and mixed for 2 minutes. The PFAD (PT Bukit Kapur Reksa, Indonesia) used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 81% (based on palmitic), respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower.
[0084] Calcium fatty acid coatings—Method 1. A calcium fatty acid salt slurry was prepared using palm fatty acid distillate and Ca(OH) 2 . Palm fatty acid distillate (ca. 88% by weight) at ca. 200° F. was added to Ca(OH) 2 (ca. 12% by weight) at ca. 80° F. and mixed for ca. 1 minute. The resultant slurry that consisted of newly formed calcium fatty acid salt, palm fatty acid distillate and Ca(OH) 2 was then applied onto ca. 70° F. pellets as the pellets tumbled in a drum coater at ca. 38 RPM. An additional charge of Ca(OH) 2 was then added to the pellets to complete the calcium fatty acid salt reaction and to separate the pellets. The pellets were tumbled for several minutes until the pellets cooled to about ambient temperature.
[0085] Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from the uncoated Megalac®-L-lysine*HCl-additive-based pellets and the Ca-fatty acid salt-coated (Method 1) pellets (see Table 2); if the Ca-fatty acid salt coating (Method 1) is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the uncoated pellet.
[0086] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 9 and Experiment 10 (Table 2)=46% and 48%, respectively.
[0087] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 9 and Experiment 10 (Table 2)=61% and 77%, respectively.
[0088] Experiment 9 and Experiment 10 of Table 2 include some additional formulation details, processing details, experimental details and efficacy/characterization results.
Example IX
[0089] Pellet preparation. Calcium salt of palm fatty acid distillate flakes with Ca(OH) 2 (Megalac®, Church & Dwight Co., Inc., Princeton, N.J. USA), L-lysine*HCl powder/granules and additive (as specified in Table 2) were batched and blended. The Megalac® used had a fat (petroleum ether extract) %, free fatty acid % (based on palmitic) and Ca(OH) 2 % of ca. 5%, ca. 0.2% and ca. 2%, respectively. Liquid palm fatty acid distillate (PFAD) liquid was then added to the dry blend and mixed for 2 minutes. The PFAD (PT Bukit Kapur Reksa, Indonesia) used had a fat (petroleum ether extract) % and free fatty acid % of ca. 100% and ca. 81% (based on palmitic), respectively. After mixing, the feed was fed to a CPM CL-3 pellet mill via an auger feeder and pelletized. The resultant pellets were screened to remove fines and cooled via an air blower.
[0090] Calcium fatty acid coatings—Method 2. A solution containing ca. 50% calcium fatty acid salt and ca. 50% palm fatty acid distillate (PFAD) was prepared; calcium fatty acid salt granules (ca. 80° F.) were added to liquid palm fatty acid distillate (ca. 240° F.) and stirred until the calcium fatty acid salt was solubilized in the palm fatty acid distillate. The resultant solution at ca. 240° F. was then spray-applied (ca. 80 psig) onto ca. 80° F. pellets as they tumbled in a drum coater at ca. 38 RPM. Calcium fatty acid salt powder that contained Ca(OH) 2 was periodically applied to the pellets to complete the fatty acid salt reaction and to separate the pellets. The pellets were tumbled for several minutes until the pellets cooled to about ambient temperature.
[0091] Solubility leaching and in-sacco bag study leaching were used to gauge the control release of L-lysine from the uncoated Megalac®-L-lysine*HCl-additive-based pellets and the Ca-fatty acid salt-coated (Method 2) pellets (see Table 2); if the Ca-fatty acid salt coating (Method 2) is effective at mitigating the loss of the L-lysine from the pellet, then elevated L-lysine concentrations in the resultant pellets will result as compared to the uncoated pellet.
[0092] Characterization—Solubility Leaching. The pellets were exposed to a phosphate buffer solution (ca. 0.2 M) at pH ca. 6.7 and at ca. 35° C. with subtle shaking. At 24 h the pellets were removed, washed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Dumas combustion method) and the % bypass (% remaining)/Solubility Index Factor (SIF), was calculated as follows: SIF=[(Combustion N % “after exposure”)/(Combustion N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. SIF for Experiment 11 and Experiment 12 (Table 2)=29% and 47%, respectively.
[0093] In-sacco Bypass (ISB). Pellets housed in nylon bags were placed in the cow's rumen and exposed to the rumen fluid for 12 h. At 12 h, the pellets were removed from the rumen, rinsed with water and then dried. Pellets “before exposure” and “after exposure” were analyzed for N-content (Kjeldahl method) and the % bypass (% remaining)/In-sacco Bypass (ISB), was calculated as follows: ISB=[(N % “after exposure”)/(N % “before exposure”)]×[(Weight of pellets “after exposure”)]/(Weight of pellets “before exposure”)]×100. ISB for Experiment 11 and Experiment 12 (Table 2)=43% and 72%, respectively.
[0094] Experiment 11 and Experiment 12 of Table 2 include some additional formulation details, processing details, experimental details and efficacy/characterization results.
[0000]
TABLE 2
Pellet and coating experimental details and efficacy/characterization results.
%
Uncoated
End
Bypass
% Bypass
Pellet or
Liquid
Feed
Pellet
(In-house
(In-sacco
Coated
Ca-fatty
L-
Reactants
Temp.
Temp.
Coating
leaching,
Bypass,
Experiment
Pellet
acid, %
lysine*HCl %
Additive, %
Die Size
L/D
(F)
(F)
Details
SIF (24 h))
ISB (12 h))
7
Uncoated
77
20
Stearic Acid, 3
3/16″ ×
5.3
140
131
None
28
55
Pellet
1″
8
Coated
“7” Coated
40
66
Pellet
with ca.
10% stearic
acid
9
Uncoated
77
20
PFAD, 3
3/16″ ×
8.0
120
147
None
46
61
Pellet
1½″
10
Coated
“9” Coated
48
77
Pellet
with ca.
10% Ca-
fatty acid
(Method 1)
11
Uncoated
77
20
PFAD, 3
3/16″ ×
8.0
125
160
None
29
43
Pellet
1½″
12
Coated
“11” Coated
47
72
Pellet
with ca.
10% Ca-
fatty acid
(Method 2)
|
This invention provides a control release formulation or rumen-bypass dietary supplement in compacted form. The formulation or supplement has the capability to transport fatty acid calcium salt and between about 1-75 percent of one or more rumen-protected undegraded biologically active agents to the post-ruminal digestive system of a ruminant. A feedstock containing the formulation or supplement for ruminants beneficially improves feed efficiency and body growth. The feedstock also is adapted to improve the lactational performance of dairy cattle.
| 0
|
TECHNICAL FIELD
This invention relates to wire and cable and the insulation and jacketing therefor and, more particularly, to telephone cable.
BACKGROUND INFORMATION
A typical telephone cable is constructed of twisted pairs of metal conductors for signal transmission. Each conductor is insulated with a polymeric material. The desired number of transmission pairs is assembled into a circular cable core, which is protected by a cable sheath incorporating metal foil and/or armor in combination with a polymeric jacketing material. The sheathing protects the transmission core against mechanical and, to some extent, environmental damage.
Of particular interest are the grease-filled telephone cables. These cables were developed in order to minimize the risk of water penetration, which can severely upset electrical signal transmission quality. A watertight cable is provided by filling the air spaces in the cable interstices with a hydrocarbon cable filler grease. While the cable filler grease extracts a portion of the antioxidants from the insulation, the watertight cable will not exhibit premature oxidative failure as long as the cable maintains its integrity.
In the cable transmission network, however, junctions of two or more watertight cables are required and this joining is often accomplished in an outdoor enclosure known as a pedestal (an interconnection box). Inside the pedestal, the cable sheathing is removed, the cable filler grease is wiped off, and the transmission wires are interconnected. The pedestal with its now exposed insulated wires is usually subjected to a severe environment, a combination of high temperature, air, and moisture. This environment together with the depletion by extraction of those antioxidants presently used in grease-filled cable can cause the insulation in the pedestal to exhibit premature oxidative failure. In its final stage, this failure is reflected in oxidatively embrittled insulation prone to cracking and flaking together with a loss of electrical transmission performance.
To counter the depletion of antioxidants, it has been proposed to add high levels of antioxidants to the polymeric insulation. However, this not only alters the performance characteristics of the insulation, but is economically unsound in view of the high cost of antioxidants. There is a need, then, for antioxidants which will resist cable filler grease extraction to the extent necessary to prevent premature oxidative failure and ensure the 30 to 40 year service life desired by industry.
DISCLOSURE OF THE INVENTION
An object of this invention, therefore, is to provide a grease-filled cable construction containing antioxidants, which will resist extraction and be maintained at a satisfactory stabilizing level. Other objects and advantages will become apparent hereinafter.
According to the invention, an article of manufacture has been discovered which meets the above object.
The article of manufacture comprises, as a first component, a plurality of electrical conductors, each surrounded by one or more layers of a composition comprising (a) one or more polyolefins and, blended therewith, (b) a mixture containing one or more alkylhydroxyphenylalkanoyl hydrazines and one or more functionalized hindered amines as defined below; and, as a second component, hydrocarbon cable filler grease within the interstices between said surrounded conductors.
In one other embodiment, the article of manufacture comprises first and second components; however, the mixture of the first component contains absorbed hydrocarbon cable filler grease or one or more of the hydrocarbon constituents thereof and, in another embodiment, the article of manufacture is comprised only of the first component wherein the mixture contains hydrocarbon cable filler grease or one or more of the hydrocarbon constituents thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyolefins used in this invention are generally thermoplastic resins, which are crosslinkable. They can be homopolymers or copolymers produced from two or more comonomers, or a blend of two or more of these polymers, conventionally used in film, sheet, and tubing, and as jacketing and/or insulating materials in wire and cable applications. The monomers useful in the production of these homopolymers and copolymers can have 2 to 20 carbon atoms, and preferably have 2 to 12 carbon atoms. Examples of these monomers are alpha-olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene; unsaturated esters such as vinyl acetate, ethyl acrylate, methyl acrylate, methyl methacrylate, t-butyl acrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate, and other alkyl acrylates; diolefins such as 1,4-pentadiene, 1,3-hexadiene, 1,5-hexadiene, 1,4-octadiene, and ethylidene norbornene, commonly the third monomer in a terpolymer; other monomers such as styrene, p-methyl styrene, alpha-methyl styrene, p-chloro styrene, vinyl naphthalene, and similar aryl olefins; nitriles such as acrylonitrile, methacrylonitrile, and alpha-chloroacrylonitrile; vinyl methyl ketone, vinyl methyl ether, vinylidene chloride, maleic anhydride, vinyl chloride, vinylidene chloride, vinyl alcohol, tetrafluoroethylene, and chlorotrifluoroethylene; and acrylic acid, methacrylic acid, and other similar unsaturated acids.
The homopolymers and copolymers referred to can be non-halogenated, or halogenated in a conventional manner, generally with chlorine or bromine. Examples of halogenated polymers are polyvinyl chloride, polyvinylidene chloride, and polytetrafluoroethylene. The homopolymers and copolymers of ethylene and propylene are preferred, both in the non-halogenated and halogenated form. Included in this preferred group are terpolymers such as ethylene/propylene/diene monomer rubbers.
Other examples of ethylene polymers are as follows: a high pressure homopolymer of ethylene; a copolymer of ethylene and one or more alpha-olefins having 3 to 12 carbon atoms; a homopolymer or copolymer of ethylene having a hydrolyzable silane grafted to their backbones; a copolymer of ethylene and an alkenyl triakloxy silane such as trimethoxy vinyl silane; or a copolymer of an alpha-olefin having 2 to 12 carbon atoms and an unsaturated ester having 4 to 20 carbon atoms, e.g., an ethylene/ethyl acrylate or vinyl acetate copolymer; an ethylene/ethyl acrylate or vinyl acetate/hydrolyzable silane terpolymer; and ethylene/ethyl acrylate or vinyl acetate copolymers having a hydrolyzable silane grafted to their backbones.
With respect to polypropylene: homopolymers and copolymers of propylene and one or more other alpha-olefins wherein the portion of the copolymer based on propylene is at least about 60 percent by weight based on the weight of the copolymer can be used to provide the polyolefin of the invention. Polypropylene can be prepared by conventional processes such as the process described in U.S. Pat. No. 4,414,132. Preferred polypropylene alpha-olefin comonomers are those having 2 or 4 to 12 carbon atoms.
The homopolymer or copolymers can be crosslinked or cured with an organic peroxide, or to make them hydrolyzable, they can be grafted with an alkenyl trialkoxy silane in the presence of an organic peroxide which acts as a free radical generator or catalyst. Useful alkenyl trialkoxy silanes include the vinyl trialkoxy silanes such as vinyl trimethoxy silane, vinyl triethoxy silane, and vinyl triisopropoxy silane. The alkenyl and alkoxy radicals can have 1 to 30 carbon atoms and preferably have 1 to 12 carbon atoms. The hydrolyzable polymers can be moisture cured in the presence of a silanol condensation catalyst such as dibutyl tin dilaurate, dioctyl tin maleate, stannous acetate, stannous octoate, lead naphthenate, zinc octoate, iron 2-ethyl hexoate, and other metal carboxylates.
The homopolymers or copolymers of ethylene wherein ethylene is the primary comonomer and the homopolymers and copolymers of propylene wherein propylene is the primary comonomer may be referred to herein as polyethylene and polypropylene, respectively.
For each 100 parts by weight of polyolefin, the other components of the insulation mixture can be present in about the following proportions:
______________________________________ Parts by WeightComponent Broad Range Preferred Range______________________________________(i) hydrazine at least 0.1 0.3 to 2.0 (ii) hindered amine at least 0.01 0.05 to 1.0 (iii) grease 3 to 30 5 to 25______________________________________
Insofar as the hydrazine and the hindered amine are concerned, there is no upper limit except the bounds of practicality, which are dictated by economics, i.e., the cost of the antioxidants. In this vein, most preferred upper limits are about 1.0 and about 0.5 part by weight, respectively.
The weight ratio of hydrazine to hindered amine can be in the range of about 1:1 to about 20:1, and is preferably in the range of about 2:1 to about 15:1. A most preferred ratio is about 3:1 to about 10:1. It should be noted that the hindered amine is effective at very low use levels relative to the hydrazine.
Alkylhydroxyphenylalkanoyl hydrazines are described in U.S. Pat. Nos. 3,660,438 and 3,773,722.
A preferred general structural formula for hydrazines useful in the invention is as follows: ##STR1## wherein n is 0 or an integer from 1 to 5; R 1 is an alkyl having 1 to 6 carbon atoms;
R 2 is hydrogen or R 1 ; and
R 3 is hydrogen, an alkanoyl having 2 to 18 carbon atoms, or the following structural formula: ##STR2## wherein R 1 , R 2 , and R 3 can be the same or different.
The defined hindered amines can have the following structural formula: ##STR3## wherein n is an integer from about 2 to about 20; x is an integer from 1 to about 20;
each R is, independently, linear or branched alkyl or alkoxy having 1 to 20 carbon atoms, or --CO(R 2 ) wherein R 2 is linear or branched alkyl having 1 to 20 carbon atoms;
R 1 is morpholino, --NR 2 , --NHR, or ##STR4## wherein each R 3 is, independently, hydrogen or R.
The polymeric structure can be terminated by any of a range of polymer terminating groups known to those skilled in the art, including but not limited to hydrogen, alkyl, hydroxyl, alkoxy, amino, alkylamino, dialkylamino.
In a preferred example, referred to as Structural Formula I, x is 6, n is 2 to 4, each R is methyl, and R 1 is morpholino. An example of the preferred compound is Cyasorb™ UV-3529, currently available from Cytec. ##STR5##
Another group of hindered amines useful in the present invention has the structural formula: ##STR6## wherein n is 1 to about 20; ##STR7## R 2 is --(CH 2 ) x -, wherein x is an integer from 1 to about 20;
R 3 is morpholino, --NR 6 2 , --NHR 6 , or ##STR8## R 4 is hydrogen, or linear or branched alkyl having 1 to 20 carbon atoms;
R 5 is hydrogen, or linear or branched alkyl or alkoxy having 1 to 20 carbons, or CO(R 7 ), wherein R 7 is linear or branched alkyl having 1 to 20 carbon atoms;
R 6 is hydrogen, or linear or branched alkyl having 1 to 20 carbon atoms
wherein each R 1 , R 3 , R 5 , and R 6 can be the same or different.
In a preferred example, Structural Formula II, n is 1 to 6; x is 6; R 3 is di-n-butylamino; R 5 is hydrogen; and R 4 is n-butyl. This compound is currently available from Ciba as CGL-2020. ##STR9##
A distinguishing characteristic of these particular hindered amines is that they have a number average molecular weight (Mn) greater than about 1000.
Hydrocarbon cable filler grease is a mixture of hydrocarbon compounds, which is semisolid at use temperatures. It is known industrially as "cable filling compound". A typical requirement of cable filling compounds is that the grease has minimal leakage from the cut end of a cable at a 60° C. or higher temperature rating. Another typical requirement is that the grease resist water leakage through a short length of cut cable when water pressure is applied at one end. Among other typical requirements are cost competitiveness; minimal detrimental effect on signal transmission; minimal detrimental effect on the physical characteristics of the polymeric insulation and cable sheathing materials; thermal and oxidative stability; and cable fabrication processability.
Cable fabrication can be accomplished by heating the cable filling compound to a temperature of approximately 100° C. This liquefies the filling compound so that it can be pumped into the multiconductor cable core to fully impregnate the interstices and eliminate all air space. Alternatively, thixotropic cable filling compounds using shear induced flow can be processed at reduced temperatures in the same manner. A cross section of a typical finished grease-filled cable trans-mission core is made up of about 52 percent insulated wire and about 48 percent interstices in terms of the areas of the total cross section. Since the interstices are completely filled with cable filling compound, a filled cable core typically contains about 48 percent by volume of cable filling compound.
The cable filling compound or one or more of its hydrocarbon constituents enter the insulation through absorption from the interstices. Generally, the insulation absorbs about 3 to about 30 parts by weight of cable filling compound or one or more of its hydrocarbon constituents, in toto, based on 100 parts by weight of polyolefin. A typical absorption is in the range of a total of about 5 to about 25 parts by weight per 100 parts by weight of polyolefin.
It will be appreciated by those skilled in the art that the combination of resin, cable filling compound constituents, and antioxidants in the insulation is more difficult to stabilize than, an insulating layer containing only resin and antioxidant, and no cable filling compound constituent.
Examples of hydrocarbon cable filler grease (cable filling compound) are petrolatum; petrolatum/polyolefin wax mixtures; oil modified thermoplastic rubber (ETPR or extended thermoplastic rubber); paraffin oil; naphthenic oil; mineral oil; the aforementioned oils thickened with a residual oil, petrolatum, or wax; polyethylene wax; mineral oil/rubber block copolymer mixture; lubricating grease; and various mixtures thereof, all of which meet industrial requirements similar to those typified above.
Generally, cable filling compounds extract insulation antioxidants and, as noted above, are absorbed into the polymeric insulation. Since each cable filling compound contains several hydrocarbons, both the absorption and the extraction behavior are preferential toward the lower molecular weight hydrocarbon wax and oil constituents. It is found that the insulation composition with its antioxidant not only has to resist extraction, but has to provide sufficient stabilization (i) to mediate against the copper conductor, which is a potential catalyst for insulation oxidative degradation; (ii) to counter the effect of residuals of chemical blowing agents present in cellular and cellular/solid (foam/skin) polymeric foamed insulation; and (iii) to counter the effect of absorbed constituents from the cable filling compound.
The polyolefin can be one polyolefin or a blend of polyolefins. The hydrazine and the functionalized hindered amine are blended with the polyolefin. The composition containing the foregoing can be used in combination with disulfides, phosphites or other non-amine antioxidants in molar ratios of about 1:1 to about 1:2 for additional oxidative and thermal stability, but, of course, it must be determined to what extent these latter compounds are extracted by the grease since this could affect the efficacy of the combination.
The following conventional additives can be added in conventional amounts if desired: ultraviolet absorbers, antistatic agents, pigments, dyes, fillers, slip agents, fire retardants, stabilizers, crosslinking agents, halogen scavengers, smoke inhibitors, crosslinking boosters, processing aids, e.g., metal carboxylates, lubricants, plasticizers, viscosity control agents, and blowing agents such as azodicarbonamide. The fillers can include, among others, magnesium hydroxide and alumina trihydrate. As noted, other antioxidants and/or metal deactivators can also be used, but for these or any of the other additives, resistance to grease extraction must be considered.
Additional information concerning grease-filled cable can be found in Eoll, The Aging of Filled Cable with Cellular Insulation, International Wire & Cable Symposium Proceeding 1978, pages 156 to 170, and Mitchell et al, Development Characterization, and Performance of an Improved Cable Filling Compound, International Wire & Cable Symposium Proceeding 1980, pages 15 to 25. The latter publication shows a typical cable construction on page 16 and gives additional examples of cable filling compounds.
The patents and other publications mentioned in this specification are incorporated by reference herein.
The invention is illustrated by the following examples.
EXAMPLES 1 THROUGH 3
Various materials used in the examples are as follows:
Polyethylene I is a copolymer of ethylene and 1-hexene. The density is 0.946 gram per cubic centimeter and the melt index is 0.80 to 0.95 gram per 10 minutes.
Antioxidant A is 1,2-bis(3,5-di-tert-butyl-4-hydroxy-hydrocinnamoyl)hydrazine.
Antioxidant B is Structural Formula I.
Antioxidant C is Structural Formula II.
10 mil polyethylene plaques are prepared for oxidation induction time (OIT) testing. The plaques are prepared from a mixture of polyethylene I and the antioxidants mentioned above. The parts by weight of each are set forth in the accompanying Table.
A laboratory procedure simulating the grease filled cable application is used to demonstrate performance. Resin samples incorporating specified antioxidants are prepared. The samples are first pelletized and then formed into approximately 10 mil (0.010 inch) thick test plaques using ASTM D-1928 methods as a guideline. There is a final melt mixing on a two roll mill or laboratory Brabender™ type mixer followed by preparation of the test plaques using a compression molding press at 150° C. Initial oxygen induction time is measured on these test plaques.
A supply of hydrocarbon cable filler grease is heated to about 80° C. and well mixed to insure uniformity. A supply of 30 millimeter dram vials are then each filled to approximately 25 millimeters with the cable filler grease. These vials are then cooled to room temperature for subsequent use. An oil extended thermoplastic rubber (ETPR) type cable filler grease is the hydrocarbon cable filler grease used in these examples. It is a typical cable filling compound.
Each ten mil test plaque is then cut to provide about twenty approximately one-half inch square test specimens. Before testing, each vial is reheated to about 70 degrees C. to allow for the easy insertion of the test specimens. The specimens are inserted into the vial one at a time together with careful wetting of all surfaces with the cable filler grease. After all of the specimens have been inserted, the vials are loosely capped and placed in a 70 degree C. circulating air oven. Specimens are removed after 1, 2, and 4 weeks for subsequent OIT testing. After the 4 week point, all of the remaining specimens are removed from the cable filler grease and are wiped flee of cable filler grease with a tissue. They are then aged in an air oven at 90 degrees C. A sample is then removed after 4 weeks at 90 degrees C. (8 weeks of aging total). The initial, 1, 2, 4, and 8 week samples are then tested for OIT.
OIT testing is accomplished in a differential scanning calorimeter with an OIT test cell. The test conditions are: uncrimped aluminum pan; no screen; heat up to 200° C. under nitrogen, followed by a switch to a 50 milliliter flow of oxygen. Oxidation induction time (OIT) is the time interval between the start of oxygen flow and the exothermic decomposition of the test specimen. OIT is reported in minutes; the greater the number of minutes, the better the OIT. OIT is used as a measure of the oxidative stability of a sample as it proceeds through the cable filler grease exposure and the oxidative aging program. Relative performance in the grease filled cable applications can be predicted by comparing initial sample OIT to OIT values after 70° C. cable filler grease exposure and 90° C. oxidative aging.
Variables and results are set forth in the following Table.
______________________________________Percent by weight: Example 1 Example 2 Example 3______________________________________Antioxidant A 0.50 0.50 0.50 Antioxidant B 0.10 none none Antioxidant C none 0.10 none Polyethylene 99.40 99.40 99.50______________________________________
Examples 1 and 2 are found to provide superior retention of OIT through the 4 weeks of exposure to cable filler grease and during the subsequent oven aging when compared to example 3, demonstrating their effectiveness in the application.
|
An article of manufacture comprising (i) a plurality of electrical conductors, each surrounded by one or more layers of a composition comprising (a) one or more polyolefins and, blended therewith, (b) a mixture containing one or more alkylhydroxyphenylalkanoyl hydrazines and one or more defined functionalized hindered amines; and (ii) hydrocarbon cable filler grease within the interstices between said surrounded conductors.
| 7
|
CROSS-REFERENCE TO RELATED APPLIATIONS
STATEMENT REGARDING FEDERALLY
SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
The present invention relates to drilling pipe used in directional underground drilling, and the like, and in particular to an improved drilling pipe and method of fabrication of drilling pipe.
Directional drilling permits a bore hole to be cut through the earth with a curved trajectory. In such drilling, a steerable bit is attached to one end of length of drilling pipe. The drilling pipe is driven by a surface motor to rotate the bit and to provide a downward cutting pressure on the bit. The bore of the drilling pipe conducts water or drilling mud to the bit to clear it of earth and rock.
As the bit progresses beneath the surface of the earth, additional drilling pipe is attached to the exposed end of the previous drilling pipe to create a drilling string of increasing length. In order to allow connections of the drilling pipe to each other, the ends of the drilling pipe have threaded couplings. The threaded portions of the pipes are inset from the outer diameter of the pipe, necessitating an increased thickness of the pipe in the end regions.
One method of providing for this increased thickness is a forging of the pipe ends to greater wall thickness followed by a machining of the threads directly to the pipe. This process is expensive and time consuming.
In a second method, a separately machined and coupling is welded to the pipe to provide for the necessary thread interfaces. Normally a friction welding technique is used for this purpose to provide a high weld strength.
In friction welding, the coupling and pipe are rotated about their axes with respect to each other and then pressed together at an interface where the weld is to be formed. The friction between the parts generates heat and removes surface oxide providing for a fusion between the two materials. Weld flash produces a slight bulging at the interface between the two parts which may then be removed by the grinding operation.
In directional boring, the drill string may follow a curved radius on the order of 40 feet. When operating with such curved trajectories, the rotation of the drill string produces constantly changing stresses on the drilling pipes frequently causing failure of their welds.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a stress shielding element spanning the weld in a drilling pipe. The element modifies the stress to which the weld is exposed, substantially increasing its life. The stress shielding element is in the form of an internal sleeve including a notch for accommodating the weld flash from the inertial welding process. The present inventors have determined that the sleeve may have a reduced diameter so as not to interfere with the relative rotation of the two components during that welding process, while still providing the necessary stress shielding.
Specifically, the present invention provides a drilling pipe for directional boring including an annular elongate pipe element having a pipe axis and an inner diameter. An end coupling is welded at a weld face to a first end of the pipe element to have its axial bore aligned with the pipe axis. A first coupling portion of the end coupling extends outward from the end coupling along the pipe axis. The end coupling also has a stress spreader with an outer diameter substantially equal to the inner diameter extending into the pipe element across the weld face. A weld flash receiving groove is cut into the end coupling aligned with the weld face when the end coupling is welded at the weld face. The weld flash receiving groove is sized to receive weld flash from a friction welding of the end coupling to the first end of the pipe element.
Thus it is one object of the invention to prolong the life of a welded drilling pipe in a way that does not interfere with an inertial welding operation. The use of the weld flash receiving groove allows expansion of molten welding material into the groove area without interference with the welding process and permits the outer diameter of the stress spreader in other areas to couple with stresses in the pipe element.
The end coupling may include a second coupling portion, opposed first coupling portion, and extending into the tube along the tube axis. The stress spreader may include a third coupling portion attachable to the second coupling portion with the stress spreader extending into the tube from the end coupling across the weld point. The second and third coupling portions may be mating, tapered pipe threads.
Thus it is another object of the invention to provide a method of constructing the end coupling of the present invention providing a weld flash receiving grooves adjacent to a weld face. Constructing the end coupling of two separable parts simplifies machining of an undercut pocket for receiving weld flash.
It is another object of the invention to find an assembly method for the two components of the end coupling that provides for good stress transfer. The pipe threads having a naturally wedging action permit a close coupling between the end coupling and the stress spreader.
The foregoing objects and advantages of the invention will appear from the following description. In the description, references are made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made, therefore, to the claims for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a simplified schematic view of a boring operation showing the connection of drilling pipes, head to tail, to form a drill string connecting a drill bit to a surface motor for rotating the same;
FIG. 2 is a fragmentary view of an end of a drilling pipe and its component end coupling and pipe element, with cutaway portions showing the two parts before friction welding and after friction welding, and in the latter case, showing weld flash produced by the friction welding;
FIG. 3 is a cross sectional view taken along the drilling pipe of the present invention showing the end coupling separated from its stress spreader;
FIG. 4 is a cross sectional view similar to FIG. 3 of the end coupling assembled with its stress spreader and positioned within a pipe element prior to frictional welding;
FIG. 5 is a detailed view of the interface between the pipe element and the end coupling of FIG. 4 showing the weld flash receiving groove formed by the stress spreader and end coupling as is positioned beneath the weld face; and
FIG. 6 is a view similar to that of FIG. 4 showing an alternative embodiment of the invention wherein the end coupling and stress spreader are a single unit.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a directional boring rig 10 includes a surface unit 12 having a motor 14 for rotating a drill string 16 composed of interconnected drilling pipes 18 terminating in a directional drill bit 20. The drilling pipes 18 define a continuous central bore (not shown) that receive a cutting fluid from surface supply 22 and conducts the fluid to the drill bit 20. During directional boring, the drill string 16 follows a curved trajectory.
Referring now to FIG. 2, a prior art drilling pipe 18 includes a pipe element 19 formed of high tensile strength steel. The pipe element 19 is cut square to its axis 24 at cut pipe end 25 to abut a radially extending flange 26 of an end coupling 28, the latter having a central bore 30 aligned and communicating with the bore of the pipe element 19.
A threaded first coupling portion 31 of the end coupling 28 extends outward from the end coupling 28 along the axis 24 away from the pipe element 19. The threaded portion 31 may have either external or internal threading depending on the end of the pipe element 19 to which it is attached. To form the drill string (shown in FIG. 1), an end of the drilling pipe 18 with external threading is joined to an end of a second drilling pipe 18 with internal threading. The bore 30 extends through the threaded portion 31.
Generally, the threaded portion 31 has an outer diameter less than the outer diameter of the pipe element 19 or end coupling 28 so as to permit a smooth outer contour of the drill string 16 when several drilling pipes 18 are connected.
The end coupling 28 is welded to the pipe element 19 by frictional welding. In this process, end coupling 28 is rotated about axis 24 with respect to pipe element 19, and then the flange 26 is pressed against the cut pipe end 25 at a weld interface 32 so that friction and mechanical abrasion provide for a clean fusing of the materials of pipe element 19 and end coupling 28.
After welding is complete, the weld interface 32' is surrounded by weld flash 34 shown as a bulge extending on each side of the weld interface 32'. The weld flash 34 on the outside of the weld is removed by a machining operation.
Referring now to FIG. 3 in the present invention an improved end coupling 36 is provided having a similar threaded portion 31, bore 30, and weld flange 26 as the end coupling 28 of FIG. 2. End coupling 36 differs from the end coupling 28 of FIG. 2 in that the bore 30 toward the weld flange 26 includes a second coupling portion 38 consisting of internally cut tapered pipe threads. The pipe threads 38 are sized to receive a corresponding third coupling portion 40 consisting of externally threaded pipe threads on a stress spreader 42. Threads 38 and 40 permit the stress spreader 42 to be tightly attached to the end coupling 36 to extend axially away from threaded portion 31.
The stress spreader 42 is generally cylindrical in shape with a central bore 44 aligning with bore 30 when the stress spreader 42 and end coupling 36 are threaded together. When so assembled, and when the end coupling 36 is positioned for welding to pipe element 19 (as shown in FIG. 4), a contacting portion 46 of the outer diameter of the stress spreader 42 extends axially beyond the flange 26 and into the pipe element 19. The outer diameter of the contacting portion 46 is substantially equal to the inner diameter of the pipe element 19 with a clearance of approximately 0.0015". This clearance has been determined to provide sufficient clearance between the contacting portion 46 and the inner diameter of the pipe element 19 to permit the inertial welding of the pipe element 19 to the end coupling 36 while still allowing the stress spreader to function in increasing the strength of the drilling pipe 18'.
Referring now to FIGS. 3, 4, and 5, an axial counterbore 47 aligned with bore 30 is cut inside of radially extending flange 26. When the end coupling 36 is assembled to the pipe element 19 (as shown in FIGS. 4 and 5), the counterbore 47 provides an undercut beneath the flange 26. When stress spreader 42 is connected with the end coupling 36, the counterbore 47 is positioned over a reduced diameter section 48 of the stress spreader 42 together to form a weld flash receiving groove 50. The reduced diameter section 48 of the stress spreader 42 separates the threads 40 from the contacting portion 46.
The weld flash receiving groove 50 thus formed is centered about the weld interface 32 beneath flange 26 to receive weld flash 34 indicated by the dotted lines in FIG. 5. By receiving the weld flash 34, inertial welding may be accomplished without interference from the stress spreader 42.
Referring now to FIG. 4, a drilling pipe may be assembled by the following steps. First, end coupling 36 is threaded to stress spreader 42 so that the reduced diameter section 48 is positioned beneath flange 26. The stress spreader 42 is then inserted into pipe element 19 and end coupling 36 moved until flange 26 is an abutment with the cut pipe end 25. End coupling 36 is then rotated rapidly about common axis 24 with respect to the pipe element 19 and then pressed against pipe element 19 to form a frictional weld between flange 26 and cut pipe end 25 with flash 34 filling the weld flash receiving groove 50 formed as previously described. The outer flash 34 may then be removed by a grinding operation.
While the inventors do not wish to be bound to a particular theory, it is believed that the closed coupling between the end coupling 36 and the stress spreader 42 bridging the weld interface 32 serve to transmit certain tensile stresses to regions outside of the weld interface 32 or to stresses on the weld interface 32 to modes in which the weld has greater strength. The slight clearance between the contacting portion 46 of the stress spreader 42 and the interior dimension of the pipe element 19 permits frictional welding yet provides sufficient stress shielding to significantly increase strength of the welded assembly.
Referring now to FIG. 6, in an alternative embodiment, the stress spreader 42 is integrally formed with the end coupling 36 such as may be done by cutting the two from a single piece of bar stock on a metal lathe as will be understood in the art. Similarly, it will be recognized that the end coupling may be joined to the stress spreader 42 by a number of other techniques including interference fits such as press or shrink fits or with adhesives such as epoxy.
The above description has been that of a preferred embodiment of the present invention. It will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made.
|
An improved drilling pipe for directional boring uses a frictionally welded threaded coupling attached to pipe ends for connecting multiple pipes in a drill string. A stress spreader of the end coupling crosses the frictionally welded region to modify stresses on the weld. A weld flash receiving groove positioned beneath the weld allows the insert to be in place during the inertial welding operation and to be closely coupled to the interior pipe surfaces to receive forces therefrom.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/435,843, filed May 12, 2003, which is a continuation-in-part of copending U.S. patent application Ser. No. 10/215,815, filed Aug. 9, 2002, each of which is hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1) Field of the Invention
[0003] The present invention relates to apparatuses and methods for forming thermoplastic materials and, more specifically, to apparatuses and methods for bending thermoplastic sheets to form ducts, channels, arcs, spirals, and the like.
[0004] 2) Description of Related Art
[0005] Longitudinal passages such as ducts, channels, arcs, spirals, and the like are used to provide passageways for a wide variety of applications. For example, tubular ducts are widely used for air flow in aircraft environmental control systems. Similarly, ducts provide passageways for transporting gases for heating and ventilation in other vehicles and in buildings. Water distribution systems, hydraulic systems, and other fluid networks also often use ducts for fluid transport. In addition, solid materials, for example, in particulate form can be delivered through ducts and channels. A variety of longitudinal shapes can also be used as conduits in which electrical wires or other components are placed. Such longitudinal passages for the foregoing and other applications can be formed of metals, plastics, ceramics, composites, and other materials.
[0006] One conventional aircraft environmental control system utilizes a network of ducts to provide air for heating, cooling, ventilation, filtering, humidity control, and/or pressure control of the cabin. In this conventional system, the ducts are formed of a composite material that includes a thermoset matrix that impregnates, and is reinforced by, a reinforcing material such as Kevlar®, registered trademark of E.I. du Pont de Nemours and Company. The thermoset matrix is typically formed of an epoxy or polyester resin, which hardens when it is subjected to heat and pressure. Ducts formed of this composite material are generally strong and lightweight, as required in many aircraft applications. However, the manufacturing process can be complicated, lengthy, and expensive, especially for ducts that include contours or features such as beads and bells. For example, in one conventional manufacturing process, ducts are formed by forming a disposable plaster mandrel, laying plies of fabric preimpregnated with the thermoset material on the mandrel, and consolidating and curing the plies to form the duct. The tools used to mold the plaster mandrel are specially sized and shaped for creating a duct of specific dimensions, so numerous such tools must be produced and maintained for manufacturing different ducts. The plaster mandrel is formed and destroyed during the manufacture of one duct, requiring time for curing and resulting in plaster that typically must be removed or destroyed as waste. Additionally, the preimpregnated plies change shape during curing and consolidation and, therefore, typically must be trimmed after curing to achieve the desired dimensions. The jigs required for trimming and for locating the proper positions for features such as holes and spuds are also typically used for only a duct of particular dimensions, so numerous jigs are required if different ducts are to be formed. Like the tools used for forming the mandrels, the jigs require time and expense for manufacture, storage, and maintenance. Additionally, ducts formed of conventional thermoset epoxies typically do not perform well in certain flammability, smoke, and toxicity tests, and the use of such materials can be unacceptable if performance requirements are strict. Further, features such as beads typically must be post-formed, or added after the formation of the duct, requiring additional manufacture time and labor.
[0007] Alternatively, ducts can be formed of thermoplastic materials. A thermoplastic duct can be manufactured by cutting a sheet of thermoplastic material to a size and shape that corresponds to the desired dimensions of the duct, bending the sheet to the desired configuration, and joining longitudinal edges of the sheet to form a longitudinal joint or seam. For example, apparatuses and methods for forming thermoplastic ducts and consolidation joining of thermoplastic ducts are provided in U.S. application Ser. Nos. 10/216,110 and 10/215,833, titled “Thermoplastic Laminate Duct” and “Consolidation Joining of Thermoplastic Laminate Ducts,” both filed on Aug. 9, 2002 and assigned to the Assignee of the present invention. Such thermoplastic ducts can be formed by retaining the thermoplastic sheet in the bent configuration until the ends are joined, and then releasing the duct so that the resulting joint continues to restrain the duct in the bent configuration. However, stresses induced in the thermoplastic material during bending can cause the duct to deform or distort from the desired configuration after joining, e.g., when released from the joining apparatus.
[0008] Thus, there exists a need for improved apparatuses and methods for forming a thermoplastic sheet to correspond generally to a desired configuration in a substantially unstressed condition. The method should not require the laying of individual plies on a disposable plaster mandrel. Preferably, the method should be compatible with thermoplastic ducts, including reinforced thermoplastic ducts formed from flat sheets, which provide high strength-to-weight ratios and meet strict flammability, smoke, and toxicity standards.
SUMMARY OF THE INVENTION
[0009] The present invention provides an apparatus and method for forming sheets to desired configurations. The sheets can be formed to the desired configuration of a finished shape such as an arc, channel, or spiral. Alternatively, each sheet can be formed as a preform that generally corresponds to the desired configuration of a finished shape such as a duct and is subsequently joined to form the finished shape. Joining can be accomplished by consolidation joining. The sheets can be formed from thermoplastic materials, such as flat sheets of reinforced thermoplastic laminate that are lightweight, strong, and perform well in flammability, smoke, and toxicity tests.
[0010] According to one embodiment of the present invention, the apparatus includes a rotatable roller, an elastically flexible shaper, and a heater. The apparatus can be used to hold the sheet in a predetermined configuration while the heater is used to heat the sheet. The shaper receives the thermoplastic sheet on one side so that rotation of the roller advances the shaper around the roller to bend the thermoplastic sheet. An index feature can be provided on the shaper for engaging the thermoplastic sheet so that the adjustment of the index feature toward the roller advances the thermoplastic sheet around the roller. The apparatus can also include a second shaper that is disposed on the thermoplastic sheet so that the second shaper is bent between the sheet and the roller and advancement of the second shaper toward the roller urges the thermoplastic sheet radially outward from the roller. Longitudinal members can be configured to adjust radially toward the roller to bend the thermoplastic sheet to a predetermined configuration.
[0011] According to another embodiment of the present invention, the apparatus includes at least two support members that extend, for example, in a longitudinal direction, to define at least one space therebetween. A shaper is configured to be disposed with one side against the support members so that the shaper extends across the at least one space. The shaper receives the thermoplastic sheet on a side opposite the support members and bends partially around the members, which can be adjustable. A heater is configured to heat the thermoplastic sheet to a processing temperature less than a glass transition temperature of the thermoplastic member and within about 70° F. of the glass transition temperature.
[0012] The present invention also provides a method of forming a thermoplastic sheet. According to one embodiment of the present invention, the thermoplastic sheet is disposed on a first side of a shaper. A longitudinal roller connected to the shaper is then rotated, for example, by at least one revolution, to advance the shaper circumferentially around the roller so that the thermoplastic sheet is disposed between the roller and the shaper and bent to a predetermined shape. Longitudinal members can be radially adjusted toward the roller to bend the thermoplastic sheet to a predetermined configuration. The shaper can be advanced toward the roller so that the shaper adjusts radially outward from the roller to define a maximum size for the thermoplastic sheet, for example, so that an index feature of the shaper engages the sheet and adjusts the sheet radially outward from the roller. According to one aspect, a second shaper is disposed on the sheet so that the second shaper is advanced around the roller between the sheet and the roller. The second shaper can be adjusted radially outward from the roller to urge the thermoplastic sheet to a predetermined configuration. The thermoplastic sheet is heated to a processing temperature, for example, within about 70° F. of a glass transition temperature of the thermoplastic sheet. The thermoplastic sheet can be cooled in the apparatus to a temperature below about 70° F. less than the glass transition temperature before the sheet is removed.
[0013] According to another embodiment of the present invention, at least two support members are provided with a space therebetween. A shaper is disposed on the support members so that the shaper extends across the space and bends partially around the support members to a predetermined shape. A thermoplastic sheet is disposed on the shaper and heated to a processing temperature. The thermoplastic sheet can be cooled to a temperature below about 70° F. less than the glass transition temperature of the thermoplastic sheet while the thermoplastic sheet and the shaper are disposed on the support members. The support members can be adjustable. According to one aspect, a second shaper can be disposed on the thermoplastic sheet opposite the first shaper and some of the support members can be adjusted in a direction toward the sheet so that the sheet is bent between the support members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0015] FIG. 1 is a perspective view illustrating a forming apparatus according to one embodiment of the present invention;
[0016] FIG. 2 is a perspective view illustrating a formed sheet according to one embodiment of the present invention;
[0017] FIG. 2A is a perspective view illustrating a formed sheet according to another embodiment of the present invention;
[0018] FIG. 3 is a section view illustrating the forming apparatus of FIG. 1 , shown with the shaper in a first position;
[0019] FIG. 4 is a section view illustrating the forming apparatus of FIG. 1 , shown with the shaper advanced to a second position;
[0020] FIG. 5 is a section view illustrating a forming apparatus according to another embodiment of the present invention, shown with a second shaper disposed on the sheet and both shapers advanced to the second position;
[0021] FIG. 6 is a section view illustrating a forming apparatus according to another embodiment of the present invention, shown with the shaper in a first position and with longitudinal members in a first position;
[0022] FIG. 7 is a section view illustrating the forming apparatus of FIG. 6 , shown with the shaper in a second position and with the longitudinal members in a second position;
[0023] FIG. 8 is a perspective view illustrating a forming apparatus according to another embodiment of the present invention;
[0024] FIG. 9 is a section view illustrating the forming apparatus of FIG. 8 , shown with a thermoplastic sheet and a shaper disposed on the support members;
[0025] FIG. 10 is a section view illustrating a forming apparatus with a second set of support members, according to another embodiment of the present invention; and
[0026] FIG. 11 is a perspective view illustrating a forming apparatus according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0028] Referring now to FIG. 1 , there is shown a forming apparatus 10 for forming a formed sheet 60 , such as the one shown in FIG. 2 , from a thermoplastic member, such as a thermoplastic sheet 50 . Forming generally refers to bending the thermoplastic member to a bent or curved configuration and processing the member, for example, using heat, so that the member generally remains in a desired configuration when unrestrained. The formed sheet 60 can be a finished shape, such as an arc, spiral, channel, and the like. Alternatively, the formed sheet 60 can be used as a preform, i.e., a formed shape that is joined or otherwise processed to form a finished shape and remains in the desired configuration when unrestrained. For example, the flat sheet 50 can be bent and heated to form the cylindrical formed sheet 60 , shown in FIG. 2 , which extends from a first end 62 to a second end 64 and defines a passage 66 . Longitudinal edges 68 , 70 of the formed sheet 60 can define a gap therebetween, can be overlapped, or can be joined to form a seam or joint. If used as a preform, the longitudinal edges 68 , 70 of the formed sheet 60 can be joined to form a duct which, when unrestrained, defines a partially closed cylindrical shape. The preform can be formed to have a diameter slightly larger or smaller than the desired diameter of the duct. Thereafter, the formed sheet 60 can be subjected to a compressive or expansion force for holding the formed sheet during subsequent processing, such as joining, to arrive at the desired configuration of the duct. The longitudinal edges 68 , 70 , or other portions of the formed sheet 60 , can be joined using adhesives, heat, or other joining methods. For example, joining can be achieved by applying heat and pressure to the edges 68 , 70 to form the seam. As the thermoplastic material of the formed sheet 60 is heated above its glass transition temperature, the material becomes plastic and the pressure consolidates and joins the interface. Joining can be performed by manual or automated methods, for example, as described in U.S. application Ser. No. 10/215,833, titled “Consolidation Joining of Thermoplastic Laminate Ducts,” the entirety of which is incorporated herein by reference. Thus, as used throughout this application, the term “formed sheet” refers generally to a sheet that has been formed to a curved or bent configuration, including sheets that are formed to a final desired configuration without joining, preforms that require joining or other processing to achieve the final configuration, and partially closed shapes that are formed by joining such preforms.
[0029] The shape of the formed sheet 60 is determined by projecting the desired shape of the formed sheet 60 onto the flat sheet 50 . Although the ends 62 , 64 and edges 68 , 70 of the formed sheet 60 are shown to be straight and parallel in FIG. 2 , the formed sheet 60 can alternatively be straight, curved, tapered, or otherwise contoured. For example, there is shown in FIG. 2A an alternative formed sheet 60 , which defines a non-uniform, or transitional, radius that tapers between the ends 62 , 64 . The sheet 50 and, hence, the formed sheet 60 can also define a variety of features such as holes, for example, for connecting spuds, brackets, and the like to the formed sheet 60 . Methods and apparatuses for forming sheets and for determining geometric patterns that correspond to ducts are provided in U.S. application Ser. No. 10/216,110, titled “Thermoplastic Laminate Duct,” the entirety of which is incorporated herein by reference. It is also appreciated that marks can be provided on the formed sheet 60 , for example, to accurately identify the location of post-formed features such as beads, bells, and assembly details or to facilitate the manufacture or assembly of the formed sheet 60 , as also provided in the application entitled “Thermoplastic Laminate Duct.”
[0030] Preferably, the formed sheet 60 is formed of a thermoplastic sheet or of a composite laminate that includes a thermoplastic matrix and a reinforcing material. Thermoplastic materials are characterized by a transition to a plastic state when heated above a glass transition temperature. For example, the formed sheet 60 can be formed of polyetherimide (PEI) or polyphenol sulfide (PPS), both of which can be thermoplastic. Thermoplastic PEI is available under the trade name Ultem®, a registered trademark of General Electric Company. According to one embodiment of the present invention, each formed sheet 60 is comprised of a composite material that includes a matrix of thermoplastic PEI that is reinforced with a reinforcing material such as carbon, glass, or an aramid fabric such as a Kevlar® aramid, or fibers of such a material. Alternatively, the formed sheet 60 can be formed of other thermoplastic materials, which can be reinforced by other reinforcing materials, or can include no reinforcing materials.
[0031] The formed sheet 60 can be used in numerous applications including, but not limited to, environmental control systems of aerospace vehicles. For example, the formed sheet 60 can be used as a preform that is used to form a duct, as described above. The resulting duct can be used as a passage in a system though which air is delivered to provide heating, cooling, ventilation, and/or pressurization of an aircraft cabin. Alternatively, the formed sheet 60 can be used without further processing, for example, as a channel or conduit for wires or cables. The ends of the formed sheet 60 can be connected to other channels, ducts, tubes, formed sheets, or other devices such as ventilators, compressors, filters, and the like. Multiple formed sheets 60 can be connected so that a longitudinal axis of each formed sheet 60 is configured at an angle relative to the longitudinal axis of the adjoining formed sheet(s). Thus, the formed sheet 60 can be connected to form an intricate passage system (not shown) that includes numerous angled or curved passages for accommodating the various devices connected by the passage system and for meeting layout restrictions as required, for example, on an aircraft where space is limited. In addition, formed sheets according to the present invention can be used to form barriers or walls that are used to separate lighted areas from darker areas, people from secure areas, or cold from warm areas. Further, the formed sheets can provide visual barriers.
[0032] The forming apparatus 10 shown in FIG. 1 includes a roller 12 and a shaper 14 , both of which are provided on a frame 16 . The roller 12 extends longitudinally and is supported by the frame 16 such that the roller 12 is rotatable. The roller 12 can be at least partially surrounded by an insulative heat shroud 18 , which extends parallel to the roller 12 and facilitates the heating of a space 20 within the shroud 18 by a heater 22 . The heater 22 can be any of various types of heaters such as electric and gas heaters, and can be positioned on either end of the shroud 18 or along the longitudinal length of the shroud 18 . The heater 22 can be configured to heat the sheet 50 through the shroud 18 or by heating air that is blown into the space 20 within the shroud 18 . Alternatively, the apparatus 10 can be used without the shroud 18 , and the heater 22 can be configured to heat the space around the roller 12 . The roller 12 can also be heated directly by a heater, for example, by an electric heater disposed within the roller 12 .
[0033] The shaper 14 is an elastically flexible laminar sheet, i.e., a sheet that can be bent from its initial configuration during forming without undergoing any appreciable plastic deformation so that the shaper 14 can return to its initial configuration after processing and can be re-used. The shaper 14 can be formed of a variety of materials, including, for example, a sheet of stainless steel which is about 0.015 inches thick. In the illustrated embodiment, the shaper 14 is configured so that a first edge 24 is parallel to the roller 12 and connected to the roller 12 , though in other embodiments, the first edge 24 can be oriented in other configurations and need not be connected to the roller 12 . The shaper 14 is slidably adjustable relative to the roller 12 so that a second edge 26 of the shaper 14 opposite the first edge 24 is adjustable between first and second positions. In the first position, the shaper 14 extends from the roller 12 as shown in FIGS. 1 and 3 . In the second position, the second edge 26 of the shaper 14 is adjusted toward the roller 12 and the shaper 14 is at least partially bent around the roller 12 , as shown in FIG. 4 . The shaper 14 can engage tracks 17 or other features provided on the frame 16 , which maintain the second edge in a parallel arrangement with the roller 12 . By the term “advanced” it is generally meant that a portion of the shaper 14 that is not bent around the roller 12 is adjusted toward the roller 12 to increase the portion of the shaper 14 that is bent around the roller 12 , for example, by increasing the diameter of the portion bent around the roller 12 or by further extending the shaper 14 circumferentially around the roller 12 . If the apparatus 10 is configured as shown in FIGS. 3 and 4 , the shaper 14 can be advanced by adjusting the second edge 26 toward the roller 12 .
[0034] Adjustment of the shaper 14 to the second position can be accomplished by rotating the roller 12 in a first direction, clockwise as shown in FIGS. 3 and 4 , so that the first edge 24 of the shaper 14 rotates around at least part of the roller 12 , the shaper 14 bends, and the second edge 26 of the shaper 14 is advanced toward the roller 12 . As the roller 12 is rotated in a second direction, counterclockwise in FIGS. 3 and 4 , the shaper 14 unrolls from the roller 12 and the second edge 26 is retracted from the roller 12 . The roller 12 can be actuated by an automated device such as an electric motor or the roller can be manually actuated, for example, by a crank 13 that is rotated by an operator. Alternatively, the roller 12 can be configured to rotate freely so that the shaper 14 can be advanced toward the roller 12 , either manually or by an actuator, thereby rotating the roller 12 and rolling the shaper 14 around the roller 12 . In another embodiment, the first edge 24 of the shaper 14 is not connected to the roller 12 , and the shaper 14 can be advanced into the shroud 18 so that the shaper 14 bends around the roller 12 , which can remain stationary. In either case, the second edge 26 of the shaper 14 can be adjusted relative to the roller 12 while the roller 12 is held in place so that a portion of the shaper 14 that is disposed around the roller 12 is adjusted radially outward from the roller 12 to a desired configuration, generally defining a maximum circumference of the sheet 50 , as described further below.
[0035] The extent to which the shaper 14 is rolled around the roller 12 can be determined according to the desired shape of the formed sheet 60 . For example, the shaper 14 and thermoplastic sheet 50 can be advanced slightly more than one revolution around the roller 12 so that the resulting formed sheet 60 defines a generally cylindrical shape with overlapping longitudinal edges that can be joined to form a tubular duct. Alternatively, the sheet 50 can be rotated less than one revolution around the roller 12 to form an arc or, channel, or spiral, or the sheet 50 can be rotated more than one revolution to form a spiral shape.
[0036] During operation, the thermoplastic sheet 50 is disposed on the shaper 14 as shown in FIG. 1 so that the sheet 50 is rolled around the roller 12 between the shaper 14 and the roller 12 . While the sheet 50 is supported between the shaper 14 and the roller 12 , the heater 22 can be used to heat the sheet 50 , e.g., by connecting a power supply (not shown) to the heater 22 and energizing the heater 22 . Preferably, the sheet 50 is heated to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 . For example, the processing temperature can be between about 5° F. and 70° F. less than the glass transition temperature. In the case of PEI, which has a glass transition temperature of about 417° F., the sheet 50 can be heated to a processing temperature of between about 347° F. and 412° F. The sheet 50 can be maintained at the processing temperature for a predetermined period, such as about 10 minutes, after which the heater 22 can be turned off and the formed sheet 60 is preferably at least partially cooled in the apparatus 10 . The formed sheet 60 can be removed from the apparatus 10 through openings 28 , 30 at the longitudinal ends of the heat shroud 18 , or the heat shroud 18 can be configured to disassemble or otherwise open to facilitate the removal of the formed sheet 60 . Alternatively, the formed sheet 60 can be removed by reversing the load process, i.e., unwinding the formed sheet 60 from the heat shroud 18 in a direction opposite to the direction in which the sheet 50 is inserted so that the formed sheet 60 unwinds around the outside of the heat shroud 18 .
[0037] The thermoplastic sheet 50 can be a precut sheet that corresponds to the desired dimensions of the formed sheet 60 so that the formed sheet 60 is trimmed only slightly or not at all after processing in the apparatus 10 . Alternatively, the thermoplastic sheet 50 can be part of a long continuous sheet, such as a roll of thermoplastic laminar material, and the sheet 50 can be cut during or after processing. In either case, the shaper 14 can include an index feature that engages a portion of the sheet 50 so that the adjustment of the sheet 50 into the apparatus 10 can be easily controlled and/or measured. For example, the shaper 14 can include a gate 32 at the second edge 26 , as shown in FIGS. 1, 3 , and 4 . The sheet 50 can be disposed on the shaper 14 so that an edge of the sheet 50 rests against the gate 32 , and the gate 32 prevents the sheet 50 from slipping relative to the shaper 14 when the shaper 14 is advanced around the roller 12 .
[0038] According to one embodiment of the present invention, the sheet 50 is disposed on the shaper 14 , and the roller 12 is rotated through a predetermined angle of rotation. The roller 12 can be rotated using the actuator or crank 13 , or the second edge 26 of the shaper 14 can be urged toward the roller 12 to rotate the roller 12 . The roller 12 is then held at the desired rotational position while the second edge 26 of the shaper 14 is adjusted toward or away from the roller 12 to increase or decrease the diameter of a generally cylindrical portion of the shaper 14 bent around the roller 12 . By keeping the second edge 26 parallel to the first edge 24 , a constant radius can be imparted to the formed sheet 60 . Alternatively, the second edge 26 can be positioned in a non-parallel, or skewed, relationship relative to the first edge 24 so that a non-uniform, or transitional radius, is imparted to the formed sheet 60 , i.e., the radius at one end 66 is different than the other end 64 of the formed sheet 60 .
[0039] The shaper 14 also adjusts the sheet 50 to a desired configuration. For example, the sheet 50 can be engaged by the gate 32 , and the gate 32 can be adjusted toward the roller 12 so that substantially all of the sheet 50 is bent around the roller 12 . Thus, if the sheet 50 is long enough to extend substantially from the first edge 24 of the shaper 14 to the gate 32 , the sheet 50 will be disposed against the shaper 14 when the shaper 14 is bent around the roller 12 . The length of the sheet 50 can be selected according to the desired size of the finished shape, and the gate 32 can be adjustable on the shaper 14 so that the shaper 14 can be used for sheets 50 of different lengths, the length of each sheet 50 generally determining the circumferential size of the formed sheet 60 . If the sheet 50 is longer than the circumference of the formed sheet 60 , the formed sheet 60 can be trimmed after forming.
[0040] A second shaper 34 similar to the first shaper 14 can also be disposed on the thermoplastic sheet 50 so that the second shaper 34 is rolled around the roller 12 between the sheet 50 and the roller 12 , as shown in FIG. 5 . The second shaper 34 can be slidably adjustable toward the roller 12 , as described above in connection with the first shaper 14 . Thus, the first shaper 14 can be advanced a predetermined distance toward the roller 12 to define a maximum outer dimension of the formed sheet 60 , and the second shaper 34 can be advanced a predetermined distance toward the roller 12 to urge the sheet 50 radially outward toward the first shaper 14 . The shapers 14 , 34 can be adjusted radially outward by advancing the rollers 14 , 34 after the roller 12 has been rotated to a desired position and held in that position. Alternatively, the shapers 14 , 34 can be adjusted radially outward by advancing the shapers 14 , 34 while the roller 12 is being rotated, the shapers 14 , 34 being advanced at a rate faster than the speed of a periphery of the roller 12 . The second shaper 34 can be connected to the roller 12 or the first shaper 14 , or the second shaper 34 can be connected to neither. In the illustrated embodiment, however, the second shaper 34 is also attached to the roller 12 , albeit at a location spaced circumferentially from the location at which the first shaper 14 is attached to the roller 12 so that the sheet 50 may be disposed therebetween. Additionally, the second shaper 34 can have a gate 35 or other index feature for engaging the sheet 50 . As shown, for example, the gate 35 of the second shaper 34 may extend toward the first shaper 14 such that the sheet 50 is retained therebetween.
[0041] In another embodiment of the present invention, the apparatus 10 includes one or more radially adjustable members 40 , as shown in FIGS. 6 and 7 . Each member 40 can be a longitudinal member such as a rod, a shoe, or the like that extends generally parallel to the roller 12 . The members 40 are configured to be adjusted relative to the roller 12 to provide support to the shaper 14 and the sheet 50 . The members 40 can be adjusted to a first position, shown in FIG. 6 , so that the members 40 do not interfere with the entry and bending of the shaper 14 and sheet 50 around the roller 12 . The members 40 can then be adjusted toward the roller 12 to bias the shaper 14 and the sheet 50 to a particular configuration. For example, if the shaper 14 and sheet 50 do not maintain a cylindrical shape when bent around the roller 12 , the members 40 can be actuated radially inwards, as shown in FIG. 7 , to engage the shaper 14 and urge the shaper 14 to the desired configuration. The members 40 can also be used to bend the shaper 14 to other shapes, including shapes with flattened portions or complex curves. Any number of members 40 can be provided in the apparatus 10 , and the members 40 need not be straight or extend the entire length of the apparatus 10 . Further, the members 40 can be positioned within the shaper 14 , i.e., between the sheet 50 and the roller 12 , so that the members 40 can be actuated outward toward the sheet 50 and shaper 14 .
[0042] FIGS. 8 and 9 illustrate an alternative forming apparatus 110 in which a shaper 114 , similar to the shaper 14 described above, is supported on a plurality of support members 140 that are supported by a frame 116 . The support members 140 can be longitudinal members such as rods or other shapes that are arranged in a generally parallel configuration, as shown in FIG. 8 , so that the members 140 define spaces 142 therebetween. In other embodiments, the support members 140 can be arranged in other configurations, in which the support members 140 need not be parallel. A heater 122 can be provided within each member 140 or elsewhere in the apparatus 110 , and the apparatus 110 can be partially or completely enclosed by an insulative shroud 118 . The thermoplastic sheet 50 is disposed on a first side of the shaper 114 , and a second side of the shaper 114 is disposed against the members 140 so that the shaper 114 extends across the spaces 142 between the members 140 and so that the sheet 50 can bend between the members 140 , as shown in FIG. 9 . The shaper 114 and the sheet 50 can be bent by gravity, or opposing support members 144 can be provided, as shown in FIG. 10 , for urging the sheet 50 to a desired configuration. A second shaper 134 can also be provided on the sheet 50 opposite the first shaper 114 , as shown in FIG. 10 , i.e., between the sheet 50 and the members 144 .
[0043] Each of the members 140 , 144 can be adjustable in position, for example, in a direction transverse to the longitudinal direction of the members 140 , 144 . Thus, as shown in FIG. 10 , each of the members 140 , 144 can be adjusted in any direction to determine the shape of the formed sheet 60 . The members 140 , 144 can be mounted on tracks or other adjustable supporting devices, and each member 140 , 144 can be adjusted manually, or actuators can be provided for such adjustment. For example, FIG. 10 illustrates a plurality of actuators 146 , each of which is configured to extend or retract a respective one of the members 140 , 144 toward or away from the sheet 50 .
[0044] During one typical method of operation, the shaper 114 is disposed on the members 140 , the sheet 50 is disposed on the shaper 114 , the second shaper 134 is disposed on the sheet 50 , and the members 140 , 144 are adjusted to a desired configuration. The heater 122 is used to heat the sheet 50 , preferably to a processing temperature that is less than the glass transition temperature of the thermoplastic material of the sheet 50 , as described above. The sheet 50 can be maintained at the processing temperature for a predetermined period, after which the heater 122 can be turned off. Preferably, the formed sheet 60 is at least partially cooled in the apparatus 110 . The formed sheet 60 is then removed from the apparatus 110 .
[0045] The support members 140 can define different shapes than that shown in FIGS. 8-10 . For example, as shown in FIG. 11 , an apparatus 110 a can include one or more rod- or tube-shaped support members 140 a defining ends that extend from a frame 116 a and upon which a shaper 114 a can be disposed. The shaper 114 a can extend perpendicular to the longitudinal direction of the support member 140 a , and the sheet 50 can be disposed on the shaper 114 a . Further, the shaper 114 a and, hence, the sheet 50 can be elastically deformed to a compound contour, i.e., bent about more than one axis. For example, as shown in FIG. 11 , the shaper 114 a can define a partial spherical surface.
[0046] As described above, the edges 68 , 70 or other portions of the formed sheet 60 can be joined, for example, by consolidation joining. Further, the formed sheet 60 can be post-formed to provide additional contours or features, such as bells, beads, and the like. A discussion regarding the formation of features such as bells and beads through post-forming, i.e., after the forming and/or the consolidation joining of the sheet, is provided in U.S. application Ser. No. 10/215,780, titled “Post-Forming of Thermoplastic Ducts” filed Aug. 9, 2002, which is assigned to the Assignee of the present invention and the entirety of which is incorporated herein by reference. It is also appreciated that marks can be provided on the thermoplastic sheet, for example, to accurately identify the location of such post-formed features or to facilitate the manufacture or assembly of the formed sheets, as provided in the application entitled “Thermoplastic Laminate Duct.”
[0047] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, it is appreciated that each of the components of the described apparatuses can be formed of a variety of materials such as aluminum, steel, and alloys thereof, and each of the working surfaces of the apparatuses can include a low friction layer or release layer, e.g., Teflon®, registered trademark of E.I. du Pont de Nemours and Company. The release layer can be a durable layer of material or a release agent that is wiped or sprayed periodically onto the working surfaces. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
|
There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims under 35 U.S.C. §119(a) the benefit of Korean Patent Application No. 10-2012-0027221, filed on Mar. 16, 2012, the entire contents of which are incorporated herein by reference.
BACKGROUND
(a) Technical Field
The present disclosure relates to a piston ring for engine wherein low friction Si-DLC is coated on the peripheral surface of the piston ring to reduce friction loss in an engine cylinder and to improve fuel efficiency, and a method for manufacturing thereof.
(b) Background Art
A piston ring is a pair of rings that fits into a groove on the outer diameter of a piston to maintain air tightness between a piston of a vehicle engine and inner cylinder wall, and to prevent entering lubricating oil to a combustion chamber by scraping out the lubricating oil of the cylinder wall.
FIG. 1 is a drawing representing coating condition of the existing piston ring for engine. In this conventional piston ring design, the piston ring has difficulty maintaining durability due to its low friction efficiency. Generally, Cr (Chrome) plating 30 or nitriding (gas nitriding) is being used on the peripheral surface of the piston ring 10 , and recently, due to high fuel cost and CO 2 regulation, various surface treatment techniques including CrN (Chrome Nitride) are also becoming more popular for reducing friction loss and improving durability.
Furthermore, methods like DLC (Diamond Like Carbon), which is an intermediate phase of diamond and graphite, and has low friction coefficient of graphite, high rigidity of diamonds and excellent chemical resistance, can further reduce friction loss of the engine when it is applied to the peripheral surface of the piston ring and can improve fuel efficiency of a vehicle in the end. However, the friction and durability of DLC becomes worse when it is exposed to higher temperatures for a long period of time, and coating is exfoliated due to high residual stress in the coating as the coating becomes thicker.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF THE DISCLOSURE
The present invention has been made in an effort to solve the above-described problems associated with prior art. It is an object of the present invention to provide a piston ring for an engine, which provides low friction properties and high durability at the same time by coating Si-DLC (Silicon doped Diamond Like Carbon) on the peripheral surface of the piston ring to reduce friction loss in an engine cylinder and to improve fuel efficiency.
In order to accomplish the above objectives, the piston ring of the present invention is characterized by comprising: a chromium (Cr) coating layer coated on the surface of a base material; a chromium nitride (CrN) coating layer coated on the Cr coating layer; and a Si-DLC coating layer, which is formed on the CrN coating layer, and alternately laminated with low content layers containing a first Si component of about 3 at % or less (not including 0 (zero)) and high content layers containing a second Si component of about 3˜10 at %.
The low content layer and the high content layer may be characterized as having a thickness of 50 nm or less (not including 0 (zero)), respectively. Furthermore, the high content layer is in contact with an inner cylinder wall due to the coating being located on the outer-most layer of the Si-DLC coating layer.
The Si-DLC coating layer may be formed by a chemical reaction of hydrocarbon gas (C x H y ) and TMS (Tetra-methylsilane, Si(CH 3 ) 4 ) gas, or hydrocarbon gas and HMDSO (Hexamethyldisiloxane, O(Si(CH 3 ) 3 ) 2 ) gas. In addition, the Cr coating layer and the Si-DLC coating layer may be coated only on the outer peripheral surface of the base material contacted with the inner cylinder wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention will now be described in detail with reference to certain exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a drawing representing conventional coating conditions of the existing piston ring for engine;
FIG. 2 is a drawing representing the piston ring for engine according to an exemplary embodiment of the present invention;
FIG. 3 is a drawing representing a cross section of the coating of the piston ring for engine illustrated in FIG. 2 ;
FIG. 4 is a device for manufacturing the piston ring for engine illustrated in FIG. 2 ; and
FIGS. 5 to 7 are drawings comparing performances of Examples and Comparative Examples of the present invention.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
Hereinafter, a piston for engine and a method for manufacturing thereof according to the preferred embodiments of the present invention now will be described in detail with reference to the accompanying drawings.
It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, plug-in hybrid electric vehicles. As referred to herein, a hybrid vehicle is a vehicle that has two or more sources of power, for example both gasoline-powered and electric-powered vehicles.
FIG. 2 is a drawing representing a piston ring for engine according to an exemplary embodiment of the present invention, and FIG. 3 is a drawing representing a cross section of the coating of the piston ring for engine illustrated in FIG. 2 .
The piston ring of the illustrative embodiment of the present invention includes a Cr coating layer 200 coated on the surface of a base material 100 , and a Si-DLC coating layer 600 , which is coated on the outer-most layer of the base material 100 , and alternately mixed with low content layers 610 containing a first Si component of about 3 at % or less (not including 0 (zero)) and high content layers 630 containing a second Si component of about 3˜10 at %. The exemplary piston ring of the illustrative embodiment of the present invention also includes a CrN coating layer 400 coated between the Cr coating layer 200 and the Si-DLC coating layer 600 .
The piston ring of the illustrative embodiment of the present invention consisting of the structure described above reduces friction loss of the piston ring and improves fuel efficiency by about 0.2˜0.5% since friction coefficient of the Si-DLC is 23% lower than Cr plating and nitriding and 11% lower than CrN. Additionally, oil film destruction can be suppressed and durability of the piston ring can be improved since resistance to scuffing of the Si-DLC is 50% or more better than Cr plating and nitriding and 30% or more better than CrN. Further, the low-friction properties and high temperature wear resistance of the DLC can be improved by doping Si on the DLC, and the durability of the piston ring can be improved since a Cr+CrN sub-multi-layer is provided in case the Si-DLC is worn away.
Meanwhile, the Si-DLC coating layer 600 is characterized that the thickness of the low content layer 610 and the high content layer 630 may be 50 nm or less (not including 0 (zero)), respectively, and preferably, the thickness of the low content layer 610 and the high content layer 630 are same.
The high content layer 630 can improve durability and reduce friction but has weak rigidity. Therefore, in order to make up for its weak rigidity, a low content layer 610 having lower content of a second Si component than the high content layer 630 is formed together one on top of the other alternately, and in this case, it is preferred to form the low content layer 610 and the high content layer 630 with the same thickness to ensure the piston ring has an uniform rigidity over the entire region.
The low content layer 610 and the high content layer 630 are alternately laminated one by one from the CrN coating layer 400 , and the high content layer 630 having excellent durability and friction reduction is coated on the outer-most layer of the Si-DLC coating layer 600 to be in contact with the inner cylinder wall. As a result, the Si-DLC coating layer 600 can maintain its low friction and durability even at higher temperature according to the Si content ratio.
Meanwhile, the Si-DLC coating layer 600 may be formed by a chemical reaction of hydrocarbon gas (C x H y ) and TMS (Tetra-methylsilane, Si(CH 3 ) 4 ) gas, or hydrocarbon gas and HMDSO (Hexamethyldisiloxane, O(Si(CH 3 ) 3 ) 2 ) gas. Furthermore, it may also be effective to coat the Cr coating layer 200 and Si-DLC coating layer 600 only on the peripheral surface of the base material 100 contacted with the inner cylinder wall.
Thus, the Si-DLC applied in the present invention is an effective coating material to improve low friction, wear resistance and resistance to scuffing of the piston ring since it has a lower friction coefficient and higher rigidity than CrN, and its low friction and durability can be maintained even at higher temperature unlike a general DLC coating (e.g., due to the present invention's low content layer 610 and the high content layer 630 according to the Si content ratio).
FIG. 4 is a device for manufacturing the piston ring for engine illustrated in FIG. 2 , and the method for manufacturing the piston ring for engine of the present invention is as follows.
The method for manufacturing the piston ring for engine according to the present invention includes a Cr coating step of coating a Cr coating layer 200 on a base material 100 of the piston ring; and a Si-DLC coating step of coating a Si-DLC coating layer 600 by a chemical reaction of hydrocarbon gas (C x H y ) and TMS (Tetra-methylsilane, Si(CH 3 ) 4 ) gas, or hydrocarbon gas and HMDSO (Hexamethyldisiloxane, O(Si(CH 3 ) 3 ) 2 ) gas, and to have low content layers 610 containing a first Si component of about 3 at % or less (not including 0 (zero)) and high content layers 630 containing a second Si component of about 3˜10 at %.
Herein, the method may further comprises a CrN coating step of coating a CrN coating layer 400 by chemically reacting N 2 gas with sputtered Cr ions between the Cr coating step and the Si-DLC coating layer. Further, in the Si-DLC coating step, the Si content may be controlled by controlling the injection amount of TMS or HMDSO gas.
Namely, the low content layer 610 can be controlled to contain the first Si component in an amount of about 3 at % or less (not including 0 (zero)) and the high content layer 630 can be controlled to contain the second Si component in an amount of about 3˜10 at %.
Specifically, as shown in FIG. 3 , the Si-DLC coating applied in the present invention is coated on the peripheral surface of the base material 100 of the piston ring into a multi-layer structure of Cr (PVD, Physical Vapor Deposition method)+Corn (PVD method)+Si-DLC (PACVD method), and the outer-most layer of the Si-DLC is coated to alternately laminate the high content layers 630 containing the second Si component of about 3˜10 at % and the low content layers 610 containing the first Si component of about 3 at % or less (not including 0 (zero)) one by one from the CrN coating layer 400 .
At this time, the low content layer 610 and the high content layer 630 may be coated to the thickness of 50 nm or less (not including 0 (zero)), respectively, and the low content layer 610 and the high content layer 630 may be coated to the same thickness, preferably.
The piston ring of the present invention may be coated in a vacuum coating device as illustrated in FIG. 4 , which uses a Cr target and a process gas of Ar, N 2 and hydrocarbon gas (C x H y ), TMS (Tetra-methylsilane, Si(CH 3 ) 4 ) or HMDSO (Hexamethyldisiloxane, O(Si(CH 3 ) 3 ) 2 ).
First, a plasmatic state is induced using Ar gas under vacuum condition, the surface of the piston ring is activated by heating a coating chamber to about 80° C., and the surface of the piston ring is cleaned by adding bias to force the Ar ions to crash into the surface of the piston ring (baking & cleaning).
Next, the Cr layer is coated using only the Cr target to improve adhesion property between the coating layer and the base material (thickness: 0.1˜1.0 μm). The CrN layer is then coated by a chemical reaction of the discharged processing gas N 2 and the sputtered Cr ions on the Cr target (thickness: 0.1˜10 μm).
Once the chemical reaction has been conducted using hydrocarbon gas and TMS, or HMDSO gas without the Cr target, C and Si are combined with each other, and the Si-DLC layer is formed (e.g., having a thickness of preferably about 0.1˜10 μm). At this time, by controlling gas containing Si (TMS or HMDSO), a low content layer 610 containing a first Si component of about 3 at % or less (not including 0 (zero)) and a high content layers 630 containing a second Si component of about 3˜10 at % can be alternatively laminated one by one.
And, FIGS. 5 to 7 are graphical illustrations comparing performances of Examples and Comparative Examples of the illustrative embodiment of the present invention.
FIG. 5 represents the comparison of friction coefficient. Friction coefficient between the piston ring and cylinder liner was measured using an oscillating friction-wearing tester. Test was conducted at load of 150 N, temperature of 150° C., oscillating period of 5 Hz and oil condition for 1 hour. As a result, friction coefficient of nitriding was the highest, and friction coefficient of Si-DLC was the lowest in order of Si-DLC<DLC<CrN<nitriding as shown in FIG. 5 . Further, fiction coefficient of the Si-DLC became lower according to doping Si while changing its content ratio as described above.
FIG. 6 represents the comparison of resistance to scuffing, and scuffing load between the piston ring and cylinder liner which were measured using an oscillating friction-wearing tester to compare resistance to oil film destruction. Test was conducted at temperature of 150° C., oscillating period of 5 Hz and oil condition while increasing load with 20 N every 20 min up to 440 N. As a result, nitriding generated scuffing most quickly in order of nitriding<CrN<DLC=Si-DLC, and scuffing load of the DLC and Si-DLC were the highest as shown in FIG. 6 .
FIG. 7 represents the comparison of high temperature wear resistance, and piston ring wear between the piston ring and cylinder liner was measured using an oscillating friction-wearing tester. Test was conducted at load of 150 N, temperature of 25° C. and 200° C., oscillating period of 5 Hz and oil condition for 1 hour. As a result, wear of the DLC was largely increased but wear of the Si-DLC was not increased significantly at high temperatures. Further, high temperature wear resistance was further improved when Si was doped while controlling its content.
Namely, the piston ring for engine of the present invention consisting of the structure described above and the method for manufacturing thereof accordingly reduces friction loss of the piston ring and improves fuel efficiency 0.2˜0.5% since the friction coefficient of the Si-DLC is 23% lower than Cr plating and nitriding and 11% lower than CrN.
Further, because resistance to scuffing of the Si-DLC is 50% or more better than Cr plating and nitriding and 30% or more better than CrN, oil film destruction is suppressed and durability of the piston ring is improved. Furthermore, the low-friction properties and high temperature wear resistance of the DLC are improved by doping Si on the DLC. Additionally, durability of the piston ring can be improved since a Cr+CrN multi-layer is at lower layer when the Si-DLC is worn away.
While the invention will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
|
Disclosed is a piston ring for engine that includes chromium (Cr) coating layer coated on the surface of a base material of the piston ring of an engine; a chromium nitride (CrN) coating layer; and a silicon-incorporated diamond-like carbon (Si-DLC) coating layer, which is formed on the CrN coating layer, and contains Si component of about 3˜10 at %, and a method for manufacturing thereof.
| 5
|
CROSS-REFERENCE TO A RELATED APPLICATION
Pursuant to 35 U.S.C. §119(a), this application claims the benefit of earlier filing date and right of priority to Korean patent Application No. 10-2008-0138627, filed on Dec. 31, 2008, the contents of which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cylinder type bistable permanent magnetic actuator, and particularly, to an actuator employed in power equipment for operating a circuit breaker or a switch.
2. Background of the Invention
Typically, a spring mechanism, a hydraulic actuator and a pneumatic actuator are used as actuators employed in power equipment. However, since such actuators require many components and should control mechanical energy for making a steering effort, they have a complicated structure and need to be repaired and maintained.
To solve such problems, an actuator employing permanent magnets and electric energy is used in the power equipment, instead of the existing mechanism. The permanent magnetic actuator is configured such that a mover thereof is held at a stroke due to magnetic energy of the permanent magnets, and electric energy is applied to a coil to move the mover to a stroke.
The permanent magnetic actuators may be categorized into a bistable type and a monostable type depending on a mechanism that the mover is held at a preset position. The bistable type permanent magnetic actuator is configured such that a mover can be held at each of both ends of a stroke due to permanent magnets, whereas the monostable type permanent magnetic actuator is configured such that a mover is held at only one of both ends of a stroke. Since the mover of the bistable type permanent magnetic actuator is held at a preset position by magnetic energy of permanent magnets upon opening or closing power equipment, it is more advantageous than the monostable type requiring for a separate maintenance mechanism, in that the bistable type can perform the closing/opening operation without a mechanical component such as a spring.
FIG. 1 shows an example of a bistable type permanent magnetic actuator according to the related art. The actuator includes an upper cylinder 10 having a groove in which a coil is to be disposed, an intermediate cylinder 12 located at a lower side of the upper cylinder 10 , and a lower cylinder 14 located at a lower side of the intermediate cylinder 12 . An inner cylinder 16 having a central portion in which a mover is to be inserted is installed inside the intermediate cylinder 12 , and a permanent magnet 20 is installed at an upper surface of an edge of the inner cylinder 16 .
Here, the mover 22 is installed to be reciprocated up and down between the upper cylinder 10 and the lower cylinder 14 . Guide shafts 24 and 26 are coupled to upper surface and lower surface of the mover 22 , respectively. The guide shafts 24 and 26 are inserted into guide holes formed in the respective upper and lower cylinders 10 and 14 . An open spring 28 is installed at a lower portion of the guide shaft 26 . The open spring 28 is configured to be compressed when the mover 22 is located at a lower side so as to upwardly apply an elastic force to the mover 12 .
An upper coil 30 and a lower coil 32 are installed in the upper cylinder 10 and the lower cylinder 14 , respectively.
An operation of the actuator will be described hereinafter. As shown in FIG. 1 , in a state of being contacted with the lower cylinder 14 , the mover 22 is held in the contacted state with the lower cylinder 14 by a magnetic flux generated by the permanent magnet 20 . Under this state, upon applying a current to the upper coil 30 , a magnetic force is upwardly applied to the mover 22 . If the magnetic force becomes stronger, the mover 22 is moved upwardly so as to come in contact with the upper cylinder 10 as shown in FIG. 2 . At this moment, the flow of the magnetic flux generated by the permanent magnet 20 is changed. Accordingly, the mover 22 is held at the upwardly moved position by the magnetic flux of the permanent magnet 20 .
On the contrary, when the mover 22 is kept located at the position shown in FIG. 2 by the magnetic force of the permanent magnet, upon applying a current to the lower coil 32 , a magnetic force is applied to the mover 22 downwardly. If the downwardly applied force becomes stronger than the force of the permanent magnet 20 , the mover 22 is then moved downwardly so as to come in contact with the lower cylinder 14 as shown in FIG. 1 . The contacted state is maintained by the magnetic force of the permanent magnet 20 . The open spring 28 may apply an elastic energy to the mover, which is accordingly moved upwardly when manually opening a contact of an external power equipment in case where the actuator is connected to the power equipment (e.g., a circuit breaker or a switch).
However, the main components, i.e., upper cylinder, lower cylinder, intermediate cylinder and inner cylinder, constructing the related art actuator should be machined into the shape of hollow cylinders, thereby increasing the machining cost. Further, since the permanent magnet mounted onto the cylinder is formed in a ring shape having a large outer diameter, the cost required for fabricating the magnet is increased as well.
Besides, such components in the cylindrical shape should be assembled on the same shaft line, which causes difficulty in the assembly. Also, one permanent magnet attracts the mover. Accordingly, the magnet has a great magnetic force, so as to problematically attract other components during the assembling process.
SUMMARY OF THE INVENTION
Therefore, to overcome the drawbacks of the related art, an object of the present invention is to provide a bistable type permanent magnetic actuator capable of being fabricated more easily and reducing the fabricating cost.
Another object of the present invention is to provide a bistable permanent magnetic actuator capable of improving assembly by solving the problem occurred during the assembly due to a magnetic force of a permanent magnet, by allowing the use of permanent magnets each having a weaker magnetic force.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a bistable type actuator including, a cylinder formed by rolling a thin plate so as to form an inner space, a mover reciprocatingly installed within the cylinder in a lengthwise direction of the cylinder, first and second coils installed near both end portions of the cylinder, respectively, by interposing the mover therebetween, and a permanent magnet installed between the first and second coils.
In the one aspect of the present invention, the cylinder forming the outer appearance of the actuator may be formed by rolling a plate not by machining, which results in non-requirement of a separate machining.
Here, the actuator may further include an intermediate plate fixed into the cylinder and formed by laminating a plurality of thin plates, and the permanent magnet may be fixed to the intermediate plate. The intermediate plate is also formed by laminating plates produced in great quantities in a manner of stamping (blanking) an original material other than machining the same, thereby allowing an easy fabrication.
Here, the intermediate plate may have a rectangular outer appearance. Besides, the intermediate plate may have a prescribed form of polygon or closed curve.
Also, the intermediate plate may be provided with a through hole through which the mover is inserted, and the permanent magnet may be provided in plurality, so as to be fixed to an inner surface of the through hole. The use of the plurality of permanent magnets allows a magnetic force of each permanent magnet to be weaker than a magnetic force required for holding a mover, which results in facilitating the handling of the permanent magnets during an assembly process.
Here, magnetic flux attraction plates may be attached onto surfaces of the plurality of permanent magnets, respectively, and each of the magnetic flux attraction plates may be formed by laminating a plurality of thin plates.
In another aspect of the present invention, there is provided a bistable type actuator including,
first and second cylinders each formed by rolling a thin plate so as to form an inner space; an intermediate plate disposed between the first and second cylinders, the intermediate plate having a through hole connected to the inner spaces of the first and second cylinders, a mover reciprocatingly installed within the first and second cylinders and the intermediate plate in a lengthwise direction of the cylinders, first and second coils installed at the first and second cylinders, respectively, by interposing the mover therebetween, a permanent magnet installed in the intermediate plate, and fixing elements configured to maintain the coupled state among the first and second cylinders and the intermediate plate.
Here, the intermediate plate may be formed by laminating a plurality of thin plates, and have a rectangular outer appearance.
The permanent magnet may be installed inside the through hole of the intermediate plate. Also, the permanent magnet may be provided in plurality, so as to be disposed inside the through hole of the intermediate plate. Here, the magnetic force of each permanent magnet may be weaker than a minimum magnetic force required for holding the mover. In addition, magnetic flux attraction plates may be attached onto surfaces of the plurality of permanent magnets, respectively, and each of the magnetic flux attraction plates may be formed by laminating a plurality of thin plates.
The fixing elements may include first and second fixed plates disposed outside the first and second cylinders, respectively, and fixing members configured to apply an attractive force between the first and second fixing plates. The fixing members may include a fixed shaft extending between the first and second fixing plates, and fixing nuts fixed to both ends of the fixed shaft.
In accordance with the aspects of the present invention having such configurations, the cylinders are formed by rolling a plate not by machining, thereby being easily fabricated due to non-requirement of the machining. Also, use of a plurality of permanent magnets each having a weak magnetic force, instead of one permanent magnet having a strong magnetic force, facilitates handling of the permanent magnets, resulting in improvement of assembly.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIGS. 1 and 2 are cross-sectional views showing an internal structure of a bistable type permanent magnetic actuator in accordance with the related art;
FIG. 3 is a perspective view showing one embodiment of a bistable type permanent magnetic actuator in accordance with the present invention;
FIG. 4 is a disassembled perspective view of the embodiment shown in FIG. 3 ; and
FIG. 5 is a cross-sectional view of the embodiment shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Description will now be given in detail of a bistable type permanent magnetic actuator in accordance with one embodiment of the present invention, with reference to the accompanying drawings.
Referring to FIG. 3 , an actuator 100 in accordance with one embodiment of the present invention is shown. The actuator 100 may include first and second fixed plates 102 and 104 fixed to uppermost and lowermost ends by sequentially interposing a first cylinder 110 , an intermediate cylinder 120 and a second cylinder 130 therebetween.
Here, the first cylinder 110 , the intermediate cylinder 120 and the second cylinder 130 may be fixed by the first and second fixed plates 102 and 104 , thereby preventing separation thereof. Four fixing bolts 106 may be disposed near each vertex between the first and second fixed plates 102 and 104 . Fixing nuts 108 may then be coupled to ends of the fixing bolts 106 , so as to apply an attractive force between the first and second fixed plates 102 and 104 .
Here, each of the first and second cylinders 110 and 130 may be configured to have a cylindrical shape by rolling a plate plural times in a cylindrical shape, and the intermediate plate 120 may be configured by laminating a plurality of rectangular plates, thereby serving to fix permanent magnets to be explained later. The first cylinder 110 , the intermediate cylinder 120 and the second cylinder 130 are coupled so as to implement an outer appearance of the actuator 100 according to the one embodiment. A bushing 140 may be fixedly disposed at a central portion of the first fixed plate 102 , and an end portion of an upper shaft of a mover may be inserted into the bushing 140 , thereby allowing a more smooth movement of the mover.
Hereinafter, an internal structure of the actuator according to the one embodiment will be described with reference to FIG. 4 .
A mover 150 may be mounted to be movable up and down within inner spaces of the first and second cylinders 110 and 130 and an inner space defined by a through hole 122 formed through the intermediate plate 120 . An upper shaft 152 and a lower shaft 154 may be coupled to both ends of the mover 150 , and a gap ring 156 may be inserted into the upper shaft 152 . The gap ring 156 may allow the mover 150 to be spaced apart from an upper core, which will be explained later, by a prescribed gap.
Meanwhile, a bobbin 160 may be inserted into each of the first and second cylinders 110 and 130 , and an upper coil 162 and a lower coil 166 may be wound on the bobbins 160 , respectively. Further, an upper core 164 and a lower core 168 may be inserted into end portions of the bobbins 160 , respectively. The upper and lower cores 164 and 168 may be magnetized by a current applied to the upper coil 162 and the lower coil 166 , so as to serve to move the mover 150 .
Permanent magnet fixing members 170 for press-welding each permanent magnet may be installed near vertexes of the inner space of the intermediate plate 120 . Each permanent magnet fixing member 170 may substantially have a rectangular shape, and have protrusions 172 formed at corners thereof. The protrusions 172 may allow the permanent magnet fixing members 170 to be stably fixed into the intermediate plate 120 by being inserted into corresponding grooves 124 formed near the vertexes of the intermediate plate 120 .
A permanent magnet 180 may be inserted between the neighboring permanent magnet fixing members 170 . The permanent magnet 180 may be fixed in a state of being pressed by the pair of permanent magnet fixing members 170 . A magnetic flux attraction plate 182 may be attached onto a surface of each permanent magnet 180 , which faces the center of the intermediate plate 120 . The magnetic flux attraction plate 182 may be formed by laminating a plurality of plates each having one side surface formed in an arcuate shape, so as to serve to attract the magnetic flux generated by the permanent magnet 180 .
In the embodiment shown in FIGS. 3 and 4 , the intermediate plate was configured to be located between two cylinders; however, without a limit to the embodiment, another embodiment may be considered that the intermediate plate may be installed inside one of cylinders.
Hereinafter, an operation of the actuator in accordance with the one embodiment will be described with reference to FIG. 5 .
Referring to FIG. 5 , the mover 150 is held with being closely adhered to the lower core 168 , which is allowed by a magnetic force of each permanent magnet 180 . Under this state, upon applying a current to the upper coil 162 , the upper core 164 is magnetized so as to apply a magnetic force to the mover 150 . If such magnetic force is gradually increased to be stronger than the magnetic force of each permanent magnet 180 , the mover 150 is moved toward the upper core 164 . Accordingly, the mover 150 can be held in the upwardly moved state by the magnetic force of each permanent magnet 180 under the state where the gap ring 156 is contacted with the upper core 164 .
Here, a force allowing the mover 150 to be held at an upper position is weaker than a force allowing the mover 150 to be held at a lower position because an air gap is formed between the upper core 164 and the mover 150 due to the gap ring 156 .
On the contrary, if a current is applied to the lower coil 166 in the state of the mover 150 being held at the upper position, the lower core 168 is magnetized so as to downwardly apply a magnetic force to the mover 150 . If the magnetic force of the lower core 168 is increased to be stronger than the magnetic force of each permanent magnet 180 , which allows the mover 150 to be held at the upper position, the mover 150 is moved downwardly so as to be returned to the state shown in FIG. 5 . Afterwards, even if the current applied to the lower coil 166 is blocked, the magnetic force of each permanent magnet 180 is applied to the lower core 166 , so the mover 150 can be maintained in the state shown in FIG. 5 .
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
As the present features may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims.
|
Disclosed is a cylinder type bistable permanent magnetic actuator, the bistable actuator including, a cylinder formed by rolling a thin plate so as to form an inner space, a mover reciprocatingly installed within the cylinder in a lengthwise direction of the cylinder, first and second coils installed near both end portions of the cylinder, respectively, by interposing the mover therebetween, and a permanent magnet installed between the first and second coils.
| 7
|
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
Not applicable.
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
One or more embodiments of the invention generally relate to clothing care. More particularly, the invention relates to means for drying clothing.
BACKGROUND OF THE INVENTION
In today's economic circumstances, consumers are being much more cautious and careful with their clothing purchases. However these consumers are buying clothing maintenance products in a much higher volume. Instead of purchasing new clothes, today's consumers are protecting the clothes they already own. Buttons, needles and thread used to mend clothes, stain removers, replacement belt buckles, at-home treatment products for dry-clean-only clothing, and other relevant product fields have enjoyed notable spikes in sales while the general clothing industry itself sits by the wayside. In other words, rather than spending money on clothing, consumers are buying products to protect the clothing they already have and to make their maintenance cheaper and easier.
Many consumers love the look and feel of fashionable fabrics, yet do not care for the trouble involved in their care. Many fashionable fabrics such as, but not limited to, wool, cashmere, and silk require special care when drying. This special care often requires the garment to be dried flat rather than being tumble or line dried. Tumble drying these fabrics can lead to shrinkage or damage. Line drying can cause stretching, creases and wrinkles, and hang drying using clothes hangers can cause shoulder bumps where the hanger contacts the garment. These clothes typically do not hold the same fashionable appearance after improper drying. Too often, special care instructions can make a consumer regret buying new, fashionable clothing because of the inconvenience. If the clothing cannot be tossed into the dryer, many consumers find their appreciation for such clothing to fade.
Proper care of clothing is important. A person's appearance in their clothes is what sets a first impression, and one mere blemish or one sign of improper maintenance of their clothing can negatively affect that first impression. That is why it is important to care for clothing in an appropriate manner. However it can be difficult to do so at times, especially with particular clothing items that require specific care. Items that require flat drying, for example, without limitation, most sweaters, can be tedious to tend to and can also be quite inconvenient to care for in limited space. Flat drying clothing can require a large amount of space, which is often not available in a typical laundry room, and most people do not want to have their clothing spread throughout their house to dry. It is therefore an objective of the present invention to provide means for flat drying clothing.
There are products currently available that are meant to make it easier to care for clothing that requires flat drying, for example, drying racks. However, no matter how easy these products make flat drying, they are not easy to work with. In fact, some of these products can make the whole process more inconvenient. These products are typically large and heavy and must be carried to a place of use. Many of these products must be unfolded and set-up, and then their location of use must be avoided until the clothes are dry. Then, they must be broken down, folded up and carried back to an area large enough to store them.
In view of the foregoing, there is a need for improved techniques for providing means for easily flat drying clothing that is easy to set up and put away and does not require a large amount of space.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIGS. 1A through 1F illustrate an exemplary flat drying device, in accordance with an embodiment of the present invention. FIG. 1A is a front perspective view. FIG. 1B is a side perspective view. FIG. 1C is a rear perspective view. FIG. 1D is a front perspective view with netting in an extended position. FIG. 1E is a front perspective, partially transparent view, and FIG. 1F is a side perspective view of a netting hem bar attached to a wall;
FIG. 2 is a front perspective view of an exemplary flat drying device in use in a laundry room, in accordance with an embodiment of the present invention; and
FIGS. 3A and 3B illustrate an exemplary box for a flat drying device, according to an embodiment of the present invention. FIG. 3A is a rear perspective view of the box in a closed position, and FIG. 3B is a front perspective view of the box in an open position.
Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.
SUMMARY OF THE INVENTION
To achieve the forgoing and other objects and in accordance with the purpose of the invention, an apparatus for flat drying garments is presented.
In one embodiment an apparatus includes a canister comprising a rear wall, a bottom and a curved front panel. The curved front panel has a horizontal slit extending across a width of the front panel. The canister is operable for being supported from a first vertical surface. A spring-loaded axle is operable for being rotated in a first direction from a first position to a second position to generate a tension sufficient to rotate the spring-loaded axle in a second direction from the second position to the first position. End caps are joined to the canister for substantially enclosing the spring-loaded axle within the canister. One of the two end caps has an opening for enabling an end of the spring-loaded axle to protrude outside of the canister. A netting supports wet garments to lay flat for drying. The netting comprises a netting width, a length, a first end, a second end. The first end is joined to the spring-loaded axle and the netting is rolled about the spring-loaded axle with the second end protruding from the horizontal slit. A hem bar is joined to the second end of the netting. Means removably secures the hem bar to a second vertical surface opposing the first vertical surface where the netting is operable for supporting wet garments to lay flat for drying. A tension knob is joined to the end of the spring-loaded axle protruding outside of the canister. The tension knob is operable for adjusting a level of the tension with the wet garments laying flat on the netting.
In another embodiment an apparatus includes means for housing a portion of the apparatus. The housing means is operable for mitigating pooling of moisture and for being supported on a first vertical surface. Means rotates in a first direction from a first position to a second position to generate a tension sufficient to rotate the rotating means in a second direction from the second position to the first position. Means encloses the rotating means in the housing means. Means supports wet garments to lay flat for drying. The supporting means is joined to the rotating means and protrudes from the housing means. Means mitigates a full retraction of the supporting means into the housing means. The mitigating means is joined to the supporting means. Means secures the mitigating means to a second vertical surface opposing the first vertical surface. Means adjusts a level of the tension with the mitigating means being secured proximate the second vertical surface, the rotating means being at the second position and the wet garments laying flat on the supporting means. The adjusting means is joined to the rotating means.
In another embodiment an apparatus includes a canister comprising a flat rear wall, a flat bottom and a curved front panel. The curved front panel has a shape operable for mitigating pooling of moisture and having a horizontal slit extending across a width of the front panel. The flat rear wall has hosting apertures operable for supporting the canister upon screws that project from a first vertical surface. A spring-loaded axle comprises a length larger than the width of the front panel. The spring-loaded axle is operable for being rotated in a first direction from a first position to a second position to generate a tension sufficient to rotate the spring-loaded axle in a second direction from the second position to the first position. Two end caps are each joined to an end of the flat rear wall, flat bottom and curved front panel to substantially enclose the spring-loaded axle within the canister. One of the two end caps has an opening for enabling an end of the spring-loaded axle to protrude outside of the canister. A netting supports wet garments to lay flat for drying. The netting comprises a netting width, a length, a first end, a second end, reinforced edges, and a waterproof coating. The netting width is less than the width of the front panel. The first end is joined to the spring-loaded axle and the netting is rolled about the spring-loaded axle with the second end protruding from the horizontal slit. A hem bar is joined to the second end of the netting. The hem bar comprises dimensions sufficient to mitigate a full retraction of the netting into the canister. The hem bar further comprises two apertures extending through the hem bar with each aperture being proximate a lateral end of the hem bar. Two hook structures are configured for securing to a second vertical surface opposing the first vertical surface at a distance less than the length of the netting. The two hook structures are further configured for removably passing through the two apertures of the hem bar to secure the hem bar proximate the second vertical surface where the netting is operable for supporting wet garments to lay flat for drying. A tension knob is joined to the end of the spring-loaded axle protruding outside of the canister. The tension knob comprises an ergonomic grip system comprising bumps and valleys for user gripping. The tension knob is operable for adjusting a level of the tension with the hem bar being secured proximate the second vertical surface, the spring-loaded axle being at the second position and the wet garments laying flat on the netting.
Other features, advantages, and objects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is best understood by reference to the detailed figures and description set forth herein.
Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.
It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention. Structures described herein are to be understood also to refer to functional equivalents of such structures. The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.
From reading the present disclosure, other variations and modifications will be apparent to persons skilled in the art. Such variations and modifications may involve equivalent and other features which are already known in the art, and which may be used instead of or in addition to features already described herein.
Although Claims have been formulated in this Application to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalization thereof, whether or not it relates to the same invention as presently claimed in any Claim and whether or not it mitigates any or all of the same technical problems as does the present invention.
Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination. The Applicants hereby give notice that new Claims may be formulated to such features and/or combinations of such features during the prosecution of the present Application or of any further Application derived therefrom.
References to “one embodiment,” “an embodiment,” “example embodiment,” “various embodiments,” etc., may indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an exemplary embodiment,” do not necessarily refer to the same embodiment, although they may.
As is well known to those skilled in the art many careful considerations and compromises typically must be made when designing for the optimal manufacture of a commercial implementation any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.
It is to be understood that any exact measurements/dimensions or particular construction materials indicated herein are solely provided as examples of suitable configurations and are not intended to be limiting in any way. Depending on the needs of the particular application, those skilled in the art will readily recognize, in light of the following teachings, a multiplicity of suitable alternative implementation details.
A preferred embodiment of the present invention and at least one variation thereof provide convenient and space-saving means for drying clothes that cannot be or are preferably not tumble or hang dried. Many preferred embodiments comprise a retractable sheet of netting that can be withdrawn from a canister upon which clothing can be laid flat for drying. Many preferred embodiments may be mounted upon a wall or other plane so that, when not in use, the drying means does not occupy a large amount of space. Many preferred embodiments can accommodate the growing number of consumers who refrain from clothes dryer use due to potential damage upon clothing, utility costs and environmental reasons. Many preferred embodiments of the present invention can encourage consumers to properly care for their clothing and can help consumers generally prevent common damages to their clothing.
FIGS. 1A through 1F illustrate an exemplary flat drying device, in accordance with an embodiment of the present invention. FIG. 1A is a front perspective view. FIG. 1B is a side perspective view. FIG. 1C is a rear perspective view. FIG. 1D is a front perspective view with netting 101 in an extended position. FIG. 1E is a front perspective, partially transparent view, and FIG. 1F is a side perspective view of a netting hem bar 105 attached to a wall. In the present embodiment the drying device comprises netting 101 , a spring-loaded axle 110 for the hosting of netting 101 , and a canister 115 which hosts spring-loaded axle 110 . Canister 115 is preferably produced of lightweight aluminum, and measures approximately twenty-seven inches in length by three inches in depth (27″×3″). Canister 115 comprises a flat rear wall 120 , a flat bottom 125 , and a curved front panel 130 that are enclosed by end caps 135 . End caps 135 are preferably produced of high-density polyethylene (HDPE). The shape of canister 115 generally ensures that moisture slides off the device and does not pool on the device, which can increase the life and attractiveness of the device. In alternate embodiments, the canister can be made in various lengths and widths. For example, without limitation, some embodiments may comprise larger canisters for use in professional applications such as, but not limited to, for a dry cleaner or a Laundromat. Furthermore, it is contemplated that the canisters in some alternate embodiments may have various different shapes such as, but not limited to, square or rectangular tubes or cylinders. Yet other alternate embodiments may be implemented without a canister in order to provide an even more space-saving design. In the present embodiment canister 115 is completely enclosed. This seals spring-loaded axle 110 within canister 115 and generally prevents a person's fingers or clothing from getting caught in spring-loaded axle 115 . Also, keeping interior components completely encased within canister 115 protects these components which can result in longer life.
Referring to FIGS. 1C and 1E , rear wall 120 of canister 115 has a flat plane, and upon each lateral side of rear wall 120 are hosting apertures 140 for support of the device upon screws 145 that slightly project from a wall or other vertical surface. Referring to FIG. 1E , within canister 115 , spring-loaded axle 110 of an approximate one and one-half inch (1½″) diameter extends from one end cap 135 of canister 115 for approximately one inch (1″). The extending portion of spring-loaded axle 115 is encased within an ergonomically styled tension knob 150 preferably produced of high-density polyethylene (HDPE). Tension knob 150 enables a user to adjust the tension of netting 101 when the device is in use. Tension knob 150 has a specially designed, ergonomic grip system comprising bumps and valleys to generally ensure that users can easily grip tension knob 150 and turn it, even when their hands are moist. The bumps enable a user to insert their fingertips into the valleys between the bumps so it is difficult for the fingers to slip or fall out of place even if the fingers are moist due to water, detergent, fabric softener, etc. Those skilled in the art, in light of the teachings of the present invention, will readily recognize that a multiplicity of suitable ergonomic designs may be used for the tension knobs in alternate embodiments such as, but not limited to, textured, grooved or ribbed surfaces; however, these designs may not be optimal as these textured surfaces may become filled with moisture, fabric softener or other residue and become slick. In some alternate embodiments, the tension knob may include a rubberized coating for added grip.
Referring to FIGS. 1E and 1F , mounted upon spring-loaded axle 110 is netting 101 that is preferably made of a nylon-polyester blend material with a waterproof coating that measures approximately six feet in length by twenty-six inches in width (72″×26″). The waterproof coating protects netting 101 as wet clothes dry on it; however, in alternate embodiments the netting may not include a waterproof coating and may come in different sizes depending on many factors including, but not limited to, the size of the canister or the intended application of the device. In the present embodiment, the outer edges of netting 101 are thicker, making them reinforced. This helps to maintain the condition of netting 101 for an extended length of time. Netting 101 will be rolled up and extended numerous times over its lifetime so the reinforced edges provide longevity and generally prevent fraying of netting 101 . The reinforced outer edges also help to support the weight of wet garments that are flat drying on netting 101 . Apertures in netting 101 enable moisture to drip from the clothing. Netting 101 can be pulled and kept taught when in use by tension knob 150 . Referring to FIG. 1D , netting 101 can be withdrawn and retracted through a horizontal slit 155 featured upon, and running the length of, front panel 130 of canister 115 . Slit 155 has a height of approximately one-half of one inch (½″) to enable netting 101 to easily pass through slit 155 . Additionally, there are no impediments near slit 155 to generally prevent friction on netting 101 which in turn generally prevents fraying and increases longevity of netting 101 .
Enlarged netting hem bar 105 is featured upon the exterior end of netting 101 for prevention of the full retraction of netting 101 into canister 115 . Hem bar 105 is preferably made of high-density polyethylene (HDPE) and has an approximate depth of three-quarters of one inch (¾″) and a height of one-half inch (½″). In alternate embodiments, the hem bar can be of various sizes to prevent it from retracting within the canister of the drying device. Hem bar 105 can be textured to provide grip to moist hands as the drying device is typically used in a laundry area so most likely a user's hands will be wet from water, detergent, fabric softener, etc. In an alternate embodiment, the hem bar may include a handle to make pulling the netting from the canister easier. In the present embodiment, referring to FIG. 1F , extending through each lateral end of hem bar 105 are two apertures 160 for the hosting of wall-mounted hooks 165 . Hooks 165 pass completely through apertures 160 of hem bar 105 to generally ensure that hem bar 105 is adequately supported and to generally eliminate the risk of hem bar 105 coming off of hooks 165 . This design also thoroughly supports netting 101 when it is pulled out from canister 115 . Hooks 165 can be screwed into a wall via a threaded shaft projecting from a rear wall 170 . In some implementations, rear wall 170 of hooks 165 may feature a slightly protruded rubber liner. This liner is pliable and helps to protect the wall in which hooks 165 are applied. In some embodiments, the hooks can feature small rubber caps that can be slipped on to the tips of the hooks. These caps cover the tips of the hooks to generally prevent items from accidently getting snagged on the hooks and to help hold the netting on the hooks when being loaded with clothing. In alternate embodiments, the hem bar itself may comprise hooks to be attached to various different objects such as, but not limited to, eyelets, other hooks, a bar, knobs, wire shelving, etc. rather than or in addition to apertures for placement on hooks.
Those skilled in the art, in light of the teachings of the present invention, will readily recognize that flat drying devices in alternate embodiments may be produced from a multiplicity of suitable combinations of adequate materials. For example, without limitation, the canister and end caps may be made of various materials such as, but not limited to, high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), various metal materials, etc. The hem bar in alternate embodiments can be made of various materials such as, but not limited to, aluminum, high-density polyethylene (HDPE) and acrylonitrile butadiene styrene (ABS). Furthermore, the netting of the drying device in alternate embodiments can be made of various applicable materials such as, but not limited to, cotton, various plastics, nylon and polyester. In some alternate embodiments the netting may be replaced by a solid sheet of an absorbent material such as, but not limited to, cotton, terry, chamois material, etc.
In the present embodiment, the drying device provides means for flat drying sweaters and other garments to provide a consumer needed accommodation for the care of particular clothing items. It is not just sweaters that need flat drying. Garments that require flat drying may be anything made out of wool, cashmere, silk and several blend combinations. Flat drying may also be recommended for manmade fabrics such as, but not limited to, polyester, rayon and even acetate. This means that the drying device may be used with almost any type of clothing including, but not limited to, sweaters, skirts, hosiery, blouses, delicate undergarments, swimsuits, jeans, etc. The drying device can also accommodate clothing that requires hanging such as, but not limited to, stockings Clothing that requires hanging can be accommodated in at least two ways, as follows, without limitation. The first way is to simply lay the clothing flat upon the netting and allow it to flat dry. All though clothing may state it can be hanged to dry; it can also be laid flat to dry so this product would work perfectly. The second way it to hang the hanger that supports the wet clothing on the reinforced outer edging of the net. The net may be secured in a taut position and the reinforced edging can support the hanger.
FIG. 2 is a front perspective view of an exemplary flat drying device 200 in use in a laundry room, in accordance with an embodiment of the present invention. In typical use of the present embodiment, a user mounts drying device 200 to a hosting wall 205 using a mounting template on the packaging, as described by way of example in FIGS. 3A and 3B . Using the same template, the user mounts hooks on an opposite wall 210 at the same height as a canister 215 . The user then withdraws a netting 220 from canister 215 and mounts a hem bar 225 upon the hooks of opposite wall 210 . The user can then lay clothing 230 flat upon netting 220 to dry. If needed, the user may rotate a tension knob 235 attached to a spring-loaded cylinder attached to netting 220 to generally ensure that netting 235 remains taut. By drying clothing 230 flat, drying device 200 does not create noticeable shoulder indentations, like those created by clothing hangers, and does not leave noticeable marks near the hems of clothing, like those created by clothespins. Drying device 200 also enables clothing 230 to dry evenly, unlike hanging methods in which moisture simply declines throughout the structure of the garment. Furthermore, drying device 200 supports clothing 230 throughout the drying process, unlike hanging methods that include a high risk of garments falling upon the floor. When clothing 230 is removed from netting 220 , the user may remove hem bar 225 from the hooks to enable netting 220 to retract back within canister 215 .
Drying device 200 enables flat drying to be done in a reserved space within the home or other environments. Drying device 200 takes advantage of unused space (i.e., vertical wall space) and satisfies a particular need of persons in small spaces such as, but not limited to, small homes, apartments, dormitories, barracks, and other living quarters. However, drying device 200 can be used in almost any location including, but not limited to, in homes and in businesses. Alternate embodiments can be implemented in formats and sizes for commercial use in businesses such as, but not limited to, hotels, motels, Laundromats, camping grounds, dormitories, and other facilities that offer clothes washing and clothes washing facilities. Some embodiments of the present invention may also be used by drycleaners and laundry service companies. In the present embodiment, drying device 200 is easy to set-up. Unlike other products that require set-up each time use is desired, drying device 200 only requires set-up during its initial installation. By requiring only initial installation, drying device 200 saves time, energy and space that other products require for their set-up, tear down and subsequent storage. In the present embodiment, the screws that mount canister 215 to wall 205 are inserted into wall 205 and the actual canister 215 can be put on the screw heads and removed from the screw heads very easily and quickly. This enables the user to keep canister 215 installed on wall 205 all the time, or the user can remove canister 215 from wall 205 to store drying device 200 somewhere and re-apply it to the screws only when needed. This also enables drying device 200 to be portable so that it can be brought to other locations for use. In alternate embodiments the canister may be permanently mounted to a wall.
FIGS. 3A and 3B illustrate an exemplary box for a flat drying device, according to an embodiment of the present invention. FIG. 3A is a rear perspective view of the box in a closed position, and FIG. 3B is a front perspective view of the box in an open position. In the present embodiment, the box of the flat drying device comprises a template 301 to generally ensure that the installation of support screws for the drying device is easy and accurate. Template 301 can be used for the simple and accurate installation of the support hooks on the opposite wall as well. The box comprises perforations around template 301 so a user can easily remove template 301 from the box without the use of scissors or any other cutting device. This feature enables the user to use template 301 without having to hold the entire box during product set-up and without needing a cutting utensil. The perforations also generally ensure that template 301 stays in good working condition as it is removed from the box. Positioned on the face of template 301 are three other perforated areas, two screw/hook indicators 305 and a horizontal slit 310 . Screw/hook indicators 305 generally ensure that the distance between the screws and hooks is accurate. Horizontal slit 310 is near the bottom center of template 301 and can hold the securing end of a tape measure. The height of the canister of the drying device and the height of the hooks on the opposite wall need to closely match each other. Horizontal slit 310 enables a user to hook a tape measure to slit 310 , pull it down to the floor and generally ensure accurate height between the canister and the hooks on the opposite wall. In alternate embodiments the template may not be perforated. In other alternate embodiments, the template may be separate from the box, for example, without limitation, a piece of cardboard or paper included in the box with the drying device. In the present embodiment, the interior face of template 301 features two adhesive areas 315 that are protected by a removable covering that may be made of a thin, removable material such as, but not limited to, wax paper or plastic. Adhesive areas 315 hold template 301 on the wall so the user can have both hands free to complete installation. The adhesive for adhesive areas 305 is hypoallergenic and residue free; therefore, it does not negatively affect users or damage the wall on which it is placed. Some alternate embodiments may not include adhesive areas on the templates.
In typical use of the present embodiment, the user removes template 301 from the box and removes screw/hook indicators 305 and horizontal slit 310 . Then, the user removes the coverings from adhesive areas 315 and places template 301 on the installation wall in the approximate area they want the canister and hooks. The user then uses a tape measure to find the desired height, and can adjust the template a few times to achieve the desired placement. Adhesive areas 315 allow for several adjustments before losing their stickiness. The user then marks the location for the screws using screw/hook indicators 305 . Once the user has the screws in place for the canister installation, they can remove template 301 and attach it to the opposite wall. The user uses the tape measure to check that the height of template 301 is the same as for the other wall and can then mark and install the hooks. This process typically ensures accurate installation the first time, which can generally prevent errant holes in the wall from the placing of screws in the wrong area. Some alternate embodiments of the present invention may not include an installation template.
In an alternate embodiment of the present invention, the rear wall of the canister is covered with a textured, rubber coating. This rubber coating can help to protect the wall on which the drying device is mounted. When a user extracts or retracts the netting, the canister moves slightly, which may cause the canister to scratch the wall. The rubber coating acts as a buffer to protect the wall. The rubber coating also provides additional grip to help maintain the product in a secure position on the wall.
It is contemplated that alternate embodiments may be implemented with a multiplicity of additional features. For example, without limitation, one alternate embodiment may be implemented with a fan for improving the speed of drying. Some alternate embodiments may include lights, hooks for hanging items, or containers for holding items such as, but not limited to, pocket change, detergent, clothespins, etc. Additionally, alternate embodiments can be produced in various colors, and may or may not bear various images, designs and/or logos, which may or may not be of registered trademark and/or copyright status.
Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing means for flat drying clothing according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. For example, the particular implementation of the drying means may vary depending upon the particular type of mounting method used. The drying means described in the foregoing were directed to wall mounted implementations; however, similar techniques are to provide means for flat drying clothing that are not wall mounted; for example, without limitation, the flat drying device may be placed on a stand or may use suction cups to be removably mounted to a surface such as, but not limited to, tile or a washing machine. Non-wall mounted implementations of the present invention are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
Claim elements and steps herein may have been numbered and/or lettered solely as an aid in readability and understanding. Any such numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims.
|
An apparatus includes a canister having a front panel. The front panel has a slit extending across a width of the panel. The canister is operable for being supported from a first vertical surface. A spring-loaded axle is operable for rotating in a first direction to generate a tension sufficient to rotate the axle in a second direction. Caps are joined to the canister for substantially enclosing the axle within the canister. A netting supports wet garments to lay flat. The netting comprises a first end and a second end. The first end is joined to the axle with the second end protruding from the slit. A hem bar is joined to the second end of the netting. Means secures the hem bar to a second vertical surface. A tension knob is joined to the end of the axle and is operable for adjusting a level of the tension.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Japanese Patent Application No. JP 2006-247097 filed in the Japanese Patent Office on Sep. 12, 2006, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an OFDM receiver and an OFDM signal receiving method for receiving an orthogonal frequency division multiplexing (OFDM) signal and demodulating the OFDM signal.
[0004] 2. Description of the Related Art
[0005] A modulation system called an orthogonal frequency division multiplexing (OFDM) system is used as a modulation and demodulation system of a terrestrial digital broadcasting system. This OFDM system is a system for providing a large number of orthogonal sub-carriers in a transmission band, allocating data to amplitudes and phases of the respective sub-carriers, and digitally modulating a signal according to PSK (Phase Shift Keying) or QAM (Quadrature Amplitude Modulation).
[0006] The OFDM system has a characteristic that, since the transmission band is divided by the large number of sub-carriers, although a band per one sub-carrier is narrowed and modulation speed is reduced, transmission speed as a whole is the same as that in the modulation system in the past. The OFDM system also has a characteristic that, since the large number of sub-carriers are transmitted in parallel, symbol speed is reduced. Therefore, in the OFDM system, a time length of a multi-path relative to a time length of a symbol can be reduced and transmission is less susceptible to a multi-path interference. Further, the OFDM system has a characteristic that, since data is allocated to the plural sub-carriers, a transmission and reception circuit can be formed by using, during modulation, an IFFT (Inverse Fast Fourier Transform) arithmetic circuit that performs inverse Fourier transform and using, during demodulation, an FFT (Fast Fourier Transform) arithmetic circuit that performs Fourier transform.
[0007] Since the OFDM system has the characteristics described above, the OFDM system is often applied to the terrestrial digital broadcast that is intensely affected by the multi-path interference. As the terrestrial digital broadcast employing such an OFDM system, there are standards such as DVB-T (Digital Video Broadcasting-Terrestrial), ISDB-T (Integrated Services Digital Broadcasting-Terrestrial) and ISDB-TSB (Integrated Services Digital Broadcasting-Terrestrial Sound Broadcasting) (see, for example, “Receiver for Terrestrial Digital Sound Broadcast-Standard (Desirable Specifications) ARIB STD-B30 version 1.1”, Association of Radio Industries and Businesses, decided on May 31, 2001 and revised on Mar. 28, 2002 and “Transmission System for Terrestrial Digital Sound Broadcast ARIB STD-B29 version 1.1”, Association of Radio Industries and Businesses, decided on May 31, 2001 and revised on Mar. 28, 2002).
[0008] A transmission signal in the OFDM system is transmitted by a unit of a symbol called an OFDM symbol. This OFDM symbol includes an effective symbol that is a signal period in which IFFT is performed during transmission and a guard interval in which a waveform of a part of the latter half of this effective symbol is directly copied. This guard interval is provided in the former half of the OFDM symbol. In the OFDM system, such a guard interval is provided to improve multi-path resistance. Plural OFDM symbols are collected to form one OFDM transmission frame. For example, in the ISDB-T standard, ten FDM transmission frames are formed by two hundred four OFDM symbols. Insertion positions of pilot signals are set with this unit of OFDM transmission frames as a reference.
[0009] In the OFDM system in which the modulation of a QAM system is used as a modulation system for each of the sub-carriers, characteristics of the amplitude and the phase are different for each of the sub-carriers because of the influence of the multi-path and the like during transmission. Therefore, on a reception side, it is necessary to equalize a reception signal to make the amplitude and the phase for each of the sub-carriers equal. In the OFDM system, on a transmission side, pilot signals of a predetermined amplitude and a predetermined phase are discretely inserted in a transmission symbol in a transmission signal. On the reception side, a frequency characteristic of a channel is calculated using the amplitude and the phase of the pilot signals and a reception signal is equalized according to the calculated characteristic of the channel.
[0010] The pilot signals used for calculating a channel characteristic are referred to as scattered pilot (SP) signals.
SUMMARY OF THE INVENTION
[0011] As a method of estimating a time direction channel in the OFDM receiver, there are known a method of estimating a time direction channel using an average-type estimator, a method of estimating a time direction channel using an interpolation-type estimator, and a method of estimating a time direction channel using a prediction-type estimator. All of the methods have advantages and disadvantages in characteristics thereof. The prediction-type estimator can accurately estimate a channel for a static channel without temporal fluctuation and a channel in which temporal fluctuation is periodic. However, the prediction-type estimator fails in prediction and may be unable to correctly estimate a channel for a channel that fluctuates at random as known in Typical Urban. On the other hand, the interpolation-type estimator is more excellent than the prediction-type estimator in that the interpolation-type estimator can estimate a channel without a very significant error even in a channel that fluctuates at random. However, when it is attempted to attain performance equivalent to that of the prediction-type estimator in a static channel or a channel that fluctuates periodically, an enormous number of taps are necessary and, therefore, a memory for holding data is also necessary. The average-type estimator attains excellent performance when the fluctuation in a channel is extremely gentle but, when fluctuation is large, the average-type estimator may be unable to follow the fluctuation.
[0012] Therefore, there is a need for providing an OFDM receiver and an OFDM signal receiving method that can receive an OFDM signal without a substantial increase in size of a circuit regardless of whether a channel is static, temporal fluctuation in the channel is periodic, or temporal fluctuation in the channel is random.
[0013] Other needs and specific advantages derived therefrom will be made more obvious from the following explanations of embodiments.
[0014] According to an embodiment of the present invention, in order to attain high performance without a substantial increase in size of a circuit regardless of whether a channel is static, temporal fluctuation in the channel is periodic, or temporal fluctuation in the channel is random, the average-type estimator, the interpolation-type estimator, and the prediction-type estimator may be switched and used.
[0015] According to an embodiment of the present invention, there is provided an OFDM receiver which may include OFDM-signal receiving means for receiving an orthogonal frequency division multiplexing (OFDM) signal, channel-characteristic estimating means for estimating a channel characteristic using pilot signals in the OFDM signal received by the OFDM-signal receiving means, and transmission-distortion compensating means for applying, on the basis of the channel characteristic estimated by the channel-characteristic estimating means, processing for compensating for transmission distortion to the OFDM signal received by the OFDM-signal receiving means. The channel-characteristic estimating means may include plural kinds of time-direction-channel estimating means used for the estimation of a channel characteristic and switching control means for switching these estimating means according to a state of a channel.
[0016] According to another embodiment of the present invention, there is provided an OFDM signal receiving method of receiving an orthogonal frequency division multiplexing (OFDM) signal, estimating a channel characteristic using pilot signals in the received OFDM signal, and applying, on the basis of the estimated channel characteristic, processing for compensating for transmission distortion to the received OFDM signal, the OFDM signal receiving method may include estimating a Doppler spectrum for the received OFDM signal and switching, according to the estimated Doppler spectrum, plural kinds of time-direction-channel estimating means used for the estimation of a channel characteristic.
[0017] According to the embodiments of the present invention, the prediction-type estimator may be used when a channel is static or when temporal fluctuation in the channel is periodic. When temporal fluctuation in the channel is random, it may be possible to switch the prediction-type estimator to the interpolation-type estimator to estimate a time direction channel. In other words, it may be possible to select an appropriate estimation method according to a state of the channel and attain excellent reception performance in all channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a block diagram showing a structure of an OFDM receiver according to an embodiment of the present invention;
[0019] FIG. 2 is a diagram for explaining transmission symbols of an OFDM signal;
[0020] FIG. 3 is a diagram for explaining an arrangement pattern of SP signals in the OFDM signal;
[0021] FIG. 4 is a block diagram showing a structure of a pilot-use channel estimator in the OFDM receiver;
[0022] FIGS. 5A and 5B are diagrams for explaining an average-type method of estimating a time direction channel in the pilot-use channel estimator;
[0023] FIGS. 6A and 6B are diagrams for explaining an interpolation-type method of estimating a time direction channel in the pilot-use channel estimator;
[0024] FIGS. 7A to 7 C are diagrams schematically showing an example of a Doppler spectrum;
[0025] FIG. 8 is a diagram for explaining sub-carries estimated by the estimation of a time direction channel in the pilot-use channel estimator;
[0026] FIG. 9 is a diagram for explaining sub-carriers estimated by a frequency-direction channel estimator in the OFDM receiver;
[0027] FIG. 10 is a block diagram showing an example of another structure of the pilot-use channel estimator in the OFDM receiver;
[0028] FIGS. 11A and 11B are diagrams for explaining a prediction-type method of estimating a time direction channel in the pilot-use channel estimator;
[0029] FIG. 12 is a block diagram showing an example of still another structure of the pilot-use channel estimator in the OFDM receiver;
[0030] FIG. 13 is a block diagram showing an example of a structure of a fluctuation-type judging device in the pilot-use channel estimator;
[0031] FIG. 14 is a flowchart showing operations of a judging device in the fluctuation-type judging device;
[0032] FIGS. 15A to 15 C are diagrams schematically showing a state of judgment of a shape of a Doppler spectrum at the time when there is no fluctuation;
[0033] FIGS. 16A to 16 C are diagrams schematically showing a state of judgment of a shape of a Doppler spectrum at the time when fluctuation is periodic; and
[0034] FIGS. 17A to 17 C are diagrams schematically showing a state of judgment of a shape of a Doppler spectrum at the time when fluctuation is random.
DETAILED DESCRIPTION
[0035] Embodiments of the present invention will be hereinafter explained in detail with reference to the accompanying drawings. It goes without saying that the present invention is not limited to the embodiments described below and can be modified arbitrarily without departing from the spirit of the present invention.
[0036] The present invention is applied to, for example, an OFDM receiver 10 having a structure shown in FIG. 1 .
[0037] The OFDM receiver 10 includes an antenna 11 , a tuner 12 , a band-pass filter (BPF) 13 , an A/D converter 14 , a digital orthogonal demodulator 15 , an FFT arithmetic circuit 16 , a pilot-use channel estimator 17 , a channel distortion compensator 18 , an error correction circuit 19 , a transmission parameter decoder 20 , a delay profile estimator 21 , and a window regenerator 22 .
[0038] A broadcast wave of a digital broadcast transmitted from a broadcasting station is received by the antenna 11 of the OFDM receiver 10 and supplied to the tuner 12 as an RF signal.
[0039] The tuner 12 includes a multiplication circuit 121 and a local oscillator 122 . The tuner 12 frequency-converts the RF signal received by the antenna 11 into an IF signal. The IF signal obtained by the tuner 12 is filtered by the band-pass filter (BPF) 13 and, then, digitized by the A/D converter 14 and supplied to the digital orthogonal demodulator 15 .
[0040] The digital orthogonal demodulator 15 orthogonally demodulates the digitized IF signal using a carrier signal of a predetermined frequency (a carrier frequency) and outputs an OFDM signal of a baseband. The OFDM signal of the baseband outputted from the digital orthogonal demodulator 15 is a signal in a so-called time domain before being subjected to an FFT operation. Therefore, a baseband signal after digital orthogonal demodulation and before the FFT operation is hereinafter referred to as an OFDM time domain signal. As a result of orthogonal demodulation, this OFDM time domain signal changes to a complex signal including a real axis component (an I channel signal) and an imaginary axis component (a Q channel signal). The OFDM time domain signal outputted by the digital orthogonal demodulator 15 is supplied to the FFT arithmetic circuit 16 , the window regenerator 22 , and the delay profile estimator 21 .
[0041] The FFT arithmetic circuit 16 applies the FFT operation to the OFDM time domain signal, extracts data orthogonally modulated in each of sub-carriers, and outputs the data. The signal outputted from the FFT arithmetic circuit 16 is a signal in a so-called frequency domain after being subjected to the FFT operation. Therefore, the signal after the FFT operation is referred to as an OFDM frequency domain signal.
[0042] The FFT arithmetic circuit 16 extracts a signal in a range of an effective symbol length from one OFDM symbol, i.e., excludes a range of a guard interval from one OFDM symbol, and applies the FFT operation to the extracted OFDM time domain signal. Specifically, as shown in FIG. 2 , a position where the arithmetic operation is started is any position from a boundary of the OFDM symbol (a position of A in FIG. 2 ) to an end position of the guard interval (a position of B in FIG. 2 ). This arithmetic operation range is referred to as an FFT window.
[0043] A transmission signal in the OFDM system is transmitted by a unit of a symbol called an OFDM symbol. This OFDM symbol includes an effective symbol that is a signal period in which IFFT is performed during transmission and a guard interval in which a waveform of a part of the latter half of this effective symbol is directly copied. This guard interval is provided in the former half of the OFDM symbol. In the OFDM system, such a guard interval is provided to improve multi-path resistance. Plural OFDM symbols are collected to form one OFDM transmission frame. For example, in the ISDB-T standard, ten FDM transmission frames are formed by two hundred four OFDM symbols. Insertion positions of pilot signals are set with this unit of OFDM transmission frames as a reference.
[0044] In the OFDM system in which the modulation of a QAM system is used as a modulation system for each of the sub-carriers, characteristics of the amplitude and the phase are different for each of the sub-carriers because of the influence of the multi-path and the like during transmission. Therefore, on a reception side, it is necessary to equalize a reception signal to make the amplitude and the phase for each of the sub-carriers equal. In the OFDM system, on a transmission side, pilot signals of a predetermined amplitude and a predetermined phase are discretely inserted in a transmission symbol in a transmission signal. On the reception side, a frequency characteristic of a channel is calculated using the amplitude and the phase of the pilot signals and a reception signal is equalized according to the calculated characteristic of the channel.
[0045] The pilot signals used for calculating a channel characteristic are referred to as scattered pilot (SP) signals. An arrangement pattern in the OFDM symbol of the SP signals adopted in the DVB-T standard and the ISDB-T standard is shown in FIG. 3 .
[0046] In the OFDM receiver 10 , the designation of this FFT window position is performed by the window regenerator 22 . As the window regenerator 22 , for example, means for performing window regeneration according to detection of a correlation value of a guard interval period using the OFDM time domain signal and means for estimating a delay profile of a channel using the delay profile estimator 21 and performing window regeneration are used.
[0047] The pilot-use channel estimator 17 extracts the SP signals inserted in the OFDM frequency domain signal calculated by the FFT arithmetic circuit 16 and estimates a channel characteristic of the sub-carriers in which the SP signals are arranged.
[0048] The pilot-use channel estimator 17 in the OFDM receiver 10 includes, for example, as in a pilot-use channel estimator 17 A shown in FIG. 4 , an SP-signal extraction circuit 171 , an average-type time-direction-channel estimator 172 , an interpolation-type time-direction-channel estimator 173 , a selector 174 , a Doppler spectrum estimator 175 , and a maximum-Doppler-frequency judging circuit 176 .
[0049] In the pilot-use channel estimator 17 A, the OFDM frequency domain signal is supplied to the SP-signal extraction circuit 171 and the Doppler spectrum estimator 175 .
[0050] The SP-signal extraction circuit 171 extracts only SP signals inserted in positions shown in FIG. 3 and removes modulation components of the pilot signals to calculate channel characteristics in the SP positions. Channel characteristics in the SP positions calculated by the SP-signal extraction circuit 171 are supplied to the average-type time-direction-channel estimator 172 and the interpolation-type time-direction-channel estimator 173 .
[0051] The average-type time-direction-channel estimator 172 includes a primary IIR filter having a structure, for example, shown in FIG. 5A . The average-type time-direction-channel estimator 172 averages channel estimated values in the SP positions estimated by the SP-signal extraction circuit 171 as shown in FIG. 5B . An IIR output is repeatedly used during the SP signals adjacent to one another in the time direction.
[0052] The interpolation-type time-direction-channel estimator 173 includes a linear interpolation circuit having a structure, for example, shown in FIG. 6A . The interpolation-type time-direction-channel estimator 173 interpolates the channel estimated values in the SP signal positions, which are estimated by the SP-signal extraction circuit 171 , in the time direction to estimate a channel during three symbols as shown in FIG. 6B .
[0053] The Doppler spectrum estimator 175 estimates a Doppler spectrum from the OFDM frequency domain signal. The maximum-Doppler-frequency judging circuit 176 calculates a maximum Doppler frequency from the Doppler spectrum estimated by the Doppler spectrum estimator 175 .
[0054] A Doppler spectrum corresponding to fluctuation in a channel is shown in FIGS. 7A to 7 C. When there is no fluctuation or fluctuation is extremely gentle, as shown in FIG. 7A , a spectrum is a linear spectrum centered in 0 [Hz]. When fluctuation is periodic, since the fluctuation can be approximated by adding up several sine waves, the Doppler spectrum can be represented by several linear spectra. A state of the Doppler spectrum represented by two linear spectra is shown in FIG. 7B . When fluctuation is random, a spectrum has a spread and, as shown in FIG. 7C , shows a well-known well-type spectrum.
[0055] The pilot-use channel estimator 17 A in the OFDM receiver 10 calculates the Doppler spectrum shown in FIGS. 7A to 7 C from the OFDM frequency domain signal and selects an optimum method of estimating a time direction channel from a shape of the spectrum and a maximum Doppler frequency to perform the estimation of a time direction channel corresponding to the fluctuation in the channel.
[0056] The selector 174 switches outputs of the average-type time-direction-channel estimator 172 and the interpolation-type time-direction-channel estimator 173 according to the maximum Doppler frequency outputted from the maximum-Doppler-frequency judging circuit 176 . When the maximum Doppler frequency is extremely small, the selector 174 selects the average-type time-direction-channel estimator 172 that executes average-type estimation of a time direction channel. When there is fluctuation, the selector 174 selects the interpolation-type time-direction-channel estimator 173 that executes interpolation-type estimation of a time direction channel. Consequently, in both a case in which temporal fluctuation in the channel is slow and a case in which temporal fluctuation in the channel is fast, it is possible to perform high-performance channel estimation and, as shown in FIG. 8 , estimate channel characteristics for every three sub-carriers in the frequency direction for all OFDM symbols.
[0057] The channel distortion compensator 18 includes a compensator 181 and a frequency-direction-channel estimator 182 .
[0058] In the channel distortion compensator 18 , the frequency-direction-channel estimator 182 subjects the channel characteristics calculated for every three sub-carriers by the pilot-use channel estimator 17 A to processing in the frequency direction to calculate channel characteristics of all the sub-carriers in the OFDM symbol as shown in FIG. 9 . As a result, it is possible to estimate channel characteristics for all the sub-carriers of the OFDM signal. The compensator 181 removes distortion due to the channel from the OFDM frequency domain signal calculated by the FFT arithmetic circuit 16 using the channel characteristics of all the sub-carriers supplied from the frequency-direction-channel estimator 182 .
[0059] The transmission parameter decoder 20 extracts transmission parameter information from the OFDM frequency domain signal by decoding a sub-carrier in which the transmission parameter information is inserted and supplies the transmission parameter information to the error correction circuit 19 .
[0060] The error correction circuit 19 applies, in accordance with the transmission parameter information supplied from the transmission parameter decoder 20 , de-interleave processing to the OFDM frequency domain signal, from which the channel distortion is removed by the channel-distortion compensator 18 . The error correction circuit 19 outputs the OFDM frequency domain signal as decoded data through depuncture, Viterbi, diffused signal removal, and RS decoding.
[0061] The delay profile estimator 21 calculates an impulse response of the channel and supplies the impulse response to the window regenerator 22 . As a method of delay profile estimation, for example, a method of using a matched filter that sets a guard interval period as a tap coefficient using the OFDM time domain signal and a method of calculating a delay profile by subjecting a channel characteristic supplied from the pilot-use channel estimator 17 to IFFT are adopted.
[0062] As the pilot-use channel estimator 17 , instead of the pilot-use channel estimator 17 A in which the average-type time-direction-channel estimator 172 and the interpolation-type time-direction-channel estimator 173 are switched by the selector 174 , a pilot-use channel estimator 17 B having a structure shown in FIG. 10 or a pilot-use channel estimator 17 C having a structure shown in FIG. 12 may be adopted.
[0063] The pilot-use channel estimator 17 B shown in FIG. 10 includes the SP-signal extraction circuit 171 , the interpolation-type time-direction-channel estimator 173 , a prediction-type time-direction-channel estimator 177 , the selector 174 , the Doppler spectrum estimator 175 , and a fluctuation-type judging device 178 .
[0064] In the pilot-use channel estimator 17 B, an OFDM frequency domain signal is supplied to the SP-signal extraction circuit 171 and the Doppler spectrum estimator 175 . The SP-signal extraction circuit 171 extracts only the SP signals inserted in the positions shown in FIG. 3 and removes modulation components of the pilot signals to calculate channel characteristics in the SP positions. The channel characteristics in the SP positions calculated by the SP-signal extraction circuit 171 are supplied to the interpolation-type time-direction-channel estimator 173 and the prediction-type time-direction-channel estimator 177 .
[0065] The interpolation-type time-direction-channel estimator 173 includes a variable-coefficient FIR filter having the structure shown in FIG. 6A . The interpolation-type time-direction-channel estimator 173 interpolates a channel estimated value in an SP position, which is estimated by the SP-signal extraction circuit 171 , in the time direction to estimate a channel during three symbols as shown in FIG. 6B .
[0066] The prediction-type time-direction-channel estimator 177 includes a primary IIR filter having a structure, for example, shown in FIG. 11A . As shown in FIG. 11B , the prediction-type time-direction-channel estimator 177 predicts a channel in the next SP position with the channel estimated value in the SP position estimated by the SP-signal extraction circuit 171 as an input. Until the next SP signal is inputted, the prediction-type time-direction-channel estimator 177 interpolates a predicted value to generate an estimated value. As a method of updating a coefficient of the filter, there is a method of using a least mean square (LMS) algorithm or the like.
[0067] The Doppler spectrum estimator 175 estimates a Doppler spectrum from the OFDM frequency domain signal. The fluctuation-type judging device 178 judges a shape of the Doppler spectrum estimated by the Doppler spectrum estimator 175 .
[0068] The selector 174 switches outputs of the interpolation-type time-direction-channel estimator 173 and the prediction-type time-direction-channel estimator 177 according to an output of the judgment by the fluctuation-type judging device 178 . When fluctuation in a channel is a linear spectrum, the selector 174 selects the prediction-type time-direction-channel estimator 177 that executes prediction-type estimation of a time direction channel. When fluctuation is random, i.e., when a spectrum has a spread, the selector 174 selects the interpolation-type time-direction-channel estimator 173 that executes interpolation-type estimation of a time direction channel. Consequently, in both a case in which temporal fluctuation in the channel is periodic (including a case in which there is no fluctuation) and a case in which the channel fluctuates at random, it is possible to perform high-performance channel estimation and, as shown in FIG. 8 , estimate channel characteristics for every three sub-carriers in the frequency direction for all OFDM symbols.
[0069] The pilot-use channel estimator 17 C shown in FIG. 12 includes the SP-signal extraction circuit 171 , the average-type time-direction-channel estimator 172 , the interpolation-type time-direction-channel estimator 173 , the prediction-type time-direction-channel estimator 177 , the selector 174 , the Doppler spectrum estimator 175 , the maximum-Doppler-frequency judging circuit 176 , and the fluctuation-type judging device 178 .
[0070] The pilot-use channel estimator 17 C is obtained by combining the pilot-use channel estimator 17 A shown in FIG. 4 and the pilot-use channel estimator 17 B shown in FIG. 10 . In the pilot-use channel estimator 17 C, the Doppler spectrum estimator 175 estimates a Doppler spectrum from the OFDM frequency domain signal. The maximum-Doppler-frequency judging circuit 176 calculates a maximum Doppler frequency. When this maximum Doppler frequency is small, the average-type method of estimating a time direction channel is selected. When fluctuation is large, the fluctuation-type judging device 178 judges whether the fluctuation is periodic fluctuation or random fluctuation. When the fluctuation is periodic fluctuation, the prediction-type method of estimating a time direction channel is selected. When the fluctuation is random fluctuation, the interpolation-type method of estimating a time direction channel is selected. This makes it possible to select an appropriate estimation method according to presence or absence of fluctuation in the channel and a type of the fluctuation and perform high-performance channel estimation.
[0071] The fluctuation-type judging device 178 includes, for example, as shown in FIG. 13 , a center clip circuit 1781 , a positive-maximum-Doppler search device 1782 , a negative-maximum-Doppler search device 1783 , an fd-section-0-count circuit 1784 , and a judging device 1785 .
[0072] In the fluctuation-type judging device 178 , first, in order to remove noise components, the center clip circuit 1781 applies center clip processing to a spectrum. The center clip circuit 1781 subtracts a threshold from the spectrum and forcibly replaces a negative portion with 0 to perform the center clip processing. The spectrum subjected to the center clip processing is supplied to the positive-maximum-Doppler search device 1782 , the negative-maximum-Doppler search device 1783 , and the fd-section-0-count circuit 1784 . The positive-maximum-Doppler-search device 1782 searches for a maximum positive index of a non-zero value. The negative-maximum-Doppler search device 1783 searches for a negative maximum index of a non-zero value. The fd-section-0-count circuit 1784 counts an index of 0 between the positive maximum Doppler index and the negative maximum Doppler index.
[0073] The judging device 1785 judges a shape of the spectrum in accordance with a procedure shown in a flowchart in FIG. 14 .
[0074] First, the judging device 1785 subtracts the negative maximum index from the positive maximum index to calculate a Doppler spread (hereinafter referred to as “Fds”) (step S 1 ).
[0075] The judging device 1785 judges whether the Doppler spread (Fds) calculated in step S 1 is smaller than the threshold (step S 2 ).
[0076] When a result of the judgment in step S 2 is TRUE, i.e., the Fds is smaller than the threshold, the judging device 1785 judges that a channel is a channel without fluctuation (step S 4 ) and finishes the processing for judging a shape of the spectrum.
[0077] A state of the judgment of a shape of a Doppler spectrum at the time when there is no fluctuation is shown in FIGS. 15A to 15 C.
[0078] The center clip circuit 1781 applies, as shown in FIG. 15A , the center clip processing to the Doppler spectrum calculated by the Doppler spectrum estimator 175 to obtain a Doppler spectrum from which noise is removed as shown in FIG. 15B . As shown in FIG. 15C , when a Doppler spread (Fds) of the Doppler spectrum is smaller than the threshold, the judging device 1785 judges that the channel is a channel without fluctuation.
[0079] When a result of the judgment in step S 2 is FALSE, i.e., the Fds is equal to or larger than the threshold, the judging device 1785 judges whether fluctuation is periodic fluctuation or random fluctuation (step S 3 ).
[0080] The judgment processing in step S 3 can be performed on the basis of a ratio of a section of 0 in the Doppler spread. When the number of 0s (hereinafter referred to as nzero) supplied from the fd-section-0-count circuit 1784 is larger than Fds* scaling (e.g., 0.9) (step S 3 : TRUE), the judging device 1785 regards the fluctuation as periodic fluctuation (step S 5 ). When the number of 0s is not larger than Fds* scaling (step S 3 : FALSE), the judging device 1785 regards the fluctuation as random fluctuation (step S 6 ) and finishes the processing for judging a shape of the spectrum.
[0081] A state of the judgment of a shape of a Doppler spectrum at the time when fluctuation is periodic is shown in FIGS. 16A to 16 C.
[0082] The center clip circuit 1781 applies, as shown in FIG. 16A , the center clip processing to the Doppler spectrum calculated by the Doppler spectrum estimator 175 to obtain a Doppler spectrum from which noise is removed as shown in FIG. 16B . As shown in FIG. 16C , when the number of indexes of 0 between the positive maximum Doppler index and the negative maximum Doppler index is larger than Fds* scaling, the judging device 1785 judges that the channel is a channel that fluctuates periodically.
[0083] A state of the judgment of a shape of a Doppler spectrum at the time when fluctuation is random is shown in FIGS. 17A to 17 C.
[0084] The center clip circuit 1781 applies, as shown in FIG. 17A , the center clip processing to the Doppler spectrum calculated by the Doppler spectrum estimator 175 to obtain a Doppler spectrum from which noise is removed as shown in FIG. 17B . As shown in FIG. 17C , when the number of indexes of 0 between the positive maximum Doppler index and the negative maximum Doppler index is equal to or smaller than Fds* scaling, the judging device 1785 judges that the channel is a channel that fluctuates at random.
[0085] In the OFDM receiver 10 according to this embodiment, according to an output of the fluctuation-type judging device 178 , the selector 174 selects the average-type time-direction-channel estimator 172 when a channel is static, selects the prediction-type time-direction-channel estimator 177 in the case of periodic temporal fluctuation, and selects the interpolation-type time-direction-channel estimator 173 in the case of random temporal fluctuation.
[0086] As described above, the selector 174 selectively switch, according to an output of the fluctuation-type judging device 178 , any one of the average-type time-direction-channel estimator 172 , the prediction-type time-direction-channel estimator 177 , and the interpolation-type time-direction-channel estimator 173 . Thus, it is possible to select an appropriate estimation method according to a state of a channel without increasing sizes of the circuits and attain excellent reception performance in all channels.
[0087] It should be understood by those skilled in the art that various modifications, combinations, sub-combinations, and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
|
An OFDM receiver may include OFDM-signal receiving means for receiving an orthogonal frequency division multiplexing (OFDM) signal; channel-characteristic estimating means for estimating a channel characteristic using pilot signals in the OFDM signal received by the OFDM-signal receiving means; and transmission-distortion compensating means for applying, on the basis of the channel characteristic estimated by the channel-characteristic estimating means, processing for compensating for transmission distortion to the OFDM signal received by the OFDM-signal receiving means. The channel-characteristic estimating means may include plural kinds of time-direction-channel estimating means used for the estimation of a channel characteristic, and switching control means for switching these estimating means according to a state of a channel.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of U.S. patent application Ser. No. 11/833,434, filed on Aug. 3, 2007, which was a continuation of International Application No. PCT/EP2005/005969, filed Jun. 3, 2005, and which designates the U.S. The disclosures of the referenced applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The invention relates to a method for manufacturing a crimped compound thread, and an apparatus for carrying out said method.
BACKGROUND OF THE INVENTION
In a method of manufacturing a crimped compound thread in a single-stage process, first a plurality of synthetic individual threads are produced by extruding a plurality of filament strands, cooling these, and drawing (stretching) them. The individual threads have different characteristics, in particular they may have different colors, so that the coloration of the compound thread depends on the combination of the individual threads. For different applications, the requirements for the appearance (particularly coloration) of the compound thread will differ. It may be particularly desirable to have a compound thread appearance wherein the separate threads do not dominate, but wherein there is not complete mixture of the threads. The dominance of a given color component in the compound thread, if too long (comprising a long segment of the compound thread in which one color dominates), may lead to so-called “flames”. However, often such “flames” are in fact desirable.
EP 0485871 A1 discloses a method and apparatus for manufacturing a multicolored compound thread, which method and apparatus have proven to be particularly useful for producing so-called “tricolor threads” for use in carpets. Here a compound thread is produced from multifilament individual threads by common crimping. To achieve such crimping, the individual threads are introduced together into a crimping chamber with the aid of an advancing nozzle. In the crimping chamber, the filaments of the individual threads are laid down into bends and loops, wherewith a common thread plug is formed. Along with the crimping, a certain intermingling of the filaments of the individual threads occurs.
To promote a certain color separation in the compound thread, each of the individual threads is separately subjected to whirl-tangling prior to the crimping, so that the interlacing of filaments in a given thread provides thread cohesion of the component thread. In this way, the intermingling of the individual threads in the compound thread can be improved with regard to color separation. In practice it is desirable to have the color characteristics of the compound thread controllable such that it is possible to manufacture a compound thread with a mixed color wherein the individual threads are intensively intermingled, or to manufacture a compound thread with strong color separation properties wherein the individual threads are not intensively intermingled.
EP 0874072 A1 discloses a method and apparatus wherein the individual threads are separately subjected to whirl-tangling and are separately crimped, prior to combining them to form the compound thread. A basic drawback of this method is that the separation in the compound thread is too pronounced, which is undesirable if one seeks to avoid the appearance of so-called “flames” in a carpet. A further drawback is that the individual threads must be separately crimped, substantially increasing equipment costs, and complicating the process (rendering it more subject to problems) in the case of a multi-thread apparatus.
DE 4202896 A1 discloses another method and apparatus, wherein the individual threads are given a “false twist” before being fed into the crimping device. This creates a risk that certain individual threads will be too dominant in the compound thread, and further that the crimping (texturizing) effect in the individual threads will be hindered.
An underlying problem of the present invention was to devise a refined method and apparatus of the type described initially supra, which enable maximum flexibility to attain particular color effects in the compound thread, in the range from mixed colors to highly separated colors.
A second underlying problem was to enable reproducible adjustability of the color appearance of the compound thread.
SUMMARY OF THE INVENTION
These problems are solved according to the invention by a method described herein, and an apparatus described herein.
Advantageous refinements of the invention are set forth in the features and combinations of features of the various embodiments described herein.
The invention is based on the concept that one can achieve very wide-ranging effects with the appropriate application of whirl-tangling of multifilament threads. E.g., by whirl-tangling a multifilament thread one can achieve intermingling or snarling of the filaments of the thread. This determines the intensity of the thread cohesion, depending on the stage of treatment of the thread. According to the invention, at least one of the multifilament threads is subjected to multiple whirl-tanglings. In particular, at least one of the multifilament individual threads is subjected to whirl-tangling a plurality of times, in a plurality of pre-treatment stages, to provide a desired filament cohesion, prior to the crimping of the individual threads. Another advantage of the invention is that the common texturizing of the individual threads can be retained in the compound thread. The multiple whirl-tangling of the individual threads enables the coloration of the compound thread to be varied within wide limits not attainable by other methods. Thus, if one seeks a high degree of color separation one will subject each of the individual threads to whirl-tangling in a number of pre-treatment stages. If one seeks the appearance of mixed coloration in the compound thread, one will preferably subject only one of the multifilament individual threads to whirl-tangling (in a plurality of pre-treatment stages).
The variant method according to which each of the multifilament individual threads is separately subjected to whirl-tangling in a first pre-treatment stage prior to drawing is distinguished in that the individual threads can be passed through the drawing device very smoothly, and disposed very close together. In this connection, the whirl-tangling of the individual threads in the first pretreatment stage can be adjusted to achieve an optimum degree of filament cohesion for the drawing of the individual threads.
In order to achieve special effects in the nature of mixing or separation of colors in the compound thread, according to a preferred variant of the method at least one of the individual threads is, or all of said threads are, subjected separately to whirl-tangling in a second pre-treatment stage following the stretching. In this way, the filament cohesion brought about via the whirl-tangling of the individual threads can be adjusted specifically for the subsequent common crimping of the individual threads.
The adjustability and range of variability of the coloration of may be improved if, in at least one of the pre-treatment stages, whirl-tangling is carried out on the individual threads, wherewith the set-point values of the compressed air in the compressed air feed are at respective different values for the different threads. In this way, one can provide different degrees of whirl-tangling in different parallel advanced individual threads. E.g. if it is desired to produce a compound thread wherein in addition to a dominant individual thread a second component is present which contributes a mixing color, the individual thread having the color-determining contribution may be subjected to whirl-tangling with a relatively high set-point value of the compressed air. It turns out that this value is proportional to the points of intermingling (“intermingling knots”) in the thread.
It is also possible to carry out whirl-tangling of the individual threads in the pre-treatment stages wherewith the set-point values of the compressed air in the compressed air feed are at respective different values for different such stages. Thus, e.g. for the drawing process the thread should have a relatively low filament cohesion, in order not to inhibit the stretching of the individual filaments. In contrast, for the common crimping of the individual threads it is desirable for the whirl-tangling to be adjusted for the desired color characteristics.
Also, it is possible to carry out whirl-tangling with pulsation of the pressure, e.g. in the second pre-treatment stage, in order to vary the mixing of the colors. This also enables the creation of special yarn effects for manufacture of “fancy yarns”.
In order to intensify the whirl-tangling treatment prior to the crimping of the individual threads, it has been found advantageous to employ a variant method according to which the multifilament individual threads are subjected to whirl-tangling with the aid of heated compressed air. Alternatively, the individual threads may be heated prior to the whirl-tangling. This has been found to exert influence on the intermingling of the filaments in the individual threads, and on the crimping of the compound thread.
In order to provide appreciable tension in the threads at the point of the crimping of the individual threads, independently of the tension in the threads in the course of the preceding stage(s) of whirl-tangling, according to a variant method it is advantageous if, prior to the crimping, the individual threads are passed multiple times around a galette unit, and are subjected to whirl-tangling in a thread segment of the resulting loops in said galette unit, prior to leaving the galette unit.
If one employs heated galettes, one may advantageously accomplish temperature-controlled simultaneous whirl-tangling of the individual threads.
In order to achieve the thread cohesion necessary for final processing of the compound thread, the compound thread is subjected to tangling after the crimping of the individual threads and prior to the winding onto a bobbin, wherewith the coloration of the compound thread which has been imparted in the pre-treatment stages and via the crimping of the individual threads is substantially preserved.
The inventive method is particularly well suited to the manufacture of a compound thread comprised of a plurality of component threads each of which preferably is different. However, the scope of the invention is not limited to situations with component threads having different characteristics, in light of the fact that, in particular, individual pre-treatment of identical individual threads can advantageously be employed to produce a compound thread. E.g., the individual threads may be given specific structural properties in the course of pre-treatment by whirl-tangling in two different stages.
In another advantageous variant of the inventive method, the individual threads undergo separate whirl-tangling in a first stage of pre-treatment and then all of them undergo a common whirl-tangling in a second stage of pre-treatment. The multi-stage whirl-tangling prior to the texturizing according to the invention provides a very high degree of flexibility in the pre-treatment of the individual threads prior to said texturizing. Thus it is also possible to subject the individual threads to a common whirl-tangling in the first pre-treatment stage and to separate whirl-tangling in the second pre-treatment stage.
Further, the scope of the inventive method is not limited to situations with common crimping of the individual threads. It is basically also possible to separately texturize each of the individual threads, prior to combining them. In another possible method, texturizing of the individual threads (commonly or separately) and combining of the individual threads to form a compound thread are carried out, following which, after cooling, the compound thread is separated again into component threads, and then said threads are subjected to common whirl-tangling prior to winding as the final compound thread. Such a variant method may be employed with individual threads of different colorations, in order to achieve additional coloration effects.
The apparatus for carrying out the inventive method is comprised of a whirl-tangling device comprised of a plurality of whirl-tangling units which are disposed in succession in the path of advance of the individual threads.
In order to be able to carry out processing steps on the individual threads between the individual whirl-tangling steps, advantageously a first whirl-tangling unit is disposed upstream of the drawing device, wherewith said first whirl-tangling unit has a respective whirl-tangling nozzle for each of the individual threads.
Advantageously a second whirl-tangling unit having a plurality of whirl-tangling nozzles is disposed between the drawing device and the crimping device.
In order to be able to carry out the whirl-tangling of the individual threads in the individual pre-treatment stages with different set-point values of the compressed air pressure, each of the whirl-tangling nozzles has a controllable compressed air supply. In this connection, a plurality of whirl-tangling nozzles may simultaneously have a common compressed air supply, or one or more whirl-tangling nozzles may have separate compressed air supplies.
In order to obtain special effects which previously were obtained by thermal whirl-tangling, the inventive apparatus may be expanded to comprise heating means associated with at least one of the whirl-tangling units, whereby certain compressed air is heated.
Alternatively, a heating device may be provided upstream of the whirl-tangling unit, for heating the individual threads.
To achieve independent adjustment of thread tension in the whirl-tangling of the individual threads and in the crimping process, preferably in the inventive apparatus the drawing device is comprised of a galette unit disposed upstream of the crimping device, wherewith the individual threads are guided over said galette unit in multiple loops; and the whirl-tangling nozzles of a second whirl-tangling unit are arranged such that the individual threads can be subjected to whirl-tangling prior to leaving the galette unit.
If the whirl-tangling nozzles of the second whirl-tangling unit are disposed in a segment looped around galettes, which segment is between two galettes, namely in the last loop, the tension of the thread(s) in the whirl-tangling process can be reduced to a desired value if the individual threads at the point of leaving the galette unit are passed over a reduced diameter step in the galette. Basically any of the segments between the two galettes is acceptable as a location for disposing the whirl-tangling nozzles for carrying out whirl-tangling in the second pre-treatment stage.
In order to achieve additional thermal effects in the whirl-tangling of the filaments, according to an advantageous refinement of the invention the galette unit is comprised of at least two driven galettes, wherewith at least one of the galettes is configured so as to be heatable.
For final establishment of the thread cohesion in the compound thread, a tangling device is disposed between the crimping device and a winding device which is provided for winding the compound thread onto a bobbin or the like.
To provide intensive and uniform crimping of the individual threads, a variant apparatus been found to be particularly advantageous in which the crimping device comprises an advancing nozzle and an associated crimping chamber, wherewith the individual threads are advanced as a group into the crimping chamber by means of the advancing nozzle, wherewith a thread plug is formed.
BRIEF DESCRIPTION OF THE DRAWINGS
The inventive method will be described in more detail hereinbelow with the aid of an exemplary embodiment of the inventive apparatus, with reference to the accompanying drawings.
FIG. 1 is a schematic drawing of a first exemplary embodiment of the inventive apparatus for carrying out the inventive method;
FIG. 2 is a schematic drawing of a second exemplary embodiment of the inventive apparatus;
FIG. 3 is a schematic drawing of a variant of the exemplary embodiment of FIG. 1 ;
FIG. 4 is a schematic drawing of a variant of the exemplary embodiment of FIG. 2 ;
FIG. 5 is a schematic drawing of a variant of the exemplary embodiments of FIGS. 1 and 2 ; and
FIG. 6 is a schematic drawing of an exemplary embodiment of a separating thread guide.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows schematically an exemplary embodiment of an inventive apparatus for carrying out the inventive method. The apparatus has a spinning device 1 which is connected to one or more melters (not shown). The spinning device has a heated spinning frame 2 which bears a plurality of spinnerets (“spinning nozzles”) ( 3 . 1 - 3 . 3 ) arrayed side by side. Each spinneret ( 3 . 1 - 3 . 3 ) has on its underside a plurality of orifices through which the polymer melt stream fed to said nozzle is extruded under pressure to form a respective individual filament. A cooling device 4 is disposed below the spinning device 1 ; the extruded filaments, which leave the spinning device at a temperature close to their melting temperature, are guided through the cooling device in order to cool said filaments. The cooling device 4 may comprise, e.g., a blower which blows cooling air essentially transversely against the filaments. After the filaments are cooled, the filament strands ( 13 . 1 - 13 . 3 ) associated with the respective spinnerets ( 3 . 1 - 3 . 3 ) are combined, at the exit of the cooling device 4 , to form respective individual threads ( 6 . 1 - 6 . 3 ).
At the outlet of the cooling device 4 , a “preparation device” 7 is provided, along with respective thread guides ( 5 . 1 - 5 . 3 ) for each of the individual threads ( 6 . 1 - 6 . 3 ).
To draw out the individual threads ( 6 . 1 - 6 . 3 ) from the spinnerets ( 3 . 1 - 3 . 3 ), a drawing device 10 is provided which comprises at least one galette device 18 (dashed lines) which is configured for drawing-out. The individual threads ( 6 . 1 - 6 . 3 ) are guided in parallel paths through the drawing device 10 . In this, the individual threads can be drawn in a common arrangement, or individual delivery devices may be employed (one for each thread).
After the drawing-out and stretching of the individual threads ( 6 . 1 - 6 . 3 ) by the drawing device 10 , the individual threads ( 6 . 1 - 6 . 3 ) are brought together in a crimping device 11 and combined to form a compound fiber 21 .
In this exemplary embodiment, the crimping device 11 is comprised of an advancing nozzle 15 and a crimping chamber 16 which cooperates with the nozzle 15 . The advancing nozzle 15 is connected to a pressure source (not shown) by means of which a conveying medium is fed to the advancing nozzle 15 . The conveying medium causes the individual threads ( 6 . 1 - 6 . 3 ) to be drawn into the advancing nozzle 15 and then advanced into the crimping chamber 16 where they are formed into a “fiber plug”. This involves a partial intermingling of the individual threads ( 6 . 1 - 6 . 3 ). The thread plug 22 , which preferably is farmed by means of a hot conveying medium, is then passed to a cooling drum 17 and cooled.
For pre-treatment of the individual threads ( 6 . 1 - 6 . 3 ), a first whirl-tangling unit 8 . 1 is provided between the preparation device 7 and the drawing device 10 ; and a second whirl-tangling unit 8 . 2 is provided between the drawing device 10 and the crimping device 11 . The first whirl-tangling unit 8 . 1 has a plurality of whirl-tangling nozzles ( 9 . 1 - 9 . 3 ), each associated with a respective individual thread ( 6 . 1 - 6 . 3 ). Each whirl-tangling nozzle ( 9 . 1 - 9 . 3 ) has a thread channel through which the individual thread is guided. A pressure channel opens out laterally into the thread channel, to introduce a high energy compressed fluid, preferably compressed air, into the thread channel. The pressure channels are connected to a pressure source via a compressed air supply line 12 . 1 and pressure adjusting means 14 . 1 . A control device 24 is provided, which is connected to the pressure adjusting means 14 . 1 , for setting the set-point for control of the compressed air.
The structure and configuration of the whirl-tangling nozzles ( 9 . 1 - 9 . 3 ) is generally known, and is described in, e.g., DE 10 2004 007073 A1.
The second whirl-tangling unit 8 . 2 associated with the crimping device 11 also has a plurality of whirl-tangling nozzles ( 9 . 4 - 9 . 6 ), having a structure and configuration essentially identical to the structure and configuration of the whirl-tangling nozzles ( 9 . 1 - 9 . 3 ) of the first whirl-tangling unit 8 . 1 . The whirl-tangling nozzles ( 9 . 4 - 9 . 6 ) are connected to a pressure source (not shown) via a compressed air supply line 12 . 2 and pressure adjusting means 14 . 2 . The pressure adjusting means 14 . 2 are connected to the control device 24 , for setting and varying the set-point for control of the compressed air. This allows the whirl-tangling units ( 8 . 1 , 8 . 2 ) to be operated mutually independently in carrying out whirl-tangling of the threads ( 6 . 1 - 6 . 3 ).
For post-treatment of the crimped compound thread 21 produced from the individual threads ( 6 . 1 - 6 . 3 ), the crimping device 11 has disposed downstream of it a “tangling device” 19 , inside which the compound thread 21 receives a final treatment required for the further processing.
Following this “tangling”, the compound thread 21 is taken up on a winding device 20 wherewith it is wound on a bobbin or the like 23 .
In the process, the winding device 20 serves simultaneously as a drawing organ, to draw the crimped compound thread 21 from the thread plug 22 . In order to be able to adjust the tension in the compound thread 21 in the winding and in the “tangling”, said thread may be drawn from the thread plug 22 by means of a galette device; and a second galette unit may be provided downstream of the “tangling device” 19 , as the thread is passed to the winding device 20 . The configurations of the devices in the post-treatment zone do not bear upon the invention—any suitable processing means and treatment stages may be chosen for influencing the compound thread 21 prior to winding onto the bobbin 23 .
In the exemplary embodiment of the inventive apparatus illustrated in FIG. 1 , three bundles of filaments ( 13 . 1 - 13 . 3 ) disposed side by side are spun in the spinnerets ( 3 . 1 - 3 . 3 ); each of these bundles has a plurality of filament strands. The filament bundles ( 13 . 1 - 13 . 3 ) may have different properties; preferably the basic polymers of which they are comprised have different colors. Indeed, the basic polymers may have different compositions or may contain different amounts of additives.
Each of the filament bundles ( 13 . 1 - 13 . 3 ) is combined to form an individual thread ( 6 . 1 - 6 . 3 ). For this purpose, the filament bundles ( 13 . 1 - 13 . 3 ) are subjected to addition of preparation agents by means of the preparation device 7 , and are passed through the thread guides ( 5 . 1 - 5 . 3 ), from which the individual threads emerge.
For further treatment of the individual threads ( 6 . 1 - 6 . 3 ), in a first pre-treatment stage immediately following the “preparation” a first whirl-tangling is carried out, in whirl-tangling unit 8 . 1 . For this, each individual thread ( 6 . 1 - 6 . 3 ) is passed through a whirl-tangling nozzle ( 9 . 1 - 9 . 3 ). The whirl-tangling unit 8 . 1 has a pressure set-point value for the compressed air which is supplied, which leads to intermingling (interlacing) of the filaments of which the individual threads are comprised. In this process, one achieves uniformization of the preparation, as well as the minimum filament cohesion required for the subsequent drawing by the galette in the drawing device 10 . In the setting of the pressure set-point value, one should take care to avoid excessive snarling of the filaments of the individual threads.
After the individual threads ( 6 . 1 - 6 . 3 ) have been drawn out and stretched, a second whirl-tangling of said threads is carried out via the whirl-tangling unit 8 . 2 , in the second pre-treatment stage. In this unit 8 . 2 , the individual threads ( 6 . 1 - 6 . 3 ) are individually separately guided and whirled, by means of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). In this process, the intermingling of the filaments in the individual threads ( 6 . 1 - 6 . 3 ) which is brought about is chosen such that a certain intermingling is achieved in the crimping of the individual threads ( 6 . 1 - 6 . 3 ) which are combined into the compound thread 21 . In particular, in producing a multicolored crimped compound thread the coloration of the compound thread 21 can be influenced within wide bounds. Thus, e.g., a compound thread with strong color separation can be produced by setting the set-point value of the pressure of the compressed air supply in the second whirl-tangling unit 8 . 2 relatively high. This causes intensive intermingling of the filaments of the individual threads, wherewith the subsequent crimping process will not be able to substantially undo this intermingling. If the set-point value of the pressure in the whirl-tangling unit 8 . 2 is set relatively low, the compound thread 21 will have an appreciably mixed coloration.
After the whirl-tangling in the second pre-treatment stage, the individual threads ( 6 . 1 - 6 . 3 ) are jointly crimped and are combined to form the compound thread 21 . In this process, the individual threads ( 6 . 1 - 6 . 3 ) are advanced through the advancing nozzle 15 by means of an advancing fluid, into an adjoining crimping chamber 16 . In the crimping chamber 16 , the filaments of the individual threads ( 6 . 1 - 6 . 3 ) are laid down into bends and loops in the course of formation of a thread plug 22 , which is subjected to thermal treatment and is then opened to yield the crimped compound thread 21 . To produce the final thread characteristics (thread cohesion, body, strength, etc.), the compound thread 21 undergoes “tangling” in the tangling device 19 prior to being wound on the bobbin 23 .
The inventive method and apparatus may be employed to produce, e.g., multicolored crimped compound threads which have high color uniformity. If necessary or desirable, particular visual characteristics can be imparted by adjusting the pre-treatment.
FIG. 2 illustrates a second exemplary embodiment of an inventive apparatus for carrying out the inventive method. This embodiment is substantially the same as the above-described embodiment; accordingly, reference is made here to the description of that embodiment, and the emphasis hereinbelow will be on describing the differences. Components with identical functions have been assigned like reference numerals.
In the exemplary embodiment according to FIG. 2 , the drawing device 10 may be comprised of, e.g., two galette units ( 18 , 27 ) for drawing out, each of which is comprised of two driven galettes or a driven galette with an “overflow roll”, wherewith the individual threads ( 6 . 1 - 6 . 3 ) are guided in parallel paths over the galettes. The galette units ( 18 , 27 ) are driven at different speeds, causing stretching of the threads ( 6 . 1 - 6 . 3 ).
In order to provide a second pre-treatment stage wherein the individual threads ( 6 . 1 - 6 . 3 ) are prepared for the crimping, a second whirl-tangling unit 8 . 2 is provided between the drawing device 10 and the crimping device 11 . The whirl-tangling unit 8 . 2 has a plurality of whirl-tangling nozzles ( 9 . 4 - 9 . 6 ), each of which is associated with a respective individual thread. These nozzles ( 9 . 4 - 9 . 6 ) are mutually independently controllable. Each of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ) has a respective compressed air feed ( 12 . 3 - 12 . 5 ) with respective pressure adjusting means ( 14 . 3 - 14 . 5 ), each of which pressure adjusting means is connected to the control device 24 , which enables providing a set-point value for the pressure for each of the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). It should be noted that the pressure adjusting means ( 14 . 3 - 14 . 5 ) are devised such that they can completely shut off the compressed air feed. This provides a high degree of flexibility in the pre-treatment of the individual threads ( 6 . 1 - 6 . 3 ) immediately upstream of the crimping stage.
Thus it is seen that the exemplary embodiment for carrying out the inventive method as illustrated in the FIG. 2 has somewhat higher flexibility to attain particular effects in a compound thread comprised of the differently whirl-tangled individual threads ( 6 . 1 - 6 . 3 ). Thus, e.g., is it possible to produce a multicolored compound thread the appearance of which results from a strongly separated pair or trio of colors, resulting from, e.g. the use of three differently colored individual threads ( 6 . 1 - 6 . 3 ) wherewith one of the threads is subjected to whirl-tangling in the second pre-treatment stage and the other threads do not receive any additional whirl-tangling in said second pre-treatment stage.
The exemplary embodiments of the inventive apparatus illustrated in FIGS. 1 and 3 can be varied by additional means, agents, and combinations, in order to, e.g., achieve special effects in the pre-treatment prior to the crimping of the individual threads. E.g., FIG. 3 shows a variant of the exemplary embodiment according to FIG. 1 ; in FIG. 3 only the drawing device 10 , whirl-tangling unit 8 . 2 , and crimping device 11 are illustrated (again, schematically). Since the components which are not illustrated are essentially identical to the corresponding components in FIG. 1 , reference is made to here the preceding descriptions, and only the differences will be described hereinbelow.
For each of the threads ( 6 . 1 - 6 . 3 ), the whirl-tangling unit 8 . 2 has a respective whirl-tangling nozzle ( 9 . 4 - 9 . 6 ), connected to a pressure source via the compressed air supply line 12 . 2 and pressure adjusting means 14 . 2 . The compressed air supply line 12 . 2 additionally has heating means 26 , for preheating the fluid introduced via the whirl-tangling nozzles ( 9 . 4 - 9 . 6 ). The heating means 26 and pressure adjusting means 14 . 2 are connected to a control device 24 .
In the exemplary embodiment illustrated in FIG. 3 the whirl-tangling of the individual threads ( 6 . 1 - 6 . 3 ) in the second pre-treating stage is accomplished with a heated fluid, which causes heating of the filaments of the individual threads. This heating influences the intermingling of the said individual filaments and leads to intensified crimping. This early intermingling substantially survives the subsequent processing.
FIG. 4 is a detail view of a variant embodiment of the inventive apparatus according to FIG. 2 . The structure and configuration of the process aggregate not shown is generally the same as in the preceding exemplary embodiment, and therefore does not require further description here. The drawing device 10 , whirl-tangling unit 8 . 2 , and crimping device 11 are included in the detail view shown in FIG. 4 . The drawing device 10 is comprised of a first galette unit 18 configured for drawing and a second galette unit 27 configured for drawing, each of which has two galettes ( 28 . 1 , 28 . 2 ) around which the individual threads ( 6 . 1 - 6 . 3 ) are passed multiple times. The galettes ( 28 . 1 , 28 . 2 ) of the galette unit 27 are heated, so that the individual threads ( 6 . 1 - 6 . 3 ) on the periphery of the galettes ( 28 . 1 , 28 . 2 ) undergo heating. The whirl-tangling unit 8 . 2 is disposed between the heated galettes ( 28 . 1 , 28 . 2 ). This whirl-tangling unit 8 . 2 is identical to that of the exemplary embodiment illustrated in FIG. 2 ; each individual thread ( 6 . 1 - 6 . 3 ) is acted on by (“has associated with it”) a respective whirl-tangling nozzle. The whirl-tangling unit 8 . 2 here is disposed in a segment of the threads between the galettes 28 . 1 and 28 . 2 . E.g., the whirl-tangling unit 8 . 2 may be disposed in the last such segment of the individual threads ( 6 . 1 - 6 . 3 ).
After the individual threads ( 6 . 1 - 6 . 3 ) leave the heated galette, they are sent together to the crimping device 11 where they are compressed to form a thread plug 22 .
In a variant of the inventive apparatus according to FIG. 4 , the whirl-tangling of the heated individual threads can be carried out with the individual thread(s) being heated, and the tensioning of the individual threads as part of the texturizing of said threads in the crimping device 11 can be chosen to be independent of the tensioning of the individual threads in the whirl-tangling in the second pre-treating stage. Thus, e.g., a diameter step may be provided on the heated galette 28 . 1 to enable setting different tensioning values for the whirl-tangling. The diameter step 33 of the galette 28 . 1 in the last segment of the individual threads is shown as a dotted line in FIG. 4 , and is implemented immediately downstream of the whirl-tangling unit 8 . 2 . Another advantage of the variant illustrated in FIG. 4 is that the individual threads have a defined point of leaving from the galettes 28 . 1 . The individual threads pass from the last galettes to the crimping device in a very smooth manner.
The arrangement illustrated in FIG. 4 may advantageously have galettes which are un-heated, wherewith the whirl-tangling is carried out at ambient temperature.
FIG. 5 illustrates yet another exemplary embodiment of a variant method and apparatus applicable to the system according to FIGS. 1 and 2 .
In the variant embodiment illustrated in FIG. 5 , there are disposed between the cooling drum 17 and the winding device 20 a first drawing galette device 29 . 1 , a separating thread guide 30 , a “tangling device” 19 , and a second drawing galette device 29 . 2 . The components disposed upstream of the cooling drum 17 may be as in the exemplary embodiment according to FIG. 1 or 2 , to which reference is made here.
In the variant embodiment illustrated in FIG. 5 , the compound thread 21 , after crimping and after cooling on the periphery of the cooling drum 17 , is drawn off via the first galette device 29 . 1 . The galette device 29 . 1 is shown here as a driven galette with an associated coordinated roll. For post-treatment, the compound thread 21 is separated into individual threads ( 6 . 1 - 6 . 3 ), by passing the individual threads through a separating thread guide 30 before they enter the tangling device 19 . In the tangling device 19 , the separately advancing individual threads ( 6 . 1 - 6 . 3 ) are once again subjected to whirl-tangling, and re-combined into a compound thread 21 . The compound thread 21 is drawn off via the drawing galette 29 . 2 and is passed on to the winding device 20 , where it is wound onto the bobbin 23 . The separation of the compound thread prior to post-treatment allows production of additional special visual effects. In this connection it is possible that, prior to the post-treatment, at least one of the individual threads is subjected to additional treatment in the form of whirl-tangling, after said separation.
In the variant embodiment illustrated in FIG. 5 , the compound thread 21 is separated into the individual threads ( 6 . 1 - 6 . 3 ). In this, preferably a separating thread guide 30 is employed which preferably is configured according to the exemplary embodiment illustrated in FIG. 6 . The separating thread guide 30 has a disc-shaped support member 32 which is fixed laterally to a machine frame. The support member 32 has a plurality of guiding eyes ( 31 . 1 - 31 . 3 ) on its periphery which are disposed at mutual distances apart. In the embodiment illustrated in FIG. 6 , these eyes ( 31 . 1 - 31 . 3 ) are disposed at the apices of an equilateral triangle. Preferably each such eye has a ceramic insert, which enables the individual threads ( 6 . 1 - 6 . 3 ) to be separately fed to the tangling device 19 , in this embodiment.
The described exemplary embodiments for carrying out the inventive method are in the nature of examples, in their arrangements and in the choice of processing devices. Thus, additional pre-treatment and post-treatment stages and means may be introduced, e.g. for the purpose of subjecting the individual threads to additional treatments prior to texturizing, or subjecting the compound thread to additional treatments after the texturizing, etc. Likewise the characteristics and form of the crimping device are in the nature of examples. To realize particular crimping characteristics, the individual threads may be texturized using different parameters. Separately performed crimping also enables the use of different crimping methods, wherewith the crimped individual threads will then be combined into a compound thread. The number of individual threads illustrated in the exemplary embodiments is, of course, in the nature of an example. A compound thread may be formed from two or more individual threads.
|
The invention relates to a method and a device for producing a crimped composite thread, wherein the inventive method consists in extruding, cooling and in drawing several yarns in the form of a plurality of strand filaments and in jointly crimping them in order to obtain a crimped composite thread. The aim of said invention is to make it possible to pre-treat the threads in a manner adaptable to each treatment step. The aim is attained by that at least one multi-treaded yarn is whirl-tangled many times during several operations prior to crimping. For this purpose, a whirl-tangling device provided with a plurality of whirl-tangling units following each other in a direction of the yarn displacement is used.
| 3
|
BRIEF SUMMARY OF THE INVENTION
This invention relates to an apparatus and method for the recovery of waste heat in asphalt mixing plants.
In conventional plants for making asphaltic concrete paving materials, a stone aggregate is combined and mixed with liquid asphalt cement to produce a paving material. To achieve a good mixing and coating action and to provide the final product with good compaction properties, the aggregate is dried and heated before it is brought into contact with the liquid asphalt. The drying and heating of aggregate consumes a major part of the energy required in an asphalt plant.
There are two basic types of asphalt plants, the batch process plant and the drum-mix plant. In the batch process, aggregate is typically dried by the application of heat to the aggregate as it passes through a drum rotating on an inclined axis. The hot, dry aggregate is then transferred to a pug mill, in which it is mixed with asphaltic cement. In a drum-mix plant, a single rotating durm is used to effect both drying and mixing. Drying of the aggregate is carried out in a first section of the drum. The aggregate then passes around a heat shield into a mixing section where it is combined with asphaltic cement.
In either type of plant, the drying of an aggregate having a typical moisture content of 5% requires approximately 250,000 BTUs per ton of asphaltic mix produced. Typically, approximately 30 to 45% to this heat is used to vaporize the water in the aggregate. The remaining heat serves to raise the temperature of the stone. In a conventional plant, the combustion products from the dryer or from the drying section of a drum mixer are exhausted to the atmosphere. When the exhaust gases come into contact with the cooler atmosphere, the water vapor content of the exhaust condenses. The condensation process liberates heat. However, the condensation of water vapor in the exhaust gases merely heats up the atmosphere and produces no useful result. Consequently, in a typical asphalt plant, at least 30-45% of the heat energy supplied to the plant is wasted.
Reduction of dryer temperature is not a satisfactory solution to the problem of energy loss because it results in undesirable moisture condensation in dust collection equipment and also because it is less sufficient and requires a larger dryer to achieve the same results.
In the past, several systems have been proposed for the recovery of waste heat in asphalt plants. For example, it has been proposed to use exhaust heat to preheat the combustion air before it enters the dryer of a batch plant or the drying section of a drum mixer. Heat pipe systems, and heat exchangers, including rotary regenerative exchangers and cyclic pebble heaters have been proposed for this purpose. However, a problem in the preheating of combustion air is that it causes the air to expand. In order to introduce a given quantity of preheated air into a dryer or drying section, it is necessary either to increase the dryer inlet aperture or to increase the air velocity. Either of these modifications results in a highly undesirable increased production of noise. Furthermore systems for preheating combustion air are generally expensive in relation to the benefits they produce.
Another proposal for heat recovery is to recycle the exhaust gases through the dryer. The recycling of exhaust gases causes moisture to accumulate, and gives rise to various technical problems in devising systems to eliminate moisture.
Still another proposal is to use infrared radiant heating for aggregate drying in order to reduce the amount of gas released to the atmosphere. Infrared heating, however, is expensive to carry out in a large-scale asphalt plant.
Finally, proposals have been made for using hot dryer exhaust gases to preheat the aggregate. This is carried out by bringing the exhaust gases into direct contact with the aggregate in a preheating unit. This approach, however, requires the exhaust gases to be maintained substantially above the dew point as they pass through the aggregate preheating unit and through the necessary dust collection devices downstream of the preheating unit. Otherwise moisture from the exhaust gases would condense on the aggregate or in the dust collectors. Because it is necessary to maintain the exhaust gases well above the dew point in these systems, they are not very effective in recovering waste heat.
The principal object of this invention is to provide a simple and inexpensive system capable of producing effective heat recovery in an asphalt drying plant and which is not subject to the aforementioned drawbacks of the prior heat recovery proposals.
Up to the present time, the indirect heating of incoming aggregate by exhaust gases was considered inefficient and impractical by those skilled in the art. This invention, however, utilizes a specific system for the indirect heating of cold aggregate or cold used asphalt-aggregate compositions by utilizing exhaust gas heat derived from an aggregate dryer or from the drying section of a drum mixer.
In accordance with the invention, a duct is provided for conducting at least part of the exhaust gas from a dryer or drying section to the feed bins provided for temporarily storing virgin aggregate or to bins used for storing used asphalt-aggregate compositions prior to recycling. At least part of the wall of the duct is arranged to conduct heat from the exhaust gas to the solid material in the bins, while isolating the exhaust gas from the solid material to prevent moisture from the exhaust gas from condensing on the material.
In accordance with a preferred embodiment of the invention, the duct is split into a plurality of ducts which pass through a feed bin or a series of bins, and which are designed with vertically elongated transverse cross-sections to provide a large area in contact with the solid material in the bins for optimum transfer of heat. Internal and external fins are provided on the duct sections for still further improvements in heat transfer. These fins are arranged in such a way as not to impede flow of exhaust gas or aggregate.
Water injection is used at the upstream end of a series of bins to initiate condensation of the exhaust gas moisture for efficient heat transfer.
The system in accordance with the invention is extremely simple in construction, yet capable of recovering a substantial portion of the heat which would otherwise be lost to the atmosphere in a conventional asphalt plant.
Other objects, features and advantages of the invention will be apparent from the following detailed description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a part of a batch process asphalt mixing plant, showing a drum dryer, a group of aggregate feed bins, and showing the special exhaust duct in accordance with the invention;
FIG. 2 is a vertical section taken through a feed bin of FIG. 1, showing plural exhaust ducts in transverse cross-section;
FIG. 3 is an oblique perspective view showing further details of the relationship between the feed bins and the exhaust ducts;
FIG. 4 is an oblique perspective view, in transverse section, of an exhaust duct, showing interior and exterior heat transfer fins; and
FIG. 5 is an oblique perspective view, in transverse section, of an exhaust duct section showing an arrangement of water injection nozzles.
DETAILED DESCRIPTION
In the preferred embodiment of the invention, as shown in FIG. 1, drying of aggregate takes place in a rotating drum dryer 4. The rotating drum is provided with a burner 5 at one end. The burner projects a flame axially into the interior of the drum. Aggregate is picked up by flights (not shown) on the interior wall of the drum, and a continuous shower of aggregate is maintained in the space within drum 4. Aggregate is received into the drum through a chute 6. The drum axis is slightly tilted with respect to the horizontal so that chute 6 is at the high end of the drum. Aggregate is discharged at the low end of the drum, and is from there transported to a pug mill (not shown) or other suitable mixing device where it is combined with asphalt cement to produce an asphaltic concrete.
An exhaust collection housing 8 is provided at the upper end of drum 4. This collection housing communicates through a duct section 10, a dust collector 12 and another duct section 14, with a blower 16. Blower 16 is arranged to draw exhaust gas from collection housing 8 through dust collector 12, and to deliver the exhaust gas to a duct section 18, which is in communication with an exhaust gas stack 20.
With blower 16 in operation, a stream of air is drawn into drum 4 at its lower end, and caused to pass through the drum in a direction opposite to the general direction of aggregate flow through the drum. Most of the dust produced in the drying operation in drum 4 is removed by dust collector 12, which is typically a bag house collector. Hot, substantially dust-free exhaust is delivered to the blower through dust collector outlet duct section 14, and is discharged into duct section 18.
The temperature of the exhaust discharged from the dryer into duct section 10 must be sufficiently high to avoid condensation in the dust collector. This is particularly important where the dust collector is a bag house, as the condensation of moisture on the filter elements would seriously interfere with the proper operation of the plant. The need to maintain high temperature at the location of the dust collector, however, would result in an excessive loss of heat to the atmosphere if the exhaust were merely discharged through exhaust stack 20.
In accordance with the invention, dampers 22 and 24 are provided in order to divert exhaust into duct section 26, which extends serially through aggregate cold feed bins 28, 30 and 32, and leads to an exhaust stack 34. Duct section 26 preferably slopes downwardly in the direction of exhaust flow to avoid accumulation of condensed water. A condensate outlet is provided at 36. Feed bins 28, 30 and 32 are provided respectively with belt feeders 38, 40 and 42, which are selectively operable to discharge aggregate from the bins onto a conveyor 44. Aggregate is discharged from conveyor 44 into chute 6 of dryer 4.
At least part of the wall of duct section 26 is in contact with the aggregate in bins 28, 30 and 32. A direct transfer of heat takes place through the wall of duct section 26 from the exhaust gas to the aggregate in the bins. The aggregate is heated, and gives up part of its moisture in the form of water vapor inside the bins, and also while it is travelling over the feeders and over conveyor 44 toward chute 6. Within conduit 26, exhaust water vapor is condensed, and the moisture flows downwardly and is discharged through outlet 36. A substantial portion of the exhaust heat is thus recovered, and used to preheat the aggregate, and eliminate part of its moisture content. Since the aggregate entering the dryer through chute 6 is preheated, and contains less moisture than the aggregate in the cold feed bins, a fuel saving is realized at the burner. While less fuel is used at the burner, the exhaust is maintained at a sufficiently high temperature to avoid condensation in the dust collector.
In the operation of the system of FIG. 1, as feeding of aggregate takes place, there is a constant turnover of the aggregate within at least one of the bins. New aggregate surfaces are continuously being presented to the portions of the walls of duct section 26 which are in contact with the aggregate. Thus, at any given time, the temperature differential between the duct walls and the aggregate surfaces is such as to promote heating of the aggregate in the bin or bins from which aggregate is being fed. Most aggregates are relatively non-porous. Most of the water is carried on the surfaces of the stones and is readily evaporated as a result of the heating of the surfaces by contact with the exhaust duct walls.
If any bin is full of aggregate, but its feeder is not operating, the temperature of the aggregate within that bin in contact with duct section 26 rises, but the rise in temperature limits the flow of heat into the inoperative bin. Consequently, most of the available heat in duct section 26 is transferred to the aggregate in the operating bin or bins. To avoid loss of heat to the atmosphere through the portion of duct section 26 which procedes the bins, and through duct section 18, suitable insulation may be provided. The bins, while shown arranged in a line and in contact with each other, may be arranged in any suitable configuration. If they are separate from each other, it is desirable to insulate portions of duct 26 which extend between the bins.
FIGS. 2 and 3 show the details of the configuration of duct 26. As shown in FIG. 3, duct section 26 is bifurcated so that it extends through the series of bins in two sections, 46 and 48. Beyond bin 32, sections 46 and 48 are rejoined as they enter exhaust stack 34.
As shown in FIG. 2, duct sections 46 and 48 are vertically elongated. That is, the vertical height of each side wall of each duct section is greater than the width of the duct section. Preferably, the side wall height is at least twice the duct section width. The vertically elongated configuration of the duct sections provides a large area of contact between the duct sections and the aggregate within the bins.
The advantage of vertical elongation is not only in the resulting increase in the surface area presented to the aggregate in the bin, but also in the fact that, for a given duct cross-section, the vertically elongated configuration minimizes the downwardly facing horizontal surface area (e.g. surfaces 54 and 56) which is substantially less effective for heat transfer purposes than the vertical surfaces of the duct sections. This is because gaps may appear underneath the downwardly facing surfaces as aggregate is discharged from the bin. Gaps are particularly likely to occur with downwardly facing surfaces of large area. The vertically elongated configuration of the duct sections within the bins also prevents the duct sections from occupying an excessive volume within the bins and from materially interfering with the flow of aggregate through the bins.
The facing walls of the duct sections are extended at 50 and 52, as shown in FIG. 2, to provide fins for further contact area. Fins, corresponding to fins 50 and 52, on a wide, vertically short duct would interfere with aggregate flow and would not be effective to increase the heat transfer contact area. However, since duct sections 46 and 48 are vertically elongated, fins such as 50 and 52 can be used much more effectively to increase the available heat transfer contact area.
As shown in FIG. 4, an array of fins 57, 59, 61, 63 and 65 is provided in the interior of duct section 48 to improve the transfer of heat to the exterior walls of the duct section. Duct section 46 has a similar array of internal fins. These fins are preferably flat, elongated fins and extend generally in the direction of exhaust flow.
Duct section 48 also has flat, external fins extending in perpendicular relationship to its side walls. The large surfaces of these fins are preferably substantially vertical. Two such fins are shown in FIG. 4 at 67 and 69. These fins provide an increased area in contact with the aggregate in the bins, without interfering with the downward flow of aggregate through the bins. Duct section 46 has similar external fins, and as shown in FIG. 2, fin 69 is common to both duct sections.
The walls of duct sections 46 and 48 are typically of 1/4 inch steel plate. Because the bins are repeatedly loaded with aggregate, considerable wear occurs, particularly at the tops of the duct sections. Accordingly, in order to minimize the need for duct replacement, the duct sections, as shown in FIGS. 2 and 3, are provided with replaceable caps 58 and 60, which are bolted to otherwise suitably secured in place. Most of the wear resulting from the dropping of aggregate into the bins takes place on these caps. However, they can be replaced much more readily than the duct sections.
The protective caps preferably extend substantially from one end wall to the opposite end wall in each bin. They are preferably of an exteriorly peaked shape to prevent aggregate from accumulating. Desirably the tops of duct sections 46 and 48 are also peaked and conform to the undersides of the caps so that heat transfer can take place through the caps when the bins are full of aggregate.
The positions and configurations of duct sections 46 and 48 are such that when bin 32 is full, the duct sections are substantially completely surrounded by aggregate in the transverse plane on which FIG. 2 is taken. Because the duct sections are substantially completely surrounded, a highly effective transfer of heat takes place from the exhaust gases within the duct sections to the aggregate within the bin.
For still further improvement of heat transfer, water spray bars 71, 73 and 75 are provided in the interior of duct section 26, as shown in FIG. 5. Each bar has a series of nozzles arranged to spray water in the direction of exhaust flow. Bar 75, for example has a series of five nozzles 77. Water is supplied through a manifold 79.
The introduction of a spray of water at a location near where the exhaust duct sections enter the first bin causes condensation to begin near that location rather than at some intermediate location between the first and last bin. This contributes to the maximization of heat transfer by causing the moisture content of the exhaust gases to give up its latent heat of vaporization while the exhaust gases are passing through the bins rather than after they are exhausted to the atmosphere. The effectiveness of heat transfer can be improved by controlling the rate of water introduction while measuring bin and exhaust gas temperatures.
In the operation of the system just described, dampers 22 and 24 can be adjusted to divert any desired proportion of the exhaust gas from duct section 18 into duct section 26. As the exhaust passes through the duct sections within the bins, it is cooled by the surrounding aggregate, and water vapor in the exhaust condenses. The condensation process continues throughout the lengths of duct sections 46 and 48 within the confines of the feed bins. A relatively constant exhaust temperature and duct section temperature of about 200° F. is maintained throughout the length of duct sections 46 and 48.
The condensate flows downwardly through the duct sections which extend through the feed bins, and flows out through outlet 36. Exhaust gas passes upwardly through exhaust stack 34.
The interior of duct sections 46 and 48 may be protected by inert lining materials or coatings to minimize corrosion. For example, liners of silicone rubber or other suitable plastic materials can be applied by spraying. Alternatively, various coatings such as epoxy paints can be used.
Various modifications can be made to the system just described. For example, while duct section 26 is bifurcated into sections 46 and 48 in the particular embodiment shown, it can be split into as many duct sections as desired to increase the duct wall area available for transfer of heat from the exhaust to the aggregate.
In another modification, the walls of the feed bins themselves can be used to transfer heat from the exhaust gases to the aggregate by providing the bins with suitable exhaust-conducting jackets.
Of course, the invention is applicable wherever aggregate is dried and heated in an asphalt plant. Thus, for example, the heating of aggregate can be carried out by feeding the exhaust from a drum mixer through the aggregate feed bins in a manner similar to that here described.
Finally, the exhaust of a drying drum or of a drum mixer can be used to preheat used asphaltic concrete before it is recycled into the asphalt-aggregate mixture. This is accomplished by feeding the dryer exhaust through or around the used asphaltic concrete feed bins in a manner similar to that specifically described above with reference to the preheating of virgin aggregate.
Various other modifications can be made to the apparatus and method specifically described herein without departing from the scope of the invention as defined in the following claims.
|
In an asphalt mixing plant, a portion of the heat used to vaporize water in the process of drying aggregate is recovered by conducting dryer exhaust gases through parallel ducts which extend serially through the aggregate cold feed bins. These parallel ducts are vertically elongated for optimum heat transfer and to avoid impeding aggregated flow. The ducts have vertically extending external fins for greater contact with the aggregate in the bins. They also have horizontally extending internal fins for improved heat transfer between the exhaust gases and the ducts. The ducts are peaked, and conforming protective caps are provided to prevent damage to the ducts during loading of the bins. Water injection is used to initiate condensation of water vapor in the exhaust gases.
| 4
|
RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Serial No. 60/803,873, entitled “Systems, Methods, and Apparatuses for Complementary Metal Oxide Semiconductor (CMOS) Antenna Switches Using Switched Resonators,” filed on Jun. 4, 2006, which is incorporated by referenced as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The invention relates generally to antenna switches, and more particularly, to CMOS (complementary metal oxide semiconductor) antenna switches.
BACKGROUND OF THE INVENTION
[0003] In the past decade, the wireless communication industry has experienced explosive growth, which has in turn accelerated the development of integrated circuit (IC) industry. In particular, in the IC industry, many mobile application systems like low noise amplifiers (LNAs), mixers, and voltage-controlled oscillators (VCOs) have been integrated into CMOS technology. Two significant mobile application components-power amplifiers (PAs) and radio frequency (RF) switches—have not yet been commercially integrated into CMOS technology.
[0004] However, IC industry research is quickly moving towards power amplifier integrated into CMOS technology. For example, current research indicates that a CMOS power amplifier may be feasible and be able to provide a significant amount of power, perhaps up to 2 W, for mobile communications. Accordingly, when the power amplifier becomes integrated into CMOS technology, there will be a need for an RF switch integrated into CMOS technology.
[0005] However, current CMOS technology presents a variety of difficulties for its application to RF switches. For example, CMOS material characteristics, including lossy substrates and low breakdown voltages due to low mobility of electrons, have prevented CMOS technology from being used for RF switches that require multi-band operation, high power levels, and/or integration with other devices and circuits.
BRIEF SUMMARY OF THE INVENTION
[0006] Embodiments of the invention may provide for CMOS RF switches, which may be referred to as a CMOS SP4T switch. According to an embodiment of the invention, the CMOS RF switch may be fabricated using a variety of processes, including a 0.18 μm process. Indeed, other processes may be utilized without departing from the embodiments of the invention. In order to provide high power handling capability in a multi-band operation (e.g., about 900 MHz and 1.9 Hz) of the CMOS RF switch, an LC switched resonator scheme may be applied to the receiver switch. According to an embodiment of the invention, the CMOS RF switch may provide higher blocking capability at the transmission (TX) mode as well as low insertion loss at the reception (RX) mode at one or more bands, including multi-band (e.g., 900 MHz and 1.9 GHz). As an illustrative example, the CMOS RF switch may achieve a P1 dB watt level power handling capability at 900 MHz and 1.90 Hz respectively with −1.4 dB insertion loss at both bands (900 MHz and 1.9 Gz) in the TX mode. Likewise, in the RX mode, the CMOS RF switch may also achieve an insertion loss of −0.9 dB and −1.4 dB at around 900 MHz and 1.9 GHz, respectively.
[0007] According to an embodiment of the invention, there is a method for providing a CMOS antenna switch. The method may include providing an antenna operative to transmit and receive signals over at least one radio frequency (RF) band, and coupling the antenna to a transmit switch, where the transmit switch is enabled to transmit a first signal to the antenna and disabled to prevent transmission of the first signal to the antenna. The method may further include coupling the antenna to a receiver switch that forms a filter when enabled and a resonant circuit when disabled, where the filter provides for reception of a second signal received by the antenna and where the resonant circuit blocks reception of at least the first signal.
[0008] According to an embodiment of the invention, there is a system for a CMOS antenna switch. The system may include an antenna that is operative to transmit and receive signals over at least one radio frequency (RF) band, and a transmit switch coupled to the antenna, where the transmit switch is enabled to transmit a respective first signal to the antenna and disabled to prevent transmission of the first signal to the antenna, and a receiver switch coupled to the antenna, where the receiver switch forms a filter when enabled and a resonant circuit when disabled, where the filter provides for reception of a second signal received by the antenna, and where the resonant circuit blocks reception of at least the first signal.
[0009] According to yet another embodiment of the invention, there is a system for a CMOS antenna switch. The system may include an antenna operative at a plurality of radio frequency (RF) bands. The system may further include means for transmitting first signals to the antenna, and means for receiving second signals from the antenna, where the means for receiving forms a filter when the means for receiving is operative, and wherein the means for receiving forms a resonant circuit when the means for transmitting is operative.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0010] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0011] FIGS. 1A and 1B illustrate simplified operations of a receiver switch in accordance with an embodiment of the invention.
[0012] FIG. 2 illustrates a CMOS switch using a switched resonator at a TX mode, in accordance with an embodiment of the invention.
[0013] FIG. 3 illustrates a CMOS switch using a switched resonator at RX mode, in accordance with an embodiment of the invention.
[0014] FIG. 4A illustrates a multi-stacked switch at a TX path, in accordance with an embodiment of the invention.
[0015] FIG. 4B illustrates a simplified equivalent model of on state switch using a body floating technique switch with signal flow, in accordance with an embodiment of the invention.
[0016] FIG. 5 illustrates exemplary receiver switch simulation results, in accordance with an embodiment of the invention.
[0017] FIGS. 6A and 6B illustrate exemplary transmit switch simulation results, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0019] Embodiments of the invention may provide for CMOS RF antenna switches, which may also be referred to as SP4T CMOS switches. The CMOS RF antenna switches in accordance with embodiments of the invention may provide for one or more of multi-band operation, high power level handling, and integration with other devices and circuits. Generally, the CMOS RF antenna switch may include at least one receiver switch and at least one transmit switch. The receiver switch may utilize one or more switched resonators, as will be described in further detail below. The transmit switch may utilize or otherwise employ a body substrate tuning technique, as will also be described in further detail below.
[0020] Description of a Receiver Switch
[0021] In accordance with an embodiment of the invention, the CMOS RF antenna switch, and in particular, the receiver switch component of the RF antenna switch will be now be described in further detail with reference to FIGS. 1-3 . FIGS. 1A and 1B provide an illustrative example of an operation of a simplified CMOS RF antenna switch having a transmit switch 102 and a receiver switch 104 , in accordance with an embodiment of the invention. As shown in FIGS. 1A and 1B , a CMOS RF antenna switch may comprise an antenna 100 in communication with at least one transmit switch 102 and at least one receiver switch 104 . As shown in FIG. 1A , when the transmit switch 102 is ON (e.g., enabled), thereby providing a transmit signal to the antenna 100 , the receiver switch 104 is OFF (e.g., disabled). Likewise, as shown in FIG. 1B , when the receiver switch 104 is ON (e.g., enabled), thereby allowing reception of a receive signal from the antenna 100 , the transmit switch 102 is OFF (e.g., disabled). According to an embodiment of the invention, the antenna 100 may be a single multi-mode (e.g., RX and TX), multi-band antenna, although a plurality of distinct antennas may be utilized according to other embodiments of the invention.
[0022] Still referring to FIGS. 1A and 1B , the receiver switch 104 may be in the form of a switched resonator, according to an embodiment of the invention. This switched resonator may provide distinctly different equivalent circuits, depending on whether the receiver switch 102 is ON or OFF, respectively. In FIG. 1A , when the receiver switch 104 is OFF, an LC resonant circuit may be formed in accordance with an embodiment of the invention. The LC resonant circuit may block the transmit signal provided from the transmit switch 102 in the ON state, thereby maximizing the power of the signal transmitted via antenna 100 . According to an embodiment of the invention, the LC resonant circuit may include at least one inductor 106 in parallel with at least one capacitor 108 . The value of the inductor 106 may be sufficiently large, perhaps over 5 nH, depending on the desired operating frequency of the resonant circuit. It will be appreciated that while the LC resonant circuit is illustrated as a parallel resonant circuit in FIG. 1A , other embodiments of the invention may utilize a series resonant circuit as well (e.g., an RLC resonant circuit).
[0023] On the other hand, in FIG. 1B , when the receiver switch 104 is ON, a filter may be formed, according to an embodiment of the invention. The filter may be a low-pass filter, with a certain cutoff frequency characteristics according to an embodiment of the invention. In addition, the filter may include a very small inductor 1 10 value at the desired operating frequency in order to provide for a low insertion loss. Accordingly, the filter 104 may provide for the reception, with low insertion loss, of at least a portion of the receive signal provided from the antenna 100 . While the above-described filter is illustrated as a low-pass filter, it will be appreciated that other embodiments of the filter may be a bandpass filter, a high-pass filter, or the like.
[0024] FIG. 2 illustrates an illustrative example of an operation of an RF antenna switch 200 in transmit (TX) mode. In particular, FIG. 2 includes an antenna 100 in communication with the transmit switch 102 and the receiver switch 104 . According to an embodiment of the invention, the transmit switch 102 may comprise signal paths for one or more transmit signals. For example, as shown in FIG. 2A , there may be two signal paths that is, signal paths TX 1 and TX 2 controlled by switches M 1 204 and M 2 206 , respectively. The switches M 1 204 and M 2 206 may comprise one or more CMOS switches. Likewise, the receiver switch 104 may include signal paths RX 1 and RX 2 , as controlled by switches M 3 208 , M 4 210 , M 5 212 , M 6 214 , M 7 216 , M 8 218 , and M 9 220 , which may each comprise one or more CMOS switches.
[0025] In FIG. 2 , according to an embodiment of the invention, the RF antenna switch 200 is illustrated as operating in TX mode for signal path TX 1 . With this TX mode configuration for transmit switch 102 , switch M 1 204 is closed and switch M 2 206 is open. In addition, the receiver switch 104 forms an resonant circuit, described in further detail below, by closing switches M 3 208 , M 4 210 while opening switches M 5 212 , M 6 214 , and M 7 216 to provide a high impedance point at node 232 . In addition, although not illustrated as such in FIG. 2 , switches M 8 218 and M 9 220 may also be closed to bypass leakage signals to ground ion order to protect the low-noise amplifier (LNA) from such leakage signals. One of ordinary skill in the art will recognize that in FIG. 2 , signal path TX 2 could have been enabled instead of signal path TX 1 without departing from embodiments of the invention. It will also be appreciated that the configuration of the transmit switch 102 and receiver switch 104 , including the numbers of transmit and receive signal paths, may be varied without departing from embodiments of the invention.
[0026] In the configuration illustrated in FIG. 2 , the power handling capability of the transmit switch 102 may be based upon the impedance of the resonant circuit and the source-to-drain breakdown voltage of cascaded switches M 5 212 , M 6 214 M 7 216 of the receiver switch 104 . In other words, the maximum transmit power of the transmit switch 102 may be dependent upon the impedance and breakdown characteristics of the receiver switch 104 .
[0027] According to an embodiment of the invention, the resonant circuit may be an LC parallel resonant circuit formed by inductors L 1 222 , L 2 224 in parallel with capacitor C 1 226 . In order to provide the desired blocking during the TX mode configuration to maximize the transmit signal power, the inductance value of inductor L 2 224 may be sufficiently large. However, the ratio of the value of inductors L 1 222 and L 2 224 may be related to the power handling of the transmit switch 102 . Accordingly, if the value of L 1 222 is too small, then a large voltage swing may be above the source-to-drain breakdown voltage of switches M 5 212 , M 6 214 , and/or M 7 216 , which are intended to be open to provide a high impedance point at node 232 . Therefore, the value of the inductor L 1 222 may be selected to yield the optimum voltage swing for the TX mode and low insertion loss for the RX mode.
[0028] In accordance with an embodiment of the invention, FIG. 3 provides an illustrative operation of an RF antenna switch 300 in transmit (RX) mode. As shown in FIG. 3 , both switch M 1 204 and switch M 2 206 of the transmit switch 102 are open to isolate antenna 100 from transmit signal paths TX 1 and TX 2 , respectively. However, in enabling receive signal path RX 1 , switches M 3 208 , M 4 210 , and MS 218 are open, while switches M 5 212 and M 6 214 are closed. Further, to bypass leakage signal to ground to protect the low noise amplifier (LNA), switch M 9 220 may be closed. One of ordinary skill in the art will recognize that signal path RX 2 could have been enabled instead of signal path RX 1 without departing from embodiments of the invention.
[0029] Still referring to FIG. 3 , a low-pass filter may be formed using inductor L 1 222 and capacitor C 2 228 . If low insertion loss is a primary consideration, then the inductor L 1 222 value may be as small as possible. However, as described above with respect to FIG. 2 , the value of inductor L 1 222 impacts the voltage swing of the TX mode, and thus, the value of inductor L 1 222 may be selected to provide the optimum voltage swing for the TX mode and low insertion loss for the RX mode.
[0030] Dual Band operation
[0031] As described with reference to FIGS. 1-3 , the receiver switch 104 (e.g., switched resonator) may provide for an LC resonator in the TX mode and an LC lowpass filter for the RX mode. In addition, as shown in FIGS. 2 and 3 , there may be two transmit signal paths TX 1 and TX 2 and two receive signal paths RX 1 and RX 2 . It will be appreciated, however, that fewer transmit or receive paths may be included as desired without departing from embodiments of the invention. In accordance with an embodiment of the invention, TX 1 and RX 1 may be provided for GSM band (e.g., 900 MHz) communications and TX 2 and RX 2 may be provided for DCS/PCS band (e.g., 1.9 GHz) communications, although different bands may be utilized as well. In addition, more than two bands-perhaps three or four bands-may also be supported without departing from embodiments of the invention.
[0032] As the number of signal paths at the antenna 100 increases, however, the power handling capability of the transmit switch 102 may drop. Accordingly, in a single-pole multi-throw switch, it may be desirable to decrease the number of signal paths at the antenna 100 . For instance, as shown in FIGS. 2 and 3 , RX 1 and RX 2 of the receiver switch 104 may share one LC parallel resonator at the antenna 100 front end, where the LC parallel resonator is comprised of inductors L 1 222 , L 2 224 and capacitor C 1 226 . As described above, the LC parallel resonator may block the transmit signals from TX 1 and TX 2 at either band. Instead of having a switched resonator with two switched transmission zeros at dual bands, the LC parallel resonator described above may have only one transmission zero, which may be at 1.5 GHz with a wide band, according to an embodiment of the invention. In addition, the LC parallel resonator may provide for −13 dB, −25 dB and −14 dB return loss at 900 MHz, 1.5 GHz, and 1.9 GHz, respectively.
[0033] Description of a Transmit Switch
[0034] The transmit switch 102 in FIGS. 2 and 3 will now be described in further detail with reference to FIGS. 4A and 4B . In particular, FIG. 4A illustrates a transmit switch 102 structure for switch M 1 204 at TX 1 and switch M 2 206 at TX 2 according to an exemplary embodiment of the invention. As shown in FIG. 4A , switches M 1 204 and M 2 206 may include stacked transistors such as CMOS transistors 402 , 404 , and 406 stacked (e.g., cascaded) from source to drain. By stacking transistors 402 , 404 , and 406 from source to drain, the cumulative breakdown voltage can be increased since it is split among the transistors 402 , 404 , and 406 , thereby providing for a higher power blocking capability. Such a high power blocking capability may be necessary, for example, at switch M 2 206 at TX 2 when switch M 1 204 at TX 1 is closed to transmit a signal. While FIG. 4 illustrates three stacked transistors, it will be appreciated that fewer or more stacked can be cascaded as well.
[0035] However, by stacking the transistors 402 , 404 , and 406 , the insertion loss of the transmit switch 102 may be increased. Accordingly, as shown in FIG. 4A , a body floating technique, which includes connecting high resistor 408 , 410 , and 412 values at the body substrate, may be applied to the transmit switch 102 in accordance with an embodiment of the invention With such a body floating technique, the transistors 402 , 404 , and 406 may use a deep N-well structure, perhaps of a 0.18-um CMOS process, which may be immune to potential latch ups due to connecting high resistor 408 , 410 , 412 values at the body substrate. The resistors 408 , 410 , 412 , which may also be referred to as body floating resistors, may reduce the insertion loss by blocking leakage current to the substrate ground.
[0036] FIG. 4B illustrates signal flow at on single stage switch—for example, transistor 402 , 404 , or 406 . As the size of a transistor 402 , 404 , 406 increases, the parasitic capacitance value becomes high enough so that source-to-body 452 and drain-to-body 454 parasitic capacitor with body floating resistor 456 may be used as signal path c at the ON state. However, if the body is grounded, signal path c in FIG. 4B is bypassed to the ground, which results in degraded insertion loss.
[0037] Simulation results
[0038] FIG. 5 illustrates simulation results for the operation of an exemplary multi-band (e.g., 900 MHz, 1.9 GHz) receiver switch 104 in accordance with an embodiment of the invention. These simulation results illustrate the insertion loss 502 , the isolation 504 from the antenna 100 to the TX, and the isolation 506 between RX 1 and RX 2 . In particular, the insertion loss 502 is illustrated by the top solid line. The isolation 504 measured between the antenna 100 and the TX is illustrated by the middle line. Likewise, the isolation 506 between RX 1 and RX 2 is illustrated by the bottom line.
[0039] FIG. 6 illustrates simulation results for the operation of an exemplary multi-band transmit switch 102 . In particular, the simulation results in FIGS. 6A illustrate the power handling capability while FIG. 6B illustrates the isolation from the antenna 100 to the RX. In both FIGS. 6A and 6B , the solid lines represent simulations at the first band of 1.9 GHz while the circled lines represent simulations at the second band of 900 MHz.
[0040] One of ordinary skill in the art will recognize that the simulation results are provided by way of example only. Indeed, the transmit switch 102 and the receiver switch 104 may be configured for other bands of operation as well. Accordingly, the simulation results may likewise be provided for other bands of operations without departing from embodiments of the invention.
[0041] Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
|
Systems and methods may be provided for a CMOS RF antenna switch. The systems and methods for the CMOS RF antenna switch may include an antenna that is operative to transmit and receive signals over at least one radio frequency (RF) band, and a transmit switch coupled to the antenna, where the transmit switch is enabled to transmit a respective first signal to the antenna and disabled to prevent transmission of the first signal to the antenna the systems and methods for the CMOS RF antenna switch may further include a receiver switch coupled to the antenna, where the receiver switch forms a filter when enabled and a resonant circuit when disabled, where the filter provides for reception of a second signal received by the antenna, and where the resonant circuit blocks reception of at least the first signal.
| 7
|
TECHNICAL FIELD
The present invention relates, in general, to computer software security, and, more particularly, to providing secure operation of transitory computer applications.
BACKGROUND OF THE INVENTION
Modern computers demonstrate their usefulness by the software applications that they run. In the days before extensive networking and the proliferation of the Internet, software applications were typically monolithic, relatively large-scaled and independent programs that were designed to do a single general task. Any data generated or obtained within the application was generally confined to that particular application. With the increased interconnectivity brought about by the Internet, larger applications may interact with transitory smaller applications which could exchange data with remote servers or other remote application, sometimes even without the computer user knowing that this communication interchange is even taking place. Such transitory applications typically are executed for a certain amount of time and eventually end either automatically or at the direction of the user. This interconnectivity, along with the existence of more nefarious applications, such as viruses, trojan horses, and the like, expose computer users to potential loss of data, damaged computers, or even losing money or credit standing through identity theft.
Because of the potential for loss and damage to computers, data, and property, processes and security software have been developed to minimize the potential losses by preventing unsafe applications from either operating or operating successfully. Firewalls attempt to prevent unauthorized access to computer systems; antivirus applications attempt to identify, destroy, and/or quarantine virus programs; and spyware programs attempt to locate and neutralize spyware that may be mining a user's computer for sensitive (or even not so sensitive, but equally personal) data. Thus, a considerable amount of research and technology has been dedicated to preventing unauthorized access to users' computers and disclosure of information located on those computers.
One area that has been addressed for increasing protection and security is in media files. When a file type represents media, such as an image, animation, sound, or the like, users of that file type generally do not expect that opening such files will expose them to any potential harm. These users view such files as containing only media. Users may, thus, develop a habit of opening media files without regard to the trustworthiness of their origin. This lack of suspicion can have great benefits for the free movement of information. However, sophisticated media file types may support embedded scripting commands, and, if a program that opens such files is not carefully written, the commands embedded in such files may perform actions that users would generally not expect or approve. Thus, a program that plays a media file type with embedded scripting commands should take precautions to protect users from unreasonable actions—i.e., such a program should avoid providing any mechanisms by which a creator of a media file can attack the computer or user information with that file. This is an important task for of what is known as a “user agent” program. User agents typically render media file types for users.
Another example system or application that benefits from more secure transactions are in the Web browser. Many modern web browsers offer to store or “remember” certain user information in order to make it easier or more convenient for a user to log into certain of his or her favorite Websites or Web applications. The user IDs and passwords that could be stored or remembered may provide access to data as insignificant as a log of jogging times that a user has amassed during various exercise sessions to critical data and control of the user's bank accounts and financial information. As various transitory applications, applets, or services (collectively “applications”) are run on the user's computer, it is critical to make sure that these applications do not access any of the user's sensitive personal information and, more importantly, that they do not send that information to an unauthorized recipient.
Whenever a computer system introduces restrictions on the actions of various applications, whether indirectly, through proxy, such as a user agent program, or directly through the operating system, it is desirable to prevent only those actions that may cause harm to users, and to allow any actions that can never cause harm. This preserves the greatest possible set of capabilities for such applications while keeping the file type safe for users. Producers and users of such applications both typically desire a rich set of capabilities, but users generally demand safe applications. This tension dictates that a good security application should be constructed to permit the maximum set of capabilities without permitting harm to users.
Many computers may contain, or have access to, data that the user considers private. A user may typically wish that this private data not be shared with an anonymous party, such as the author or provider of a particular application, without the user's express consent. This private data may include presence information, names, or contents of files on the computer's local file systems; presence information, names, or contents of files on other computers in a private local network; configuration of the computer and any applications installed on it; personally identifying information about the user; passwords to various computer and non-computer systems; a history of the consumer's actions; and a considerable number of other forms of private data; or the like.
One type of action that a security system or application would likely prevent is the disclosure of any of the users' private data back to the creator or provider of the application. Such a disclosure becomes a risk whenever the set of embedded commands that the security application supports for any application type includes both the ability to obtain private data from the user or the user's computer, and the ability to send data using a network. An application with both of these capabilities could obtain private data from the user or the user's computer and then use a network to send that private data back to the creator or provider of that application. One tension that a security application or system may resolve is that, on one hand, it may be useful for some applications to be able to obtain private data from the user or the user's computer, and also useful for some applications to be able to send data using a network; but that, on the other hand, it may be dangerous to permit a single application to perform both of these actions.
One technology that has been used to secure data from unauthorized disclosure is referred to as “tainting.” Tainting, in general, is the process of tagging or marking the origin of every single piece of data that comes into the computer system and preventing certain of that data from flowing out of the system. A tainting security application or system checks each of the tags or marks on each piece of data and determines which of those pieces of data may be either accessed, transmitted, or other such operation. Tainting, while allowing a flexible security system, is extremely complex and problematic. Problems arise because the tag or mark should be preserved throughout the life of that data, whether the data is modified, copied, sent through some application programming interface (API), or otherwise changed or processed in any manner. If the tag or mark is not preserved, then it would be very easy to defeat the tainting security system simply by copying or only slightly modifying the information The problem with this is that it is very difficult to implement correctly. The complexity of monitoring each piece of data throughout its life and attempting to preserve all of the tainting tags and marks makes it very easy to introduce bugs or flaws into a system that already has tainting built into it. The complexity also makes it very difficult for programmers to understand as well, because the tainting system can produce very baffling failures that are difficult to reproduce because everything is dependent on a very sensitive set of conditions.
BRIEF SUMMARY OF THE INVENTION
Representative embodiments of the present invention are related to the determination of conditions within a computer application that would create the desire to allow or disallow access to certain system functions or features by the application. The security application analyzes the conditions and sets a lock that enables the application to perform only certain types of actions that would be considered secure by the security application.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a computer network including a user computer configured according to one embodiment of the present invention;
FIG. 2 is a block diagram illustrating a computer network including a user computer configured according to one embodiment of the present invention;
FIG. 3A is a flowchart illustrating example steps executed to implement one embodiment of the present invention;
FIG. 3B is a flowchart illustrating example steps executed to implement one embodiment of the present invention;
FIG. 3C is a flowchart illustrating example steps executed to implement one embodiment of the present invention;
FIG. 4 is a block diagram illustrating a media player configured according to one embodiment of the present invention; and
FIG. 5 illustrates a computer system adapted to use embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram illustrating computer network 10 including user computer 100 configured according to one embodiment of the present invention. User computer 100 with display 107 connect to Internet 101 via network interface 104 . In normal operation, the user runs various programs and applications, such as word processing programs, spreadsheet programs, game programs, graphics programs, and the like. When accessing Internet 101 , the user could operate a Web browser on user computer 100 that interprets the Hypertext Markup Language (HTML) documents to display various Web pages, or operates multimedia players or plugins, such as Adobe Systems Incorporated's, FLASH PLAYER®, which operates to play media files or rich internet applications (RIA), RealNetworks, Inc.'s REALPLAYER™, Microsoft Corp.'s WINDOWS MEDIA PLAYER™, or the like, which operate to play media.
Modern software packages usually include some kind of online support, such that the programs themselves access Internet 101 and check their home sites for software updates, verify licenses, and the like. The user may or may not know or be made aware that these software products are accessing Internet 101 to obtain or exchange this information. However, in order to prevent an application running on user computer 100 from improperly accessing personal data on user computer 100 and sending it to a remote server, such as servers 108 and 109 via Internet 101 , user computer 100 operates security application 105 . It should be noted that security application 105 may be a separate program running within user computer 100 or may be a system utility that either comes with or has been added to the operating system or administrative software of user computer 100 .
When application 106 is loaded into memory for execution, it first registers with security application 105 . The registration process allows application 106 to declare which rights it maintains for operating or accessing the system functionality of user computer 100 . Once the declaration has been made, security application 105 monitors the operation of application 106 and provides instructions executed by processor 102 that prohibit application 106 from operating or accessing the system functionality that was not declared. For example, it may be advantageous for application 106 to access remote server 109 in order to receive program updates. This advantageous process would support application 106 accessing Internet 101 through network interface 104 . Therefore, when application 106 starts up, it declares to security application 105 that it will access network interface 104 in order to access remote server 109 through Internet 101 .
If application 106 attempts to access personal information in storage 103 , security application 105 intercepts the access request and prohibits application 106 from accessing storage 103 in violation of its initial declaration. In this manner, application 106 is able to perform its beneficial task of interacting with Internet 101 and remote server 109 , but user computer 100 is secured from personal information being read from storage 103 and broadcast over Internet 101 .
It should be noted that many different system functions may be a part of the declaration process for applications. In the example above, only two such functions were mentioned: accessing storage 103 for personal data, and accessing network interface 104 for performing communications with Internet 101 . However, the various additional and/or alternative embodiments of the present invention are not limited only to two available choices for system functionality. Available system functions could include accessing certain memory locations, deleting from memory or from certain memory locations, writing to memory or certain memory locations, accessing system configuration information, modifying system administration programs, forming an ad hoc network with a neighboring computer, and the like. The various embodiments of the present invention may provide for an application to declare one or more system functions, it may alternatively form the multiple functions into discrete groups that the application could only choose one group or another, it may further detail certain combinations of system functions that may not be declared by any one application. Any combination of selections for system functions would be operable with the various embodiments of the present invention.
It should further be noted that, instead of providing for a declarative system, where each application explicitly declares which system functionality it selects to have access to, a dynamic system may be used, where the security system, such as security application 105 , monitors the activities of the application and, based on those activities, security application 105 would assign available system functionality or a combination thereof to the running application. For purposes of example, FIG. 1 may also be used to describe this more dynamic alternative embodiment. As application 106 starts up, security application 105 would begin monitoring each activity that application 106 performs, in this alternative embodiment. On start up, one of the first hidden tasks that application 106 performs is to connect to remote server 109 to check for any updates to the software. When application 106 accesses network interface 104 to establish connection to Internet 101 , security application 105 assigns a category of operation that would allow application 106 to access Internet 101 through network interface 104 , but would prohibit application 106 from accessing storage 103 to obtain personal information. With this dynamic system, the application would not need the additional coding to implement the declarative system.
FIG. 2 is a block diagram illustrating computer network 20 including user computer 200 configured according to one embodiment of the present invention. Unlike security application 105 ( FIG. 1 ), which operates as a separate security application either as a part of the operating system or working in concert with the operating system or other administrative software, the secure aspect of the present invention, as implemented in the presently described embodiment of FIG. 2 , operates in a standard helper program, such as user agent 205 . A user agent is a client application used with a particular network protocol for retrieving and rendering or assisting to retrieve and render content. Examples, of various types of user agents include Web browsers, media players, plug-ins, and other programs—including assistive technologies—that help in retrieving and rendering content. Thus, a user agent will often act as a container within which the application will execute.
Returning to FIG. 2 , when application 206 is called up to run, user agent 205 is activated and runs or renders application 206 within its container. Processor 202 executes the instructions of user agent 205 and the instructions of application 206 , to the extent that user agent 205 permits those instructions. The security features available within user agent 205 operate similarly to those described in FIG. 1 (both in the declarative and dynamic embodiments). For example, if user agent 205 is configured to operate in a declarative way according to one embodiment of the present invention, as application 206 begins to run, it declares to user agent 205 what system functions it will maintain access to. For purposes of the example represented in FIG. 2 , application 206 selects to access personal data in storage 203 and retain authority to modify such data and store the modified data back into storage 203 . Once the declaration has been made, user agent 205 monitors the activity of application 206 and its interaction with user computer 200 . Requests for personal information within storage 203 will be allowed. However, if application 206 requests access to network interface 204 in order to access Internet 101 , user agent 205 prohibits application 206 from accessing network interface 204 .
It should be noted that, in the declarative embodiments, if an application, such as application 206 , attempts to declare system features that combine to create a security risk, user agent 205 would consider application 206 an invalid application and shut it down before it can begin normal operation.
As a complementary example of FIG. 2 , if user agent 205 is configured to operate in a dynamic way according to one embodiment of the present invention, as application 206 begins to run, user agent 205 monitors its actions. Depending on the actions that application 206 performs, user agent 205 creates a profile for application 206 that includes acceptable system features and prohibited system features. For example, if application 206 begins by accessing personal information from storage 203 , user agent 205 would establish the profile for application 206 to prohibit any access to network interface 204 for connecting to Internet 101 . Alternatively, if application begins by accessing network interface 204 to connect to remote servers 207 and/or 208 through Internet 101 , user agent would establish the profile to prohibit access to personal information on storage 203 . If application 206 would thereafter attempt to access one of the prohibited system features or functions, user agent 205 would intercept and prevent such access, thus, preserving the security of user computer 200 .
It should be noted that in additional and/or alternative embodiments of the present invention, instead of performing the declaration or dynamic assignment of system functionality access rights during the runtime of a particular application, the various embodiments of the present invention may be implemented to determine the access rights of the application before runtime. Without executing the application, the security system could analyze the code or script of the application to determine the various system features and functionality that should be accessible to the application.
Applying this additional and/or alternative embodiment to FIG. 1 , security application 105 is programmed to parse through the code of application 106 prior to execution to analyze the system functionality that application 106 will use. After analyzing the code of application 106 , security application 105 would determine that application 106 should be able to access network interface 104 in order to connect to Internet 101 , but should be prohibited from accessing personal information in storage 103 . In similar application to FIG. 2 , prior to executing application 206 , user agent 205 analyzes the code and operability of application 206 to determine that it should be allowed to access personal information stored in storage 203 , but prohibited from accessing network interface 204 to connect to Internet 101 . In this manner of implementation, the access rights are determined prior to executing the application. This pre-approval process adds a layer of security to the user's computer.
FIG. 3A is a flowchart illustrating example steps executed to implement one embodiment of the present invention. In step 300 , a declaration is received from a computer application, where the declaration includes a set of actions performable by the computer application. A plurality of system functions are compared with the set of actions in step 301 . Non-secure combinations of any of the system functions and the set of actions are determined in step 302 . Non-secure or unsafe combination of system functions are any two or more system functions that, when available for operation to a single application, may present opportunities for the application to perform a set of actions that places the security or safety of the user's computer at risk. For example, allowing an application the combination to access sensitive personal information and also access a network interface would provide a means for the application to copy such personal information and transmit over the network with the user's knowledge or approval. Another example of a non-secure or unsafe combination is providing an application a combination of the ability to access and modify parts of the operating system stored on the user's computer. In a virus example, a virus may gain access to and modify the Master Boot Record on the computer hard disk, thus, potentially damaging or deleting critical system attributes.
In step 303 , certain ones of the system functions that comprise the non-secure combinations are selected. A set of restrictions is created, in step 304 , responsive to the selection. Responsive to the set of actions, the set of restrictions are assigned, in step 306 , to the computer application, where the restrictions prevent the computer application from accessing select ones of the system functions. For example, a particular application may be assigned a set of restrictions that includes no access to personal information, no modification of system files, and no modification of hardware configuration files. A different application may be assigned a set of restrictions that includes no access to the network interface; no access or modification rights for system files, and no access or modification of hardware configuration files. Various different combinations of such system functions may be compiled and assigned to particular applications. If, in step 307 , another declaration is received from the computer application that includes one or more actions within the set of restrictions, the system will either cease execution of the computer application or reject the other declaration in step 308 . In step 309 , execution of the computer application is monitored. The computer application is prohibited from accessing the select ones of the system functions within the set of restrictions in step 310 .
It should be noted that in alternative embodiments of the present invention, instead of the set of restrictions being created on an ad hoc basis, there would be a predetermined list of combinations of system functions that are non-secure. In such an embodiment, instead of executing steps 301 - 304 , a set of restrictions are selected, in step 305 , from a database of pre-determined non-secure combinations of any of the system functions with any of the set of actions, wherein the selection is responsive to the set of actions.
FIG. 3B is a flowchart illustrating example steps executed to implement one embodiment of the present invention. Several of the steps executed in FIG. 3B were also executed in the embodiment described in FIG. 3A . Therefore, the same element numbers are used in those instances to avoid confusion. In step 309 , execution of the computer application is monitored. A profile of actions is created, in step 311 , for the computer application, responsive to the monitoring, wherein the profile of actions is stored as the set of actions. A plurality of system functions are compared with the set of actions in step 301 . Non-secure combinations of any of the system functions and the set of actions are determined in step 302 . In step 303 , certain ones of the system functions that comprise the non-secure combinations are selected. A set of restrictions is created, in step 304 , responsive to the selection. Responsive to the set of actions, the set of restrictions are assigned, in step 306 , to the computer application, where the restrictions prevent the computer application from accessing select ones of the system functions. The computer application is prohibited from accessing the select ones of the system functions within the set of restrictions in step 310 .
As with the example from FIG. 3A , a predetermined list of combinations of system functions that are non-secure may be used to select the set of restrictions, in step 305 , instead of executing steps 301 - 304 .
FIG. 3C is a flowchart illustrating example steps executed to implement one embodiment of the present invention. Again, several of the steps from FIGS. 3A & 3B are executed in the embodiment described in FIG. 3C . In those instances, the same element numbers have been used to avoid confusion. In step 312 , the code defining a computer application is analyzed prior to execution of the application. In step 313 , a set of actions performable by a computer application is determined, responsive to the pre-execution code analysis. A plurality of system functions are compared with the set of actions in step 301 . Non-secure combinations of any of the system functions and the set of actions are determined in step 302 . In step 303 , certain ones of the system functions that comprise the non-secure combinations are selected. A set of restrictions is created, in step 304 , responsive to the selection. Alternatively, a set of restrictions are selected, in step 305 , from a database of pre-determined non-secure combinations of any of the system functions with any of the set of actions, wherein the selection is responsive to the set of actions. Responsive to the set of actions, the set of restrictions are assigned, in step 306 , to the computer application, where the restrictions prevent the computer application from accessing select ones of the system functions. In step 309 , execution of the computer application is monitored. The computer application is prohibited from accessing the select ones of the system functions within the set of restrictions in step 310 .
FIG. 4 is a block diagram illustrating media player 402 configured according to one embodiment of the present invention. Media player 402 is capable of obtaining private user data from local files 405 and also is capable of communicating with remote server 407 over Internet 101 . Because allowing both system functions could jeopardize the security of the user of computer 400 , media player 402 includes a security considerations as implemented by the presently-described embodiment. When a user desires to play a media file, such as media file 404 , media player 402 is activated. Media file 404 is run within the container of media player 402 . On start up, media file 404 declares to media player 402 that it will operate in the “access local files only” mode. This mode allows media player 402 to obtain personal information from local files 405 , but signals media player 402 that media file 404 is not allowed to access Internet 101 through network interface 406 . Therefore, if the script within media file 404 is written to access personal information on local files 405 , but is also written to attempt to access Internet 101 through network interface 406 , media player 402 would prohibit any access to network interface 406 .
It should be noted that, as described in the previous examples, additional and alternative embodiments of the present invention could provide for media player 402 to assign a set of restrictions to media file 404 based on its observing media file 404 perform a set of actions. Further additional and alternative embodiments of the present invention could provide for media player 402 to analyze the set of actions operable by media file 404 without actually running or executing media file 404 . In such an embodiment, the restrictions would be set prior to the application even executing.
The program or code segments making up the various embodiments of the present invention may be stored in a computer readable medium or transmitted by a computer data signal embodied in a carrier wave, or a signal modulated by a carrier, over a transmission medium. The “computer readable medium” may include any medium that can store or transfer information. Examples of the computer readable medium include an electronic circuit, a semiconductor memory device, a ROM, a flash memory, an erasable ROM (EROM), a floppy diskette, a compact disk CD-ROM, an optical disk, a hard disk, a fiber optic medium, a radio frequency (RF) link, and the like. The computer data signal may include any signal that can propagate over a transmission medium such as electronic network channels, optical fibers, air, electromagnetic, RF links, and the like. The code segments may be downloaded via computer networks such as the Internet, Intranet, and the like.
FIG. 5 illustrates computer system 500 adapted to use embodiments of the present invention, e.g. storing and/or executing software associated with the embodiments. Central processing unit (CPU) 501 is coupled to system bus 502 . The CPU 501 may be any general purpose CPU. However, embodiments of the present invention are not restricted by the architecture of CPU 501 as long as CPU 501 supports the inventive operations as described herein. Bus 502 is coupled to random access memory (RAM) 503 , which may be SRAM, DRAM, or SDRAM. ROM 504 is also coupled to bus 502 , which may be PROM, EPROM, or EEPROM. RAM 503 and ROM 504 hold user and system data and programs as is well known in the art.
Bus 502 is also coupled to input/output (I/O) controller card 505 , communications adapter card 511 , user interface card 508 , and display card 509 . The I/O adapter card 505 connects storage devices 506 , such as one or more of a hard drive, a CD drive, a floppy disk drive, a tape drive, to computer system 500 . The I/O adapter 505 is also connected to a printer (not shown), which would allow the system to print paper copies of information such as documents, photographs, articles, and the like. Note that the printer may be a printer (e.g., dot matrix, laser, and the like), a fax machine, scanner, or a copier machine. Communications card 511 is adapted to couple the computer system 500 to a network 512 , which may be one or more of a telephone network, a local (LAN) and/or a wide-area (WAN) network, an Ethernet network, and/or the Internet network. User interface card 508 couples user input devices, such as keyboard 513 , pointing device 507 , and the like, to the computer system 500 . The display card 509 is driven by CPU 501 to control the display on display device 510 .
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
|
A security application is described for determining conditions within a computer application that would create the desire to allow or disallow access to certain system functions or features by the application. The security application analyzes the conditions and sets a lock that enables the application to perform only certain types of actions that would be considered secure by the security application.
| 6
|
BACKGROUND
[0001] The invention relates to a carabiner comprising a bow exhibiting an insertion opening, which exhibits first and second ends delimiting the insertion opening, a closing part, which adopts a closed position in the closed state of the carabiner, in which position the closing part closes the insertion opening, wherein first and second ends of the closing part engage with the first and second ends of the bow, and which can be pivoted relative to the bow into a first open position about a pivot axis configured in the region of the first ends of the bow and of the closing part engaged with one another, in order to open the carabiner, wherein the second end of the closing part moves into the area of an interior of the carabiner enclosed by the bow and the closing part in the closed state of the carabiner, and an operating arm, which keeps the closing part in its closed position in an initial position and which can be adjusted to open the carabiner.
[0002] A carabiner of this kind is disclosed in EP 1 229 258 A2. The operating arm is mounted at its first end on a portion of the bow opposite the insertion opening. Its second end is operatively connected to the closing part, for example in that it passes through an elongated opening in the closing part. When the operating arm is manipulated on the closing part, a tensile force pivoting the closing part into the opening position can be exerted via this second end.
[0003] A carabiner is disclosed in FR 2 536 805 A1, which exhibits a locking bolt to secure the closing part and prevent accidental opening. This locking bolt is pivotably mounted on a portion of the bow opposite the insertion opening. In its initial position predetermined by spring preloading, its free end lies on the inside of the closing part and prevents the closing part from pivoting inwards. After the pivoting of the locking bolt, the closing part can be pivoted inwards and the carabiner opened. Further carabiners of this kind are disclosed in FR 2 439 330 A and FR 2 485 658 A.
[0004] DE 19839853 A1 shows a carabiner comprising a member which restricts the movement space of an object, particularly a rope, suspended therein. Transverse loads on the carabiner, which could cause the carabiner to fracture, should thereby be avoided. This member restricting the movement space extends in the area between the closing part and the rear area of the bow opposite the closing part, for example it is pivotably mounted on the rear portion of the bow and its free end is adjacent to the closing part.
[0005] Carabiner hooks with pivotably mounted locking bolts on or in the closing part, which secure the carabiner in the closed state, are disclosed in WO 91/13264 and AT 400976 B, for example.
SUMMARY
[0006] The objective to be addressed by the invention is to provide a carabiner of the kind mentioned above with an extended function. This is achieved by a carabiner having one or more features of the invention.
[0007] In the case of the carabiner in the invention, the closing part can be moved into two different open positions, wherein it is pivoted about different pivot axes. In the first open position, the closing part is pivoted about a pivot axis, which is formed by the first ends of the bow and of the closing part which are engaged with one another. The second ends of the bow and of the closing part, which are engaged in the closed position of the closing part, in which position the carabiner is closed, are disengaged in this case when the closing part is pivoted about this pivot axis. In the second open position of the closing part, the closing part is pivoted about a pivot axis, which is formed by the second ends of the bow and of the closing part which are engaged with one another. When the closing part is pivoted, starting from its closed position, into its second open position, the first ends of the bow and of the closing part which are engaged in the closed position are disengaged.
[0008] In the closed state of the carabiner, in which the closing part is in its closed position, the operating arm adopts an initial position. In this initial position, the operating arm supports the closing part to prevent pivoting, both about the pivot axis formed by the engaged first ends of the closing part and of the bow and also about the pivot axis formed by the second ends of the closing part and of the bow which are engaged with one another, and keeps both the first ends of the bow and of the closing part and also the second ends of the bow and of the closing part engaged with one another. The operating arm is adjustable starting from its mid-position in the direction of a first end position or in the direction of a second end position. This adjustment may be made by a pivoting and/or movement of the operating arm as a whole or by a bending of the operating arm. The pivoting or movement or bending takes place in this case with adjustments in the direction of the first and of the second end position in opposite directions.
[0009] During its adjustment into the first end position or into the second end position, the operating arm advantageously not only releases the closing part for pivoting about one of its two pivot axes, but exerts a force on the closing part which pivots said closing part into the first open position or the second open position. For this reason, in a possible embodiment, the second end of the operating arm is conducted via an elongated hole guide (=link block guide) opposite the closing part. The elongated hole (=slotted link opening) in this case is preferably configured in the closing part and is passed through by the operating arm in the area of its second end.
[0010] If the operating arm is adjusted into its end position, starting from its initial position, the closing part is pivoted into its open position. If the operating arm is pivoted into the second end position, starting from its initial position, the closing part is pivoted into its second open position. In the starting position of the operating arm, a pivoting of the closing part about both pivot axes is blocked and both the first ends of the bow and of the closing part and also the second ends of the bow and of the closing part are kept in mutual engagement by the operating arm and the carabiner is in its closed state.
[0011] The operating arm is adjustable from its initial position either in the direction of the first end position or in the direction of the second end position against the restoring force of at least one spring-biased member. Without the influence of external forces, the operating arm is held in its initial position by at least one spring-biased member.
[0012] The operating arm is advantageously connected to a rear portion of the bow opposite the insertion opening in the area of its first end and in the area of its second end to the closing part, wherein it divides the interior enclosed by the bow and the closing part in the closed state of the carabiner into two separate compartments. Opening in the first compartment takes place in this case by pivoting the closing part into its first end position; opening of the second compartment takes place by pivoting the closing part into its second open position. The compartments are therefore alternatively accessible by pivoting the closing part into its first open position and by pivoting the closing part into its second open position, in order to suspend a loop, for example, or for suspension in an anchored rope.
[0013] It is conceivable and possible for a locking device to be provided, through which the pivoting of the closing part about one of its pivot axes can be blocked. If an object, for example a loop, is suspended in the associated compartment of the carabiner and the pivoting of the closing part about its pivot axis is blocked using the locking device, the carabiner is secured at the suspended object, but the second compartment can still be opened by pivoting of the closing part about the other pivot axis, in order to suspend the carabiner in different objects, for example different portions of an anchored rope. Separate blocking devices could also be provided for pivoting about both pivot axes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Further advantages and details of the invention are explained using the attached drawing. In the drawing:
[0015] FIG. 1 shows a view of a carabiner according to a first embodiment of the invention in the closed state;
[0016] FIG. 2 shows the carabiner from FIG. 1 in the first open position of the closed part;
[0017] FIG. 3 shows a front view of the carabiner hook in the state in FIG. 2 , viewed in direction A;
[0018] FIG. 4 shows the carabiner from FIG. 1 in the second open position of the closed part;
[0019] FIG. 5 shows a schematic representation of the forces in the case of a force acting decentrally on the closed closing part;
[0020] FIG. 6 shows a representation of the ends of the bow and of the closing part during the opening of the closing part in the area of these ends;
[0021] FIG. 7 shows a representation of the ends of the bow and of the closing part when pivoting the closing part about the pivot axis formed by these engaged ends;
[0022] FIG. 8 shows a view of a carabiner in the closed state according to a second embodiment;
[0023] FIG. 9 shows a view of a carabiner in the closed state according to a third embodiment;
[0024] FIG. 10 shows a view of a carabiner in the closed state according to a fourth embodiment, and
[0025] FIG. 11 shows the carabiner from FIG. 10 in one of the open positions of the closing part.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Parts which are similar or have the same effect are labeled with the same reference numbers in the different embodiments.
[0027] A first exemplary embodiment of a carabiner according to the invention is represented in FIGS. 1 to 7 in partially schematic form. The carabiner comprises a substantially C-shaped bow 1 exhibiting an insertion opening 2 . The insertion opening 2 lies between the first and second ends 3 , 4 of the bow 1 . A rear portion 5 of the bow 1 lies opposite the insertion opening 2 . The rear portion 5 is connected to the first end 3 of the bow 1 via a first bow portion 6 extending in a curved manner and the second end 4 of the bow 1 is connected to the rear portion 5 via a second bow portion 7 extending in a curved manner. The first and second bow portions 6 , 7 in the exemplary embodiment are configured in a continuously curved manner up to an end portion adjoining the respective end. A straight-running portion could also exist, for example, in the case of one of the bow portions 6 , 7 or in the case of both bow portions 6 , 7 between two portions extending in a curved manner.
[0028] A closing part 8 is used to close the insertion opening 2 in a closed state of the carabiner. The closing part 8 exhibits first and second ends 9 , 10 and extends in a (straight-line) longitudinal direction in the exemplary embodiment, as this is preferred. This longitudinal direction lies parallel to the rear portion 5 in this case. An angular alignment in respect of the rear portion 5 is also possible. Asymmetric carabiners of this kind are used as mountaineering carabiners, for example.
[0029] In the closed state of the carabiner, in which the closing part 8 is in its closed position, the first end 9 of the closing part 8 is engaged with the first end 3 of the bow 1 and the second end 10 of the closing part 8 is engaged with the second end 4 of the bow 1 . In the closed position of the closing part 8 , the bow 1 and the closing part 8 together enclose an interior 11 of the carabiner over the entire periphery of the interior 11 , in other words in the manner of a closed ring.
[0030] The bow 1 , the closing part 8 and the interior 11 , which can also be referred to as the carabiner opening, lie on a common plane in this case (=plane or central plane of the carabiner).
[0031] The first end 9 of the closing part 8 and the first end 3 of the bow 1 are engaged when a bolt 12 fixed on the bow 1 is held in a slot 13 open to the edge of the closing part 8 facing away from the interior 11 , said slot being formed in the closing part 8 in the area of the first end 9 thereof. The bolt 12 extends between two side walls 14 , 15 of the bow 1 , which are made available by a recess in the end portion of the bow 1 . The end 9 of the closing part 8 lies between these side walls 14 , 15 .
[0032] In the same way, the second ends 4 , 10 of the bow 1 and of the closing part 8 are in mutual engagement. The bolt 12 ′, which extends between the side walls 14 ′, 15 ′, is held in the slot 13 ′, which is formed in the area of the second end 10 of the closing part 8 and is in turn open to the edge of the closing part 8 facing away from the interior 11 . The end 10 of the closing part 8 lies between the side walls 14 ′, 15 ′.
[0033] The bolt 12 , 12 ′ could also project on both sides beyond a center bar disposed at the respective end of the bow 1 or else bolt parts of this kind could stick out on both sides from a center bar. The slots 13 , 13 ′ at the respective end of the closing part 8 could then be disposed on side walls which overlap the center bar on both sides.
[0034] The reverse configuration, in which the bolts 12 , 12 ′ are fixed to the closing part 8 in the end areas of the closing part 8 and the slots 13 , 13 ′ are disposed in the end areas of the bow 1 , is also conceivable and possible. In turn, side walls could also be formed in this case by a recess in the respective end 3 , 4 of the bow 1 or in the respective end 9 , 10 of the closing part 8 , between which the end portion of the other of these two parts 1 , 8 projects. If the slots 13 , 13 ′ were disposed in the end portions of the bow 1 , they would be designed open to the interior 11 .
[0035] To open the carabiner 1 starting from its closed state represented in FIG. 1 , the closing part 8 is pivoted either about the pivot axis 16 formed by the first ends 3 , 9 of the bow 1 and of the closing part 8 , which are engaged with one another, or in the pivot axis 17 formed by the two ends 4 , 10 of the bow 1 and of the closing part 8 , which are engaged with one another. FIG. 2 shows the maximum pivot of the closing part 8 about the pivot axis 16 , in which the closing part 8 is located in its first open position. FIG. 4 shows the maximum pivot about the pivot axis 17 , in which the closing part 8 is located in its second open position. When the closing part 8 is pivoted about the pivot axis 16 , the second ends 4 , 10 of the bow 1 and of the closing part 8 become disengaged and the second end 10 of the closing part 8 moves into the area of the interior 11 . During pivoting about the pivot axis 17 , the first ends 3 , 9 of the bow 1 and of the closing part 8 become disengaged and the first end 9 of the closing part 8 moves into the area of the interior 11 .
[0036] The pivot axes 16 , 17 are at right angles to the plane in which the bow 1 , the closing part 8 and the interior 11 lie (=main plane of the carabiner).
[0037] In order to keep the first ends 3 , 9 of the bow 1 and of the closing part 8 and also the second ends 4 , 10 of the bow 1 and of the closing part 8 in the closed position of the closing part 8 in mutual engagement, an operating arm 18 is provided. The operating arm 18 is connected to the rear portion 5 of the bow 1 via its first end and to the closing part 8 via its second end. In the initial position of the operating arm 18 , in which it keeps the closing part 8 in its closed position, the second end of the operating arm 18 is connected to the closing part 8 in the area between the two pivot axes 16 , 17 thereof.
[0038] In the exemplary embodiment, the operating arm 18 is pivotably mounted by its first end to the rear section 5 of the bow 1 . The connection of the operating arm 18 to the closing part 8 is made in the exemplary embodiment via an elongated hole guide, which may also be referred to as a link block guide, wherein the second end of the operating arm 18 passes through an elongated hole 19 formed in the closing part 8 . The elongated hole 19 exhibits an arc-shaped course, with the pivot axis 20 of the operating arm 18 as the center.
[0039] The pivot axis 20 of the operating arm 18 lies at right angles to the shared plane of the bow 1 , of the closing part 8 and of the interior 11 or else parallel to the pivot axes 16 , 17 .
[0040] The operating arm 18 passes through the interior 11 in the area between its ends connected to the rear portion 5 , on the one hand, and to the closing part 8 , on the other, and divides said interior into compartments 11 a , 11 b . In the first open position of the closing part 8 , an object to be suspended in the carabiner through the insertion opening 2 of the bow 1 can be introduced into the compartment 11 a ( FIG. 2 ), in the second open position of the closing part 8 into the compartment 11 b ( FIG. 4 ).
[0041] The operating arm 18 is represented in FIG. 1 in its initial position. In this position, the operating arm 18 is held against the restoring force of spring elements 21 , 22 . The spring elements 21 , 22 may be formed, for example, by compression springs held in the elongated hole 19 , which are supported between the edge lying at the longitudinal end of the elongated hole 19 in each case and the operating arm 18 .
[0042] In the first open position of the closing part 8 illustrated in FIG. 2 , the operating arm 18 is located in its first end position; in the second open position of the closing part 8 represented in FIG. 4 , the operating arm 18 is in its second end position. In the exemplary embodiment, in which the operating arm 18 is pivotably mounted about the pivot axis 20 , the operating arm 18 is adjusted from its initial position into one of its end positions by pivoting about the pivot axis 20 . In this case, the pivoting direction during pivoting into the first end position is opposite to the pivoting direction during adjustment into the second end position.
[0043] In the exemplary embodiment of a symmetrical carabiner shown, the initial position of the operating arm 18 preferably lies in the middle between the two end positions.
[0044] In order to lock the closing part 8 in its closed position, the operating arm 18 interacts with a support surface 23 of the operating arm 18 facing the interior 11 . In the exemplary embodiment, this support surface is formed by the edge of the elongated hole 19 . At this support surface 23 , the closing part 8 is supported on the operating arm 18 to prevent pivoting about one of its pivot axes 16 , 17 and to prevent movement in the direction of the rear portion 5 . The surface normal on the support surface 23 faces the point at which a compressive force acting on the operating arm 18 is deflected onto the bow 1 , in other words onto the pivot axis 20 of the operating arm 18 in this exemplary embodiment.
[0045] If the operating arm 18 is adjusted starting from its mid-position in the direction of one of the two end positions, the locking of the closing part 8 in its closed position continues to exist in a first segment of the adjustment path, which is advantageously at least 30% of the total adjustment path in the respective adjustment direction.
[0046] If the operating arm 18 reaches the end of the adjustment path in the elongated hole guide formed by the elongated hole 19 during adjustment in the direction of one of its settings, then during further adjustment of the operating arm 18 in the direction of its end position in each case, the closing part 8 is pivoted about the respective pivot axis 16 , 17 by the operating arm 18 , in other words, during adjustment of the operating arm 18 in the direction of its first end position, about the pivot axis 16 formed by the engaged first ends 3 , 9 of the bow 1 and of the closing part 8 , and during adjustment of the operating arm 18 in the direction of its second end position, about the pivot axis 17 formed by the engaged second ends 4 , 10 of the bow 1 and of the closing part 8 . In the exemplary embodiment shown, the end of the adjustment path is reached in the elongated hole 19 when the respective spring element 21 , 22 formed by a compression spring reaches the limit stop. At the end of the adjustment path, the second end of the operating arm 18 engaged with the closing part 8 in this embodiment has pivoted at least until it is proximate to the connecting line between the respective pivot axis 16 , 17 of the closing part 8 and the pivot axis 20 of the operating arm 18 (“proximate” in this context means that at least 90% of the pivot angle has been covered by the time this connecting line is reached). When the operating arm 18 is further adjusted in the direction of its end position in each case, the pivoting of the closing part 8 in the direction of its open position in each case takes place as a result of the tensile force exerted by the operating arm 18 on the closing part 8 .
[0047] If the operating arm 18 is thereby moved by the user, starting from its initial position into one of its end positions, the closing part 8 is pivoted by the operating arm 18 into one of its two open positions, as a result of which the carabiner is opened towards one of the two compartments 11 a , 11 b.
[0048] FIG. 5 illustrates the forces which arise when, in the closed state of the carabiner, a force acts on the closing part 8 in an area lying laterally next to the support of the operating arm 18 on the supporting surface 23 of the closing part 8 , which acts in the manner of a pressing of the closing part 8 into the interior 11 . The counterforces are applied by the support of the operating arm 18 on the support surface 23 and by the engagement of the opposite end 9 of the closing part 8 in the end 3 of the bow 1 interacting therewith.
[0049] FIG. 6 depicts how the end of the closing part 8 opposite the active pivot axis 16 , 17 in each case, the first end 9 in this case, can be disengaged from the corresponding end 3 of the bow 1 when pivoting begins. So that the first ends 3 , 9 and the second ends 4 , 10 are disengaged, the bolt 12 , 12 ′ travels out of the slot 13 , 13 ′ in which it is held to form the pivot axis 16 , 17 in each case.
[0050] FIG. 7 shows that as soon as a particular angle of the pivoting of the closing part 8 about one of the pivot axes is reached, for example as illustrated the pivot axis 16 , the corresponding end 9 of the closing part 8 , by which this pivot angle 16 is formed in conjunction with the associated end 3 of the bow 1 , can no longer be disengaged from the associated end 3 of the bow 1 . This angle advantageously lies within the range of 5° to 25°.
[0051] Through the division of the interior 11 into two compartments 11 a , 11 b , a transverse positioning of the carabiner between two objects suspended in the carabiner, between which a tensile force is transmitted via the carabiner, can be prevented. The forces which can be transferred by the carabiner in a transverse direction are normally smaller than the forces which can be transferred in a longitudinal direction (if the suspended objects are located in the area of the bow portions 6 and 7 ).
[0052] A slightly modified embodiment is represented in FIG. 8 . In this case, the spring elements 21 , 22 are not disposed within the elongated hole 19 , but are each connected at their one end to the rear portion 5 and at their other end to the operating arm 18 spaced apart from the pivot axis 20 . The end of the adjustment path of the operating arm 18 in the elongated hole 19 is achieved in this case in each of the two adjustment directions, when the operating arm 18 runs up to the respective end of the elongated hole 19 . When the operating arm 18 is further adjusted in this adjustment direction, the closing part 8 is pivoted by the operating arm 18 in the direction of the open position of the closing part 8 in each case. Otherwise, this exemplary embodiment corresponds to the exemplary embodiment described previously.
[0053] The exemplary embodiment represented in FIG. 9 corresponds to the previously described exemplary embodiments, apart from the following differences:
[0054] The operating arm 18 in this case is configured in a spring-biased bendable manner. This is achieved in the exemplary embodiment shown by a block-wound compression spring 24 . This spring-biased configuration of the operating arm 18 forms the spring-biased member, which exerts a restoring force against an adjustment of the operating arm from its initial position. The adjustment of the operating arm 18 in the direction of one of its two end positions is achieved in this case by bending the operating arm 18 in the corresponding direction (within the main plane of the carabiner). The end position of the movability of the operating arm 18 in the elongated hole 19 in one of the adjustment directions of the operating arm 18 is reached when the operating arm 18 runs up to the respective end of the elongated hole 19 . Consequently, the operating arm 18 pivots the closing part 8 during its further adjustment in the direction of one of its end positions about the corresponding pivot axis 16 , 17 .
[0055] In the closed position of the closing part 8 , the operating arm 18 in turn supports the closing part 8 against pressing (moving and/or pivoting) inwards.
[0056] The operating arm 18 in this exemplary embodiment comprises the compression spring 24 and the head 25 attached to the compression spring 24 , which exhibits a pin passing through the elongated hole 19 .
[0057] Elastically bendable operating arms 18 , which can support the closing part 8 in the closed position thereof against inward deflection, could also be configured in another way.
[0058] A further exemplary embodiment of the invention is illustrated in FIGS. 10 and 11 . In this exemplary embodiment, the operating arm 18 is not pivotably, but movably, mounted on the rear portion 5 of the bow 1 . For this purpose, as represented, for example, the operating arm 18 exhibits a sleeve movably disposed on the rear portion 5 . The arm part 27 is attached to the sleeve 26 . The end of the arm part 27 remote from the rear portion 5 is connected to the closing part 8 via an elongated hole guide, for example, as depicted. In the exemplary embodiment shown, the elongated hole 19 is arranged in the closing part 8 and the arm part 27 engages with this elongated hole 19 .
[0059] The operating arm 18 is held in the initial position by spring elements 21 , 22 . The operating arm 18 in turn keeps the first and second ends 9 , 10 of the closing part 8 in engagement with the first and second ends 3 , 4 of the bow 1 in this position, when the support surface 23 of the closing part 8 is supported at the end of the operating arm 18 remote from the rear portion 5 . The spring elements 21 , 22 are formed by compression springs disposed on the rear section 5 , for example. Embodiments would also be possible, for example, in which the spring elements 21 , 22 are disposed within the rear portion.
[0060] In the initial position of the operating arm 18 , the end of the operating arm 18 remote from the rear portion 5 is located in a middle section of the elongated hole 19 , in which said elongated hole runs parallel to the rear section 5 . End portions, in which the elongated hole is remote from the rear portion 5 towards the respective end, are attached to the middle portion of the elongated hole 19 on both sides. If the operating arm 18 is moved from its initial position into one of its two end positions, the end of the operating arm 18 remote from the rear portion 5 arrives in the corresponding end portion of the elongated hole, once it has passed through the middle portion of the elongated hole 19 , wherein it pivots the closing part 8 about the corresponding pivot axis. The pivoting about the pivot axis formed by the engaged first ends 3 , 9 of the bow 1 and of the closing part 8 is illustrated in FIG. 11 . When the operating arm 18 is adjusted into the other end position, the closing part 8 pivots about the pivot axis 17 formed by the engaged second ends 4 , 10 of the bow 1 and of the closing part 8 .
[0061] As soon as the end of the operating arm 18 remote from the rear portion 5 is located in the middle portion of the elongated hole 19 , the closing part 8 is locked to prevent opening.
[0062] Otherwise, this exemplary embodiment corresponds to the previously described exemplary embodiments.
[0063] In all exemplary embodiments described, the following modifications are possible, for example, without falling outside the field of the invention:
[0064] A locking device (securing device) for the operating arm 18 could be provided, by which the operating arm 18 is locked in its initial position in a locked position. Only by adjusting the locking device into its release position is an adjustment of the operating arm 18 in the direction of one of its end positions made possible. Locking devices of this kind interacting with the operating arm 18 can be realized in different ways, for example by locking levers, safety catches or the like, which block the pivoting or movement of the operating arm 18 . Each of the two operating directions of the operating arm 18 could be provided with its own locking member in this case or with a locking member acting in both operating directions.
[0065] The end of the operating arm 18 remote from the rear portion 5 could also be connected to the closing part 8 via a part movably mounted on or in the closing part 8 . This movably mounted part could be movably mounted on a (partially or completely) curved track, so that the end of the operating arm 18 remote from the rear portion 5 is guided on a corresponding track, which may correspond, for example, to the track represented in the respective exemplary embodiment in the figures. The end of the operating arm 18 remote from the rear portion 5 could be pivotably connected to this movably conducted part.
[0066] An elongated hole guide could also be configured in this way, such that at the end of the operating arm 18 remote from the rear portion 5 , an arm part is present with an enlarged extension in the direction of the closing part 8 , which exhibits an elongated hole, with which a pin connected to the closing part 8 engages. In the case of the exemplary embodiments depicted in FIGS. 1 to 9 , the elongated hole could exhibit the same shape as the elongated hole 19 of the closing part 8 depicted. In the case of the exemplary embodiment in FIGS. 10 and 11 , the end portions of this elongated hole attached to the middle portion lying parallel to the rear portion 5 could draw near to the rear portion 5 .
[0067] The invention is not limited to a symmetrical configuration of the bow 1 in accordance with the exemplary embodiments, but can likewise be used with asymmetric carabiners. In this case, the rear portion 5 is aligned at an angle to the longitudinal extension of the closing part 8 . Asymmetrical carabiners of this kind, which are used for mountaineering, for example, emerge from the state of the art mentioned above in accordance with EP 1 229 258 A2, for example.
[0068] The first ends 3 , 4 and the second ends 5 , 10 of the bow 1 and of the closing part 8 engaged with one another could also exhibit another form for the configuration of pivot axes 16 , 17 , for example a joint head could be disposed at one end in each case, said joint head engaging with a joint socket in the other of the two ends.
[0069] The elongated hole 19 in all embodiments described could also be open to the interior 11 in a middle portion, i.e. the closing part 8 exhibits a recess which extends in the middle section of the elongated hole 19 between the elongated hole 19 and the interior 11 . A bolt device could be provided for the operating arm 18 in the area of this recess. In the closed state of the bolt device, said device blocks an adjustment of the end of the operating arm 18 remote from the rear portion 5 against an adjustment in the elongated hole 19 and keeps the operating arm 18 secure in its initial position. In the release position, the bolt device releases the operating arm 18 for adjustment.
KEY TO THE REFERENCE NUMBERS
[0070] 1 Bow
[0071] 2 Insertion opening
[0072] 3 First end
[0073] 4 Second end
[0074] 5 Rear portion
[0075] 6 First bow portion
[0076] 7 Second bow portion
[0077] 8 Closing part
[0078] 9 First end
[0079] 10 Second end
[0080] 11 Interior
[0081] 11 a Compartment
[0082] 11 b Compartment
[0083] 12 , 12 ′ Bolt
[0084] 13 , 13 ′ Slot
[0085] 14 , 14 ′ Side wall
[0086] 15 , 15 ′ Side wall
[0087] 16 Pivot axis
[0088] 17 Pivot axis
[0089] 18 Operating arm
[0090] 19 Elongated hole
[0091] 20 Pivot axis
[0092] 21 Spring element
[0093] 22 Spring element
[0094] 23 Support surface
[0095] 24 Compression spring
[0096] 25 Head
[0097] 26 Sleeve
[0098] 27 Arm part
|
A carabiner having a bow, which has an insertion opening and first and second ends that bound the insertion opening, a closing part, which assumes a closed position in the closed state of the carabiner, in which it closes the insertion opening, first and second ends of the closing part engage with the first and second ends of the bow, and the closing part can be pivoted relative to the bow about a pivot axis formed at the engaging first ends of the bow and the closing part into a first open position in order to open the carabiner, and an actuating arm, which retains the closing part in the closed position in an initial position and is movable in order to open the carabiner. The closing part can be further pivoted relative to the bow about a pivot axis formed the engaging second ends of the bow and of the closing part into a second open position in order to open the carabiner in an alternative manner.
| 8
|
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of and hereby incorporates by reference Application Ser. No. 08/232,615 filed Apr. 25, 1994, and issuing as U.S. Pat. No. 5,980,513, entitled, “Laser Beam Delivery and Eye Tracking System” commonly owned with the instant application.
FIELD OF THE INVENTION
The invention relates generally to laser systems, and more particularly to a laser system used to erode a moving surface such as an eye's corneal tissue.
BACKGROUND OF THE INVENTION
Use of lasers to erode all or a portion of a workpiece's surface is known in the art. In the field of ophthalmic medicine, photorefractive keratectomy (PRK) is a procedure for laser correction of focusing deficiencies of the eye by modification of corneal curvature. PRK is distinct from the use of laser-based devices for more traditional ophthalmic surgical purposes, such as tissue cutting or thermal coagulation. PRK is generally accomplished by use of a 193 nanometer wavelength excimer laser beam that ablates away the workpiece, i.e., corneal tissue, in a photo decomposition process. Most clinical work to this point has been done with a laser operating at a fluence level of 120-195 mJ/cm 2 and a pulse-repetition rate of approximately 5-10 Hz. The procedure has been referred to as “corneal sculpting.”
Before sculpting of the cornea takes place, the epithelium or outer layer of the cornea is mechanically removed to expose Bowman's membrane on the anterior surface of the stroma. At this point, laser ablation at Bowman's layer can begin. An excimer laser beam is preferred for this procedure. The beam may be variably masked during the ablation to remove corneal tissue to varying depths as necessary for recontouring the anterior stroma. Afterward, the epithelium rapidly regrows and resurfaces the contoured area, resulting in an optically correct (or much more nearly so) cornea. In some cases, a surface flap of the cornea is folded aside and the exposed surface of the cornea's stroma is ablated to the desired surface shape with the surface flap then being replaced.
Phototherapeutic keratectomy (PTK) is a procedure involving equipment functionally identical to the equipment required for PRK. The PTK procedure differs from PRK in that rather than reshaping the cornea, PTK uses the aforementioned excimer laser to treat pathological superficial corneal dystrophies, which might otherwise require corneal transplants.
In both of these procedures, surgical errors due to application of the treatment laser during unwanted eye movement can degrade the refractive outcome of the surgery. The eye movement or eye positioning is critical since the treatment laser is centered on the patient's theoretical visual axis which, practically speaking, is approximately the center of the patient's pupil. However, this visual axis is difficult to determine due in part to residual eye movement and involuntary eye movement known as saccadic eye movement. Saccadic eye movement is high-speed movement (i.e., of very short duration, 10-20 milliseconds, and typically up to 10 of eye rotation) inherent in human vision and is used to provide dynamic scene to the retina. Saccadic eye movement, while being small in amplitude, varies greatly from patient to patient due to psychological effects, body chemistry, surgical lighting conditions, etc. Thus, even though a surgeon may be able to recognize some eye movement and can typically inhibit/restart a treatment laser by operation of a manual switch, the surgeon's reaction time is not fast enough to move the treatment laser in correspondence with eye movement.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a laser beam delivery and eye tracking method and system that is used in conjunction with a laser system capable of eroding a surface.
Another object of the present invention is to provide a system for delivering a treatment laser to a surface and for automatically redirecting the treatment laser to compensate for movement of the surface.
Still another object of the present invention is to provide a system for delivering a corneal ablating laser beam to the surface of an eye in a specific pattern about the optical center of the eye, and for automatically redirecting the corneal ablating laser beam to compensate for eye movement such that the resulting ablating pattern is the same regardless of eye movement.
Yet another object of the present invention is to provide a laser beam delivery and eye tracking system for use with an ophthalmic treatment laser where the tracking operation detects eye movement in a non-intrusive fashion.
A further object of the present invention is to provide a laser beam delivery and eye tracking system for automatically delivering and maintaining a corneal ablating laser beam with respect to the geometric center of an eye's pupil or a doctor defined offset from the center of the eye's pupil. A special object of this invention is the use of the laser pulses which are distributed in a pattern of discrete ablations to shape objects other than for corneal ablating.
Other objects and advantages of the present invention will become more obvious hereinafter in the specification and drawings.
In accordance with the present invention, an eye treatment laser beam delivery and eye tracking system is provided. A treatment laser and its projection optics generate laser light along an original beam path (i.e., the optical axis of the system) at an energy level suitable for treating the eye. An optical translator shifts the original beam path in accordance with a specific scanning pattern so that the original beam is shifted onto a resulting beam path that is parallel to the original beam path. An optical angle adjuster changes the resulting beam path's angle relative to the original beam path such that the laser light is incident on the eye.
An eye movement sensor detects measurable amounts of movement of the eye relative to the system's optical axis and then generates error control signals indicative of the movement. The eye movement sensor includes: 1) a light source for generating light energy that is non-damaging with respect to the eye, 2) an optical delivery arrangement for delivering the light energy on a delivery light path to the optical angle adjuster in a parallel relationship with the resulting beam path of the treatment laser, and 3) an optical receiving arrangement. The parallel relationship between the eye movement sensor's delivery light path and the treatment laser's resulting beam path is maintained by the optical angle adjuster. In this way, the treatment laser light and the eye movement sensor's light energy are incident on the eye in their parallel relationship.
A portion of the eye movement sensor's light energy is reflected from the eye as reflected energy traveling on a reflected light path back through the optical angle adjuster. The optical receiving arrangement detects the reflected energy and generates the error control signals based on the reflected energy. The optical angle adjuster is responsive to the error control signals to change the treatment laser's resulting beam path and the eye movement sensor's delivery light path in correspondence with one another. In this way, the beam originating from the treatment laser and the light energy originating from the eye movement sensor track along with the eye's movement.
In carrying out this technique, the pattern constitutes overlapping but not coaxial locations for ablation to occur with each pulse removing a microvolume of material by ablation or erosion. For different depths, a pattern is repeated over those areas where increased ablation is needed. The laser pulses are usually at a certain pulse repetition rate. The subsequent pulses in a sequence are spaced at least one pulse beam width from the previous pulse and at a distance the ablated particles will not substantialy interfere with the subsequent pulse. In order to maximize the speed of the ablation, the subsequent pulse is spaced sufficiently close to enable the beam to be moved to the successive location within the time of the pulse repetition. The ablation is carried out on an object until a desired specific shape is achieved.
This technique is fundamentally new and may be used on objects other than corneas.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a laser beam delivery and eye tracking system in accordance with the present invention as it would be used in conjunction with an ophthalmic treatment laser;
FIG. 2 is a sectional view of the projection optics used with the ophthalmic treatment laser embodiment of the laser beam delivery portion of the present invention;
FIG. 3 illustrates diagrammatically an optical arrangement of mirrors used to produce translational shifts in a light beam along one axis;
FIG. 4 is a block diagram of the servo controller/motor driver circuitry used in the ophthalmic treatment laser embodiment of the present invention; and
FIG. 5 is a block diagram of a preferred embodiment eye movement sensor used in the ophthalmic treatment laser embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIG. 1, a block diagram is shown of a laser beam delivery and eye tracking system referenced generally by the numeral 5 . The laser beam delivery portion of system 5 includes treatment laser source 500 , projection optics 510 , X-Y translation mirror optics 520 , beam translation controller 530 , dichroic beamsplitter 200 , and beam angle adjustment mirror optics 300 . By way of example, it will be assumed that treatment laser 500 is a 193 nanometer wavelength excimer laser used in an ophthalmic PRK (or PTK) procedure performed on a movable workpiece. e.g., eye 10 . However, it is to be understood that the method and system of the present invention will apply equally as well to movable workpieces other than an eye, and further to other wavelength surface treatment or surface eroding lasers. The laser pulses are distributed as shots over the area to be ablated or eroded, preferably in a distributed sequence. A single laser pulse of sufficient power to cause ablation creates a micro cloud of ablated particles which interferes with the next laser pulse if located in the same or immediate point. To avoid this interference, the next laser pulse is spatially distributed to a next point of erosion or ablation that is located a sufficient distance so as to avoid the cloud of ablated particles. Once the cloud is dissipated, another laser pulse is made adjacent the area prior eroded so that after the pattern of shots is completed the cumulative shots fill in and complete said pattern so that the desired shape of the object or cornea is achieved.
In operation of the beam delivery portion of system 5 , laser source 500 produces laser beam 502 which is incident upon projection optics 510 . Projection optics 510 adjusts the diameter and distance to focus of beam 502 depending on the requirements of the particular procedure being performed. For the illustrative example of an excimer laser used in the PRK or PTK procedure, projection optics 510 includes planar concave lens 512 , and fixed focus lenses 514 and 516 as shown in the sectional view of FIG. 2 . Lenses 512 and 514 act together to form an A-focal telescope that expands the diameter of beam 502 . Fixed focus lens 516 focuses the expanded beam 502 at the workpiece, i.e., eye 10 , and provides sufficient depth, indicated by arrow 518 , in the plane of focus of lens 516 . This provides flexibility in the placement of projection optics 510 relative to the surface of the workpiece. An alternative implementation is to eliminate lens 514 when less flexibility can be tolerated.
After exiting projection optics 510 , beam 502 impinges on X-Y translation mirror optics 520 where beam 502 is translated or shifted independently along each of two orthogonal translation axes as governed by beam translation controller 530 . Controller 530 is typically a processor programmed with a predetermined set of two-dimensional translations or shifts of beam 502 depending on the particular ophthalmic procedure being performed. For the illustrative example of the excimer laser used in a PRK or PTK procedure, controller 530 may be programmed in accordance with the aforementioned copending patent application entitled “Laser Sculpting System and Method”. The programmed shifts of beam 502 are implemented by X-Y translation mirror optics 520 .
Each X and Y axis of translation is independently controlled by a translating mirror. As shown diagrammatically in FIG. 3, the Y-translation operation of X-Y translation mirror optics 520 is implemented using translating mirror 522 . Translating mirror 522 is movable between the position shown and the position indicated by dotted line 526 . Movement of translating mirror 522 is such that the angle of the output beam with respect to the input beam remains constant. Such movement is brought about by translation mirror motor and control 525 driven by inputs received from beam translation controller 530 . By way of example, motor and control 525 can be realized with a motor from Trilogy Systems Corporation (e.g., model T050) and a control board from Delta Tau Systems (e.g., model 400-602276 PMAC).
With translating mirror 522 positioned as shown, beam 502 travels the path traced by solid line 528 a. With translating mirror 522 positioned along dotted line 526 , beam 502 travels the path traced by dotted line 528 b. A similar translating mirror (not shown) would be used for the X-translation operation. The X-translation operation is accomplished in the same fashion but is orthogonal to the Y-translation. The X-translation may be implemented prior or subsequent to the Y-translation operation.
The eye tracking portion of system 5 includes eye movement sensor 100 , dichroic beamsplitter 200 and beam angle adjustment mirror optics 300 . Sensor 100 determines the amount of eye movement and uses same to adjust mirrors 310 and 320 to track along with such eye movement. To do this, sensor 100 first transmits light energy 101 -T which has been selected to transmit through dichroic beamsplitter 200 . At the same time, after undergoing beam translation in accordance with the particular treatment procedure, beam 502 impinges on dichroic beamsplitter 200 which has been selected to reflect beam 502 (e.g., 193 nanometer wavelength laser beam) to beam angle adjustment mirror optics 300 .
Light energy 101 -T is aligned such that it is parallel to beam 502 as it impinges on beam angle adjustment mirror optics 300 . It is to be understood that the term “parallel” as used herein includes the possibility that light energy 101 -T and beam 502 can be coincident or collinear. Both light energy 101 -T and beam 502 are adjusted in correspondence with one another by optics 300 . Accordingly, light energy 101 -T and beam 502 retain their parallel relationship when they are incident on eye 10 . Since X-Y translation mirror optics 520 shifts the position of beam 502 in translation independently of optics 300 , the parallel relationship between beam 502 and light energy 101 -T is maintained throughout the particular ophthalmic procedure.
Beam angle adjustment mirror optics consists of independently rotating mirrors 310 and 320 . Mirror 310 is rotatable about axis 312 as indicated by arrow 314 while mirror 320 is rotatable about axis 322 as indicated by arrow 324 . Axes 312 and 322 are orthogonal to one another. In this way, mirror 310 is capable of sweeping light energy 101 -T and beam 502 in a first plane (e.g., elevation) while mirror 320 is capable of independently sweeping light energy 101 -T and beam 502 in a second plane (e.g., azimuth) that is perpendicular to the first plane. Upon exiting beam angle adjustment mirror optics 300 , light energy 101 -T and beam 502 impinge on eye 10 .
Movement of mirrors 310 and 320 is typically accomplished with servo controller/motor drivers 316 and 326 , respectively. FIG. 4 is a block diagram of a preferred embodiment servo controller/motor driver 316 used for the illustrative PRK/PTK treatment example. (The same structure is used for servo controller/motor driver 326 .) In general, drivers 316 and 326 must be able to react quickly when the measured error from eye movement sensor 100 is large, and further must provide very high gain from low frequencies (DC) to about 100 radians per second to virtually eliminate both steady state and transient error.
More specifically, eye movement sensor 100 provides a measure of the error between the center of the pupil (or an offset from the center of the pupil that the doctor selected) and the location where mirror 310 is pointed. Position sensor 3166 is provided to directly measure the position of the drive shaft (not shown) of galvanometer motor 3164 . The output of position sensor 3166 is differentiated at differentiator 3168 to provide the velocity of the drive shaft of motor 3164 .
This velocity is summed with the error from eye movement sensor 100 . The sum is integrated at integrator 3160 and input to current amplifier 3162 to drive galvanometer motor 3164 . As the drive shaft of motor 3164 rotates mirror 310 , the error that eye movement sensor 100 measures decreases to a negligible amount. The velocity feedback via position sensor 3166 and differentiator 3168 provides servo controller/motor driver 316 with the ability to react quickly when the measured sensor error is large.
Light energy reflected from eye 10 , as designated by reference numeral 101 -R, travels back through optics 300 and beamsplitter 200 for detection at sensor 100 . Sensor 100 determines the amount of eye movement based on the changes in reflection energy 101 -R. Error control signals indicative of the amount of eye movement are fed back by sensor 100 to beam angle adjustment mirror optics 300 . The error control signals govern the movement or realignment of mirrors 310 and 320 in an effort to drive the error control signals to zero. In doing this, light energy 101 -T and beam 502 are moved in correspondence with eye movement while the actual position of beam 502 relative to the center of the pupil is controlled by X-Y translation mirror optics 520 .
In order to take advantage of the properties of beamsplitter 200 , light energy 101 -T must be of a different wavelength than that of treatment laser beam 502 . The light energy should preferably lie outside the visible spectrum so as not to interfere or obstruct a surgeon's view of eye 10 . Further, if the present invention is to be used in ophthalmic surgical procedures, light energy 101 -T must be “eye safe” as defined by the American National Standards Institute (ANSI). While a variety of light wavelengths satisfy the above requirements, by way of example, light energy 101 -T is infrared light energy in the 900 nanometer wavelength region. Light in this region meets the above noted criteria and is further produced by readily available, economically affordable light sources. One such light source is a high pulse repetition rate GaAs 905 nanometer laser operating at 4 kHz which produces an ANSI defined eye safe pulse of 10 nanojoules in a 50 nanosecond pulse.
A preferred embodiment method for determining the amount of eye movement, as well as eye movement sensor 100 for carrying out such a method, are described in detail in the aforementioned copending patent application. However, for purpose of a complete description, sensor 100 will be described briefly with the aid of the block diagram shown in FIG. 2 . Sensor 100 may be broken down into a delivery portion and a receiving portion. Essentially, the delivery portion projects light energy 101 -T in the form of light spots 21 , 22 , 23 and 24 onto a boundary (e.g., iris/pupil boundary 14 ) on the surface of eye 10 . The receiving portion monitors light energy 101 -R in the form of reflections caused by light spots 21 , 22 , 23 and 24 .
In delivery, spots 21 and 23 are focused and positioned on axis 25 while spots 22 and 24 are focused and positioned on axis 26 as shown. Axes 25 and 26 are orthogonal to one another. Spots 21 , 22 , 23 and 24 are focused to be incident on and evenly spaced about iris/pupil boundary 14 . The four spots 21 , 22 , 23 and 24 are of equal energy and are spaced evenly about and on iris/pupil boundary 14 . This placement provides for two-axis motion sensing in the following manner. Each light spot 21 , 22 , 23 and 24 causes a certain amount of reflection at its position on iris/pupil boundary 14 . Since boundary 14 moves in coincidence with eye movement, the amount of reflection from light spots 21 , 22 , 23 and 24 changes in accordance with eye movement. By spacing the four spots evenly about the circular boundary geometry, horizontal or vertical eye movement is detected by changes in the amount of reflection from adjacent pairs of spots. For example, horizontal eye movement is monitored by comparing the combined reflection from light spots 21 and 24 with the combined reflection from light spots 22 and 23 . In a similar fashion, vertical eye movement is monitored by comparing the combined reflection from light spots 21 and 22 with the combined reflection from light spots 23 and 24 .
More specifically, the delivery portion includes a 905 nanometer pulsed diode laser 102 transmitting light through optical fiber 104 to an optical fiber assembly 105 that splits and delays each pulse from laser 102 into preferably four equal energy pulses. Assembly 105 includes one-to-four optical splitter 106 that outputs four pulses of equal energy into optical fibers 108 , 110 , 112 , 114 . In order to use a single processor to process the reflections caused by each pulse transmitted by fibers 108 , 110 , 112 and 114 , each pulse is uniquely delayed by a respective fiber optic delay line 109 , 111 , 113 and 115 . For example, delay line 109 causes a delay of zero, i.e., DELAY=0x where x is the delay increment; delay line 111 causes a delay of x, i.e., DELAY=1x; etc.
The pulse repetition frequency and delay increment x are chosen so that the data rate of sensor 100 is greater than the speed of the movement of interest. In terms of saccadic eye movement, the data rate of sensor 100 must be on the order of at least several hundred hertz. For example, a sensor data rate of approximately 4 kHz is achieved by 1) selecting a small but sufficient value for x to allow processor 160 to handle the data (e.g., 160 nanoseconds), and 2) selecting the time between pulses from laser 102 to be 250 microseconds (i.e., laser 102 is pulsed at a 4 kHz rate).
The four equal energy pulses exit assembly 105 via optical fibers 116 , 118 , 120 and 122 which are configured as a fiber optic bundle 123 . Bundle 123 arranges the optical fibers such that the center of each fiber forms the corner of a square. Light from assembly 105 is passed through an optical polarizer 124 that outputs horizontally polarized light beams as indicated by arrow 126 . Horizontally polarized light beams 126 pass to focusing optics 130 where spacing between beams 126 is adjusted based on the boundary of interest. Additionally, a zoom capability (not shown) can be provided to allow for adjustment of the size of the pattern formed by spots 21 , 22 , 23 and 24 . This capability allows sensor 100 to adapt to different patients, boundaries, etc.
A polarizing beam splitting cube 140 receives horizontally polarized light beams 126 from focusing optics 130 . Cube 140 is configured to transmit horizontal polarization and reflect vertical polarization. Accordingly, cube 140 transmits only horizontally polarized light beams 126 as indicated by arrow 142 . Thus, it is only horizontally polarized light that is incident on eye 10 as spots 21 , 22 , 23 and 24 . Upon reflection from eye 10 , the light energy is depolarized (i.e., it has both horizontal and vertical polarization components) as indicated by crossed arrows 150 .
The receiving portion first directs the vertical component of the reflected light as indicated by arrow 152 . Thus, cube 140 serves to separate the transmitted light energy from the reflected light energy for accurate measurement. The vertically polarized portion of the reflection from spots 21 , 22 , 23 and 24 , is passed through focusing lens 154 for imaging onto an infrared detector 156 . Detector 156 passes its signal to a multiplexing peak detecting circuit 158 which is essentially a plurality of peak sample and hold circuits, a variety of which are well known in the art. Circuit 158 is configured to sample (and hold the peak value from) detector 156 in accordance with the pulse repetition frequency of laser 102 and the delay x. For example, if the pulse repetition frequency of laser 102 is 4 kHz, circuit 158 gathers reflections from spots 21 , 22 , 23 and 24 every 250 microseconds.
The values associated with the reflected energy for each group of four spots (i.e., each pulse of laser 102 ) are passed to a processor 160 where horizontal and vertical components of eye movement are determined. For example let R 21 , R 22 , R 23 and R 24 represent the detected amount of reflection from one group of spots 21 , 22 , 23 and 24 , respectively. A quantitative amount of horizontal movement is determined directly from the normalized relationship ( R 21 + R 24 ) - ( R 22 + R 23 ) R 21 + R 22 + R 23 + R 24 ( 1 )
while a quantitative amount of vertical movement is determined directly from the normalized relationship ( R 21 + R 22 ) - ( R 23 + R 24 ) R 21 + R 22 + R 23 + R 24 ( 2 )
Note that normalizing (i.e., dividing by R 21 +R 22 +R 23 +R 24 ) reduces the effects of variations in signal strength. Once determined, the measured amounts of eye movement are sent to beam angle adjustment mirror optics 300 .
The advantages of the present invention are numerous. Eye movement is measured quantitatively and used to automatically redirect both the laser delivery and eye tracking portions of the system independent of the laser positioning mechanism. The system operates without interfering with the particular treatment laser or the surgeon performing the eye treatment procedure.
Although the invention has been described relative to a specific embodiment thereof, there are numerous variations and modifications that will be readily apparent to those skilled in the art in the light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described.
|
A surface treatment laser beam delivery and tracking system is provided. The laser generates laser light along a original beam path at an energy level suitable for treating (e.g., eroding) a surface. An optical translator shifts the original beam path onto a resulting beam path. An optical angle adjuster changes the angle of the resulting beam path relative to the original beam path such that the laser light is incident on, and spatially distributed, the surface to be treated. A motion sensor transmits light energy to the surface and receives reflected light energy from the surface via the optical angle adjuster. The light energy transmitted by the motion sensor travels on a path that is parallel to the shifted beam as they travel through the optical angle adjuster. The reflected light energy is used by the motion sensor to detect movement of the surface relative to the original beam path and generate error control signals indicative of the movement. The optical angle adjuster is responsive to the error control signals to change the angle of the resulting beam path and the angle of the motion sensor's light energy in correspondence with one another. In this way, the beam originating from the treatment laser and the light energy originating from the motion sensor track together with the surface movement.
| 0
|
This is a continuation-in-part of application Ser. No. 913,639 filed June 8, 1978, entitled "Method of and Solution of Electroplating Chomium and Chromium Alloys and Method of Making the Solution," which in turn is a continuation-in-part of application Ser. No. 833,634, filed Sept. 15, 1977 entitled "Method of and Solution for Electroplating Chromium and Chromium Alloys and Method of Making the Solution," now abandoned, which in turn is a continuation-in-part of application Ser. No. 637,483, filed Dec. 3, 1975 entitled "Electrodeposition of Chromium," now U.S. Pat. No. 4,062,737.
BACKGROUND OF THE INVENTION
The present invention relates to the electroplating of chromium or a chromium-containing alloy.
In U.S. Pat. No. 4,062,737, there is described and claimed a chromium or chromium alloy electroplating solution in which the source of chromium comprises an aqueous solution of a chromium(III) thiocyanate complex and a process of plating chromium or a chromium-containing alloy comprising passing an electric plating current between an anode and a cathode in such a solution.
The preferred complexes described in said U.S. Pat. No. 4,062,737 are chromium(III) aquothiocyanate complexes prepared by equilibrating chromium perchlorate and sodium thiocyanate in an aqueous solution. The complexes so formed are described by the general formula:
((H.sub.2 O).sub.6-n Cr(III).(NCS).sub.n).sup.(3-n) where n=1 to 6
(Subscripts are always positive, but superscripts may be positive, negative or zero.)
In the specification of our copending application, Ser. No. 913,639, filed June 8, 1978, entitled: "Method of and Solution for Electroplating Chromium and Chromium Alloys and Method of Making the Solution," there is described and claimed a chromium or a chromium alloy electroplating solution in which the source of chromium comprises an aqueous solution of a chromium(III) thiocyanate complex having at least one ligand other than thiocyanate or water in the inner coordination sphere of the complex. Chromium(III) species in solution are ocatahedral with six ligands coordinated to the chromium atom. These ligands occupy and define the inner coordination sphere of the chromium atom and are inert inasmuch as they exchange very slowly with free ligands in the solution, e.g., the reaction:
(Cr(H.sub.2 O).sub.5 (NCS)).sup.+2 +*(NCS).sup.- →(Cr(H.sub.2 O).sub.5 *(NCS)).sup.+2 +(NCS).sup.-
is very slow. It is the slowness of reactions of this type which complicates the chemistry of chromium(III) and necessitates equilibration at high temperatures. See the book by Basolo and Pearson, Mechanism of Inorganic Reactions: Study of Metal Complexes in Solution, published by Wiley. The linear thiocyanate anion, NCS - , has unique catalytic properties through its ability to coordinate to metal ions through its nitrogen and sulphur atoms. Also, its electron density is extensively localized across the three atoms.
The thiocyanate anion is believed to catalyze the electron transfer reaction:
Cr(III)+3e.sup.- →Cr(0)
through the formation of multiple-ligand bridges between a thiocyanate Cr(III) complex and the surface of the cathode. The electro-active intermediate can be identified as:
Cr(III)-NCS-M
where M is the metal surface of the cathode which is Cr(0) after an initial monolayer of chromium is plated. The "hard" nitrogen coordinates to the Cr(III) atom and the "soft" sulphur to the metal surface M of the cathode. Multiple-ligand bridging by thiocyanate in the electrochemical oxidation of chromium(II) at mercury electrodes is described in Inorganic Chemistry 9, 1024 (1970).
One embodiment of the invention described in our above-mentioned application Ser. No. 913,639 comprises a particularly advantageous chromium or a chromium alloy electroplating solution in which the source of chromium comprises an aqueous solution of a chromium(III) sulphatothiocyanate complex. More particularly, the chromium(III) sulphatothiocyanate complex comprises mixed chromium(III) thiocyanate complexes having the formula:
((H.sub.2 O).sub.6-m-n Cr(III) Cl.sub.m (NCS).sub.n).sup.3-m-n
where m and n are both positive integers, but where m+n does not exceed six. Preparation of this aqueous solution of chromium(III) chlorothiocyanate complex was by equilibrating an aqueous solution of chromic chloride (CrCl 3 .6H 2 O) and sodium or potassium thiocyanate.
Commercially, chromium has been plated from aqueous chromic acid baths prepared from chromic oxide (CrO 3 ) and sulphuric acid. Such baths in which the chromium is in hexavalent form present a considerable health hazard as a result of the emission of chromic acid fumes. Further, if the plating current is interrupted for any reason, a deposit of unsatisfactory milky appearance is produced. In addition, delamination of the deposited chromium occurs. Thus, accidental interruption of the plating current can cause significant losses, and barrel chromium plating is rendered extremely difficult since it is difficult to apply more than very thin deposits of chromium and to ensure that the deposit covers and adheres to the articles to be plated.
Chromic acid plating baths have the further disadvantages that the plating efficiency is low and, therefore, the rate of deposition is low, the throwing power is limited, and it is difficult to deposit layers of uniform thickness over substantial areas. More metal is deposited on high current density areas, such as edges, and in certain circumstances, "burning" appears. It should also be noted that chromic acid plating baths contain a very high concentration of chromium, 100-200 grams per liter. However, since chromium salts are relatively expensive, the chromium concentration should be kept as low as possible to minimize the cost of making up the bath and to reduce "drag-out" on work pieces. The reduction in drag-out loss in making decorative chromium deposits is important since drag-out can amount to six or more times the weight of metal plated.
Numerous attempts have been made to use trivalent chromium salts to deposit chromium or a chromium-containing alloy.
The specification of United Kingdom Pat. No. 1,144,913 describes a solution for electroplating chromium, which includes chromium chloride contained in a dipolar aprotic solvent (such as dimethylformamide) and water. United Kingdom Pat. No. 1,333,714 describes another solution which includes chromium ammonium sulphate in a dipolar aprotic solvent and water.
However, such solutions possess limitations which hindered their industrial acceptance. In particular, parts of complex shapes could not be plated satisfactory and the poor electrical conductivity, due to the presence of the dipolar aprotic solvent, required a power supply capable of supplying up to 20 volts. Reduction in the quantity of the dipolar aprotic solvent resulted in an unsatable bath. In addition, the solution was relatively expensive. The plating solution also contained between 0.5 and 1.5 M chromium ions, a relatively high concentration. There are also health hazards associated with the use of dimethylformamide.
U.S. Pat. No. 3,917,517, claiming priority from United Kingdom patent application No. 47424/73, describes a chromium or chromium alloy electroplating solution comprising chromic chloride or sulphate having hypophosphite ions as a supplement to or replacement of the dipolar aprotic solvent disclosed in the last two mentioned United Kingdom patent specifications. The addition of hypophosphite ions to a trivalent chromium electroplating solution is said to "mitigate" or "overcome" many of the disadvantages of the solutions containing the dipolar aprotic solvent. However, the plating efficiency is stated to be lower than with high levels of the dipolar aprotic solvent and plating rates of 0.05 to 0.15 microns per minute, similar to the best rates available with the hexavalent chromic acid plating solutions, were obtained. Preferred range of temperature for plating is stated to be 25°±5° C. with a practical maximum being 35° C. for a chromic chloride solution and 55° C. for a chromic sulphate solution. The concentration of chromium was given as being 0.5 M to 1.75 M with a preferred range of 0.7 M to 1.3 M.
German Offenlegungsschrift Nos. 2,612,443 and 2,612,444, claiming priority from United Kingdom patent application Nos. 12774/75 and 12776/75, respectively, describe an aqueous electroplating solution comprising chromic sulphate having hypophosphite or glycine ions as "weak complexing agents" and chloride or fluoride ions, respectively. The maximum plating rate was again approximately 0.15 microns per minute and the preferred temperature range 25°-35° C. The preferred concentration of chromium for decorative plating was given as 1 M.
German Offenlegungsschrift No. 2,550,615, which corresponds to United Kingdom application No. 38320/72, also discloses a trivalent electroplating solution containing chromic sulphate or chloride, ammonium sulphate or chloride, boric acid, and a variety of alternative additional "weak complexing" materials, including glycine ions and hypophosphite ions. However, in the examples, the concentration of the additional buffer material was relatively high.
United Kingdom Pat. Nos. 1,445,580 and 1,455,841 described another approach that has been used to deposit chromium from aqueous solutions to trivalent salts. In these patents, the source of chromium ions was chromic chloride or chromic sulphate or chromic fluoride. In addition, bromide ions, ammonium ions and formate or acetate ions are stated to be essential. The plating rate was stated to be 0.15 microns per minute and a temperature in the range of 15°-30° C. The concentration of chromium was given as between 0.1 and 1.2 M, the preferred value being given as 0.4 M chromium ions.
SUMMARY OF THE INVENTION
The present invention provides a chromium or a chromium alloy electroplating solution in which the source of chromium comprises an aqueous equilibrated solution of a chromium(III) thiocyanate complex and a buffer material, the buffer material providing one of the ligands for the complex.
The buffer material is preferably an amino acid such as Glycine (NH 2 CH 2 COOH) or peptides which are amino acid polymers. The amino acids are strong buffering agents, but also are able to form, during equilibration, complexes with metal ions, such as chromium(III), by coordination through their nitrogen or oxygen atoms. Thus by equilibrating an amino acid with a chromium(III) thiocyanate complex, mixed amino acid chromium(III) thiocyanate complexes are formed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In use, the electroplating solution of the present invention, having buffers which provide one of the ligands for a chromium(III) thiocyanate complex, has been found to have a number of highly desirable properties enhancing the catalytic characteristics of the chromium(III) thiocyanate plating solutions described above. First, the plating range can be extended and bright deposits have been produced over the range 10 to 1000+ ma/cm 2 ; second, plating rates of up to 0.9 microns per minute have been achieved; third, the temperature range over which bright chromium can be deposited is very wide, i.e., 20° to 70° C.; and fourth, the concentration of chromium ions in the solution can be kept very low.
It is believed that in earlier attempts to deposit chromium from trivalent solutions, plating was inhibited at high current densities by the deposition of a hydroxy chromium(III) species on the cathode. The deposition of chromium from the solution of the present invention is facilitated at high current densities, both by the catalytic effect of the thiocyanate and by the intimate buffering at the cathode by the amino acid released from the chromium atom as it discharges onto the cathode.
Other buffer materials could be used, such as formates, acetates, etc. However, the combination of the catalytic properties of thiocyanate and the intimate buffering of the complexed buffer material is what achieves the remarkable improvements provided by the present invention.
The chromium(III) thiocyanate complexes of the present invention may be chromium(III) sulphatothiocyante complexes or chromium(III) chlorothiocyanate complexes.
It will be clear that by the addition of nickel, cobalt or other metal salts to the solution, alloys of chromium and these metals can be plated. In addition, it will be understood that chromium and chromium alloys can be plated through photoresist masks.
The invention will now be described by way of example with reference to the following examples.
EXAMPLE I
Preparation of a plating solution according to the invention comprised of preparation of an 0.05 M aqueous solution of chromic chloride (CrCl 3 .6H 2 O).
The solution was saturated with 50 g/liter of boric acid (H 3 BO 3 ) and equilibrated at 80° C. for one hour with 0.75 M sodium thiocyanate (NaNCS), 0.16 M glycine (NH 2 CH 2 COOH), 0.5 M potassium chloride (KCl) and 2 M potassium bromide. The potassium chloride and bromide were added to improve the conductivity of the solution. The equilibrated solution was cooled, its pH adjusted to 3.0 by the addition of dilute sodium hydroxide and 1 gram/liter sodium lauryl sulphate (wetting agent) was added.
The plating solution was introduced into a Hull cell having a flat platinized titanium anode and a flat brass Hull cell test cathode. No ion exchange membrane was used to separate the anode and cathode, and the temperature of the solution was 22° C. A plating current of 5 A was passed through the solution for two minutes. Bright chromium was deposited from 10 mA/cm 2 to the top of the plate (580+ mA/cm 2 ).
EXAMPLE II
To illustrate the effect of equilibrating glycine with chromium(III) thiocyanate producing an aqueous equilibrated mixed glycine chromium(III) sulphato thiocyanate complex solution, a solution was prepared in the following stages:
A. a plating solution was prepared by providing a 0.075 M chromic sulphate solution (Cr(SO 4 ) 3 .15H 2 O). The solution was saturated with 80 grams/liter of boric acid (H 3 BO 3 ) and equilibrated at 80° C. for one hour with 0.15 M sodium thiocyanate and 0.8 M sodium sulphate. The sodium sluphate was added to improve the conductivity of the solution. The equilibrated solution was cooled, its pH adjusted to 2.5 by the addition of dilute sodium hydroxide and 0.6 grams/liter sodium lauryl sulphate (wetting agent) was added.
This plating solution was introduced into a standard Hull cell, as in Example I, and the temperature of the solution was maintained at 20° C. A plating current of 5 A was passed for two minutes. Bright chromium was deposited on the Hull cell plate from 5 mA/cm 2 to 125 mA/cm 2 .
B. the solution prepared in Step A above was reequilibrated at 80° C. for one hour with the addition of 5 grams/liter of glycine (0.065 M). The pH was adjusted to 2.5 by the addition of dilute sodium hydroxide.
A current of 5 A was passed through solution B at a temperature of 25° C. in a standard Hull cell for two minutes. Bright chromium was deposited over the range 5 to 275 mA/cm 2 .
C. the solution prepared in Step A above was reequilibrated at 80° C. for one hour with the addition of 10 grams/liter of glycine (0.13 M). The pH was adjusted to 2.6 by the addition of dilute sodium hydroxide. A current of 1.6 A was passed through solution C at a temperature of 47° C., using a 12 cm 2 cathode (130 mA/cm 2 ) for thirty minutes. A chromium depost 10 microns thick was deposited (i.e., 0.33 microns per minute).
D. the effect of temperature is illustrated by the following: Solution B was heated to 45° C. and a current of 5 A was again passed through the solution in a standard Hull cell for two minutes. Bright chromium was now found to be deposited from 12 mA/cm 2 to 400 mA/cm 2 .
EXAMPLE III
A plating solution was prepared substantially as described in Example I of the instant inventor's U.S. patent application Ser. No. 913,639, i.e., 150 grams of sodium dichromate (Na 2 Cr 2 O 7 ) was added to 485 mls of perchloric acid (HClO 4 ) and 525 mls water. About 400 mls hydrogen peroxide was added in drop-wise fashion until the solution became deep blue. When this state was reached, the solution was boiled down to half its volume, driving off hydrogen peroxide and leaving the required solution of chromium perchlorate Cr(ClO 4 ) 3 . This solution provided a source solution of chromium(III) for plating.
Ten grams of glycine were dissolved in water and the pH adjusted to 2.0 with perchloric acid. 100 mls of the chromium source solution was added to the glycine solution, the pH of which was again adjusted to 2.0 with sodium hydroxide solution and the volume adjusted to 1 liter by the addition of water. This solution was equilibrated with sodium thiocyanate (0.3 M) and sodium perchlorate (1 M) for one hour at 80° C. The solution was cooled to 40° C., saturated with 70 grams/liter of boric acid (H 3 BO 3 ), and 1 gram/liter of sodium lauryl sulphate was added.
The following plating results were obtained with the solution prepared in Example III.
A. bright chromium could be deposited at temperatures in the range 25° C. to 70° C. The best results were attained at temperatures above 35° C.
B. the solution was introduced into a Hull cell and heated to 70° C. A brass Hull cell cathode was plated at a total current of 10 A for two minutes, using a flat platinized titanium anode. Bright chromium was deposited on the brass plate from the 20 mA/cm 2 position to the top of the plate (1000+ mA/cm 2 ). There was no sign of burning or poor deposit.
C. the solution was heated to 70° C. and a 6.3 mm diameter brass rod was plated at 300 mA/cm 2 for ten minutes, the rod being agitated during plating. The thickness of the chromium deposit, measured by weighing, was 9 microns.
D. the solution was heated to 70° C. and a 6.3 mm diameter brass rod was plated at 135 mA/cm 2 for ten minutes, the rod being agitated during plating. The thickness of the chromium deposit, measured by weighing, was 6 microns.
EXAMPLE IV
A plating solution was prepared as in Example II-C, except that 1 M sodium perchlorate was used to improve the conductivity of the solution in place of the 0.8 M sodium sulphate. A bright chromium deposit 0.85 microns thick was plated on both sides of a brass strip 2×5 cm, under the following conditions: ph=2.55, temperature 46° C., current 2A, and time 2.5 minutes. The current density was 100 mA/cm 2 and the chromium was deposited at 0.3 microns/minute.
EXAMPLE V
Preparation of another plating solution according to the present invention involves the following steps (the amounts of the constituents are for 1 liter of plating solution):
A. 60 grams of boric acid (H 3 BO 3 ) is added to 600 ml of deionized or distilled water. The solution is heated and stirred until dissolved. The pH is adjusted to between 2 and 2.4 with 10% NaOH or 10% H 2 SO 4 .
B. 33.12 grams of chromium(III) sulphate (Cr 2 (SO 4 ) 3 .15H 2 O) is added to the boric acid solution prepared in Step A above.
C. 32.43 grams sodium thiocyanate (NaSCN) is added to the solution made in Step B. The mixture is heated and maintained at 85° C.±5° C. It is stirred for ninety minutes.
D. the solution is cooled to room temperature. 10 grams of glycine (NH 2 .CH 2 COOH) are added to the solution. The pH is adjusted as in Step A. The solution is heated and maintained at 85° C.±5° C., stirring for ninety minutes.
E. the solution is cooled to room temperature and 140 grams of sodium perchlorate (NaClO 4 .H 2 O) are added. The mixture is heated and stirred until dissolved.
F. the pH is adjusted as in Step A.
G. the solution is brought up to one liter with distilled or deionized water.
H. 1 gram of sodium lauryl sulphate or 1 gram of FC98 is added and the solution is stirred to dissolve. The solution is then ready for plating.
(FC98 is a wetting agent and a product of the 3M Corporation.)
Suitable plating conditions are as follows.
The bath can be operated over a range of current density, pH and temperature. Suitable conditions are 50-150 mA/cm 2 , pH 2.0-4.0 and temperature 25°-60° C. At 105 mA/cm 2 , pH 3.5 and temperature 50° C., 0.6 microns chromium is deposited in two minutes (20-23% efficiency).
The anode current density should be maintained at about 40 mA/cm 2 . The anodes can be of platinized titanium or carbon.
Fume extraction should be used as small electrochemical breakdown of the thiocyanate anion occurs at the cathode.
EXAMPLES VI and VII
A plating solution was prepared as in Example V, except that the ligand buffer glycine was replaced by glycilglycine (GLY.GLY) in one case and glycilglycilglycine (GLY.GLY.GLY) in the other (diglycine and triglycine, respectively). The concentration of each ligand buffer was varied between 1 gram/liter and 20 grams/liter. Bright plating was obtained over this range. The efficiency increased from 11% at 1 gram/liter to 16% at 10 grams/liter and decreased to 5% at 20 grams/liter.
EXAMPLE VIII
A plating solution was prepared as in Example V, except that the quantity of NaSCN was reduced to 16.2 grams and glycilglycine was substituted for glycine. The concentration of glycilglycine was varied from 1 gram/liter to 5 grams/liter. Bright plating was obtained with efficiencies similar to those obtained in Example VI.
EXAMPLE IX
A plating solution was prepared as in Example V, except that the ligand buffer glycilglycine was added to the solution already containing 10 grams of the ligand buffer glycine. The concentration of glycilglycine was varied from 1 gram to 5 gram per liter. Bright plating was obtained with the efficiency decreasing from 19% to 13.5% with increasing concentration of glycilglycine in the range of 1-5 grams/liter.
EXAMPLE X
A plating solution was prepared as in Example IX, except that the quantity of NaSCN was reduced to 16.2 grams. The efficiency decreased from 15% to 13.5% with increasing concentration of glycilglycine in the range of 1-5 grams/liter. Bright plating was obtained over this range.
EXAMPLE XI
A plating solution was prepared as in Example V, except that the quantity of NaSCN was reduced to 16.2 grams/liter and aspartic acid at a concentration of 0.05 M was substituted for the ligand buffer glycine. This produced good bright plating over a wide range 10 mA/cm 2 to 500+ mA/cm 2 and an efficiency of 23% was obtained.
EXAMPLE XII
The concentration of aspartic acid in Example XI was increased to 0.1 M. Bright plating produced complete cover over a 10 A Hull cell plate. Plating could be carried out up to a temperature of 80° C. at an efficiency of 23%.
EXAMPLE XIII and XIV
A plating solution was prepared as in Example V, except that the ligand buffer glycine was replaced by argnine in one case and by histidine in the other and the quantity of NaSCN was reduced to 16.2 grams/liter. With both arginine and histidine, bright plating was achieved at concentrations of 0.05 M and an efficiency of 13.8% was obtained.
EXAMPLE XV
A plating solution was prepared as in Example V, except that the quantity of NaNCS was reduced to 16.2 grams and sodium acetate (CH 3 .COO Na) was substituted for the ligand buffer glycine. The concentration of sodium acetate was 8.2 grams/liter i.e., 0.1 M. The solution produced bright clean deposits over the range 5 mA/cm 2 up to approximately 600 mA/cm 2 with an efficiency of 14%. In this example, the solution temperature was 40° C. and had a pH of 2.5.
EXAMPLE XVI
A plating solution was prepared as in Example V, except that the quantity of NaNCS was reduced to 16.2 grams and sodium formate (H.COO Na) was substituted for the ligand buffer glycine. The concentration of sodium formate was 6.8 grams/liter, i.e., 0.1 M. The solution produced bright clean deposits over the range 5 mA/cm 2 up to approximately 600 mA/cm 2 with an efficiency of 14%. In this example, the solution temperature was 40° C. and had a pH of 2.5.
EXAMPLE XVII
A plating solution was prepared as in Example V, except that the quantity of NaNCS was reduced to 16.2 grams and sodium hypophosphite (NaH 2 PO 2 ) was substituted for the ligand buffer glycine. The concentration of sodium hypophosphite was 8.8 grams/liter, i.e., 0.1 M. The solution produced bright clean deposits over the range 15 mA/cm 2 up to approximately 300 mA/cm 2 with an efficiency of 14%. In this example, the solution temperature was 40° C. and had a pH of 2.5.
|
A chromium or chromium alloy plating system and material are disclosed. The chromium is supplied by an aqueous equilibrated solution of a chromium (III) thiocyanate complex. A buffer material which also supplies one of the ligands to the chromium complex is provided. The buffer material is selected from amino acids, peptides, formates, acetates and hypophosphites.
DESCRIPTION
Related Applications
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of U.S. Provisional Application Ser. No. 65/050,192, filed Sep. 14, 2014, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates in general to test and inspection systems and more specifically to a robotically assisted flexible test and inspection system.
BACKGROUND
[0003] Test and inspection systems are used in manufacturing operations in order to test and/or inspect products that have been manufactured in order determine if the manufactured product is working to the product's design specifications. Most test and inspection systems tend to be designed for a particular product that will be tested/inspected, making them good for the particular test application they have been designed for, but inflexible when it comes to testing the same product if it has been modified or testing/inspecting other products or multiple products. Another problem with current testing and inspection system, especially those used to test industrial products such as aircraft products (e.g., systems, subassemblies, parts, etc.) is that the test/inspection systems tend to be large fixed systems that are located in a particular location, requiring the products that are to be tested and/or inspected to be brought to the test/inspection system in order for the testing to be performed. This presents issues for manufactures that want flexibility in their manufacturing operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention may best be understood by reference to the following description, taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements, and in which:
[0005] FIG. 1 shows a drawing of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
[0006] FIG. 2 shows a picture of a top side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
[0007] FIG. 3 shows a picture of a side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
[0008] FIG. 4 shows a picture of a robotic arm in accordance with an embodiment of the invention.
[0009] FIG. 5 shows another picture of a robotic arm in accordance with an embodiment of the invention.
[0010] FIG. 6 shows a side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
[0011] FIG. 7 shows another side view of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
[0012] FIG. 8 shows a block diagram of a portable robotically assisted test and inspection system in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0013] While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures.
[0014] Referring to FIG. 1 , there is shown a drawing of a portable test and inspection system 100 in accordance with an embodiment of the invention. Test and inspection system 100 includes a portable test cart 102 having a set of wheels 122 for portability and movability. The test cart 102 includes a support member 104 used in holding a keyboard, mouse, scanner, etc. that is used by the test operator to control and monitor the testing process. A monitor support arm 106 is coupled to the support member 104 and supports a monitor 108 such as an LED or LCD monitor that can provide visual and/or touch screen interface capability for the test operator that is using the test and inspection system 100 . Monitor 108 allows the test operator to select to re-run any sub-tests within a particular test sequence.
[0015] Although not shown in FIG. 1 , a test system controller such as a computer is coupled to the monitor 108 and is used to control the functionality of the test and inspection system 100 . In one embodiment the computer is located in the bottom shelf 124 of the portable test cart 102 along with a power supply to provide power to the product being tested, switching and/or testing equipment and/or instruments (not shown) that can also be under the control of the computer and used for conducting tests of the product being tested. Depending on the particular design requirements, portable test cart 102 can have any number of shelves to accommodate different testing/inspection requirements. The computer (not shown) can be a personal computer or specialized test system controller such as a card based computer mounted onto a test rack slot with other electronic boards such as switching/testing boards being mounted on other slots of the test rack.
[0016] Portable test cart 102 includes a top shelf 114 which is used to receive a product to be tested. The product to be tested which will be referred to as a unit-under-test (UUT) 118 can be anything from a single component, electronic board, sub-assembly, etc. In one embodiment, the UUT 118 comprises an Astronics PECO division aircraft Passenger Service Unit (PSU) which is an aircraft assembly that is typically located overhead above airline passenger seats in an aircraft and that includes the passenger reading lights, air vents, flight attendant call buttons, emergency oxygen mask door, etc.
[0017] A computer controlled robotic arm 112 , such as one manufactured by Energid Technologies/Robai is located on a shelf 110 underneath of the top shelf 114 . Robotic arm 112 is capable of grasping numerous tools such as a button press tool in order to activate controls such as switches found on the UUT 118 . Besides switches/controls found on the UUT 118 , the robotic arm can close an emergency oxygen mask door when it is opened during testing, it can also toggle a switch which sends the attendant light to the front or back of the airplane. The robotic arm 112 is strong enough to pick up and use different types of tools for testing of different UUTs.
[0018] The top shelf 114 tray has one or more apertures (openings) to allow for certain parts of the UUT 118 to be accessible to the robotic arm 112 which is located underneath the top shelf 114 . In one embodiment, there is a singular large opening that allows access to the majority of the UUT 118 to the robotic arm except for a small amount of the edge margin of the UUT which is required to support the UUT to the top shelf 114 . The top shelf 114 can include one or more blocks or retention members to fix and register the UUT 118 to a specific location on the top shelf 114 . One or more clamps or other type of fixating devices can also be included on the top shelf 114 in order for the UUT 118 to be securely fastened in place prior to the robotic arm 112 activating the controls found on the UUT 118 during the testing sequence. In one embodiment, the robotic arm 112 is under control of the test system controller and has been programmed to test the different controls such as the light switches (buttons) located on the UUT 118 . Since the UUT 118 is firmly fixed in place using clamps or other fastening techniques, the robot arm 112 uses predetermined movements and positional alignments under the control of software executed by the test system controller to activate these switches on the UUT 118 .
[0019] Robotic test and inspection system 100 reduces the time for a human to inspect and test an electro-mechanical device such as UUT 118 , collecting the data, analyzing the data through statistical process control (SPC) techniques, developing traceability data, and archiving the data by generating quality inspection reports for a variety of consumer or industrial products, like the aircraft PSU mentioned above. The pass/fail data for the UUTs 118 that have been tested using test system 100 is compared to customer defined limits and the software can document and alert the test operator when results are outside of expected limits. The test operator alerts can comprise audio and/or visual alerts. This helps the test operator make an early detection of a production lot that is potentially defective before more are manufactured and/or tested. Since test system 100 is computer controlled and robotically assisted, it can determine if a UUT 118 has been built and operates to the manufacturers predetermined set of requirements. Test system 100 replaces human vision inspection, audio testing, and touch of buttons with a humanoid manipulator (robotic arm) 112 and computer hardware and software to perform the same tasks as a human tester with higher reliability, all in a small and portable form factor.
[0020] Test system 100 also automates the image (e.g., photographic/video) capture of the UUT 118 to validate that the test/inspection was performed, and stores the information in a database along with the part number and serial number information to meet regulatory agency requirements such as the Federal Aviation Administration (FAA) for the collection and archiving of quality inspection reports. The serial number and/or part number of the UUT 118 can be scanned using a scanner or using digital camera 126 or camera 128 , depending on the particular design objectives of test system 100 . The database can be a local or remote database depending on the particular design requirements for the test system.
[0021] Image capture in test system 100 is performed by a machine vision camera 128 located on shelf 110 which is used to take an images (pictures) of the UUT 118 on the side facing the robotic arm 118 . The picture(s) taken by camera 128 can be compared using vision compare software run by the computer to a UUT that has been properly manufactured. The vision compare software can detect if any switches, parts, etc. are missing. In one embodiment, the picture or pictures taken by the machine vision camera 128 are stored in a folder with a Log.csv file and is given a unique name (UUTID_YYYYDDMMHHmm.png). The file name is then saved to the database so that when loaded in Excel (and format the row as a link) the picture can be opened in one click.
[0022] In test system 100 a second camera 126 is mounted onto support member 120 which is connected to support members 116 which are coupled to the test cart 102 . The second or top camera 126 takes a picture and sends it to the vision software found in the test system controller, which inspects the placement and existence of critical components such as screws, wires, lanyards, doors, etc. which make part of UUT 118 . Using both cameras 126 and 128 allows for the vision software to inspect both sides of the UUT 118 for any flaws, missing parts and the like. The cameras 126 and 128 and accompanying software can also perform edge detection, color comparison, objection comparison, scan barcodes, determine illumination strength of lights that are activated, etc.
[0023] Although in the preferred embodiment, test system 100 is used to test an aircraft PSU, the test system 100 can be configured to test a wide variety of consumer or industrial electronic or electro-mechanical products. The top test shelf 114 can also be designed so that it is easily removable from the test cart 102 and replaced with another top test shelf that can accommodate a different UUT having different dimensions, etc. The new top test shelf can have different aperture(s) (openings) to allow different parts of the UUT to be accessible to the robotic arm 112 . The top shelf 114 can be designed to be easily removed using fast disconnect fasteners as known in the art, top support members 116 can be designed to connect to the sides of the test cart 102 so that they are not in the way when the top shelf needs to be replace to accommodate a different UUT.
[0024] Referring now to FIG. 2 , there is shown a top side view of the test system 100 . As shown, a digital camera (camera 126 shown in FIG. 1 ) is located on the top bracket and is used to take images of one side of the UUT (UUT 118 shown in FIG. 1 ). In this case, the camera 126 takes images of the back side of the UUT 118 , in order to verify the components are all there. As shown, the UUT 118 is placed in proper position by a series of support/registration members which hold and align the edges of UUT 118 . At the bottom of the picture are locking mechanisms that keeps the UUT 118 firmly positioned in place so that when the robotic arm 112 is actuating the switches, the UUT 118 does not move out of place.
[0025] Shown in FIG. 3 is a side view of the portable test system, showing several shelves, one holding the robotic arm, the other two supporting the test system controller (computer) and any necessary switching and test equipment needed to test and inspect the UUT Also shown in this view is a cable connected to the UUT on the lower left corner that is connected to a power supply, power converter, and any test/switching equipment which are used to test the UUT 118 . The switching equipment includes a switch card that allows the test system 100 to control power to different components of the UUT individually and use both AC and DC power.
[0026] Referring to FIG. 4 , there is shown a close up view of the robotic arm 112 which is located on shelf 110 . The vision camera 128 is also shown on shelf 110 . In this view a microphone 402 is shown which can be used to verify that any audio signals that the UUT 118 needs to produce are in fact produced during testing. Besides a microphone 402 , other equipment such as a light detector could also be added in order to check for any light emissions for other UUTs, temperature sensors, etc. can also be included if the UUT requires other types of performance tests. The camera 128 rests on shelf 110 and is used to take images of the side of the UUT which the robotic arm 112 is interacting with. In FIG. 5 there is shown a close up view of the robotic arm 112 using the switch activation tool to activate (press) a light switch found in the UUT 118 . In FIG. 5 there is also shown the opening in top shelf 114 which allows a good portion of the UUT 118 to be accessible to robotic arm 112 . The robotic arm is shown grasping a switch testing tool used for activating the switches found in the UUT.
[0027] In FIGS. 6 and FIG. 7 there are shown side view drawings of the test system 100 . In FIG. 6 there is shown a few of the support members 602 that are used to hold and register the UUT in proper position for testing. One of the lock down clamps 604 which is used to hold down the UUT for testing is also shown.
[0028] Referring now to FIG. 8 , a simplified block diagram of the test system 100 is shown in accordance with an embodiment of the invention. A controller 802 as previously mentioned which can take the form of a personal computer, test controller, or other known in the art control unit can be used to control and execute the software needed to run the test and inspection system 100 . Controller 802 executes the robotic arm and vision software needed to operate the robotic arm 804 and cameras 126 and 128 . The vision software for example can be used to determine if a light in the UUT 118 is operational by taking a picture with the camera 128 and sending the picture to the vision compare software that is executed by controller 802 . The vision compare software compares the picture that has been taken to a pre-programmed picture and determines if the light is on or off during testing. Controller 802 is also coupled to input/output devices such as monitor 108 , a keyboard, cameras 128 and 126 , a microphone, a scanner for scanning bar code or other information from the UUT 806 , etc. A database 812 is coupled to the controller 802 and is used to store the information collected from the test and inspection of the UUT. The database 812 can be located either locally or remotely. Database 812 can also have stored therein pictures of UUT's 806 which have been manufactured correctly so the portable test and inspection system 100 can take images with cameras 126 and 128 and compare those images to those stored in database 812 for correctly built UUT's 806 . If the image information do not match, for example a control switch is missing from the UUT 806 , a warning message can be provided to the test operator using monitor 108 and the problem noted in the test report which can be stored in the database 812 and/or controller 802 . Such as warning message can cause the UUT 806 to fail the test/inspection. Test system 100 in one embodiment stores in database 812 for each UUT 806 that is tested operator/user information, UUT serial number, UUT part number, pass/fail information for each test conducted, a picture file name for each picture/image associated with the particular UUT test. Controller 802 also provides control to any necessary power supply and test and switching equipment 808 , as well as the keyboard, scanner, cameras, microphone, etc. 810 used to test and inspect the UUT 806 .
[0029] While the preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims.
|
A robotically assisted flexible test and inspection system that is portable and adaptable to test and/or inspect products is described. The test and inspection system is a compact system that can be moved easily to different locations and includes a robotic arm which is used for testing and inspection of a unit-under-test (UUT). The robotic arm can be used to activate different controls in the UUT or cause different functionality of the UUT to be tested. The robotic arm can use different tools such as a switch activator tool, to accomplish its tasks. The test and inspection system in one embodiment is a movable test cart, wherein the robotic arm is located in one of the shelves of the test rack and the UUT is located in another shelf of the test rack which has an aperture that presents portions of the UUT to the robotic arm. Another shelf or shelves of the moveable test rack can accommodate a test system controller, testing and inspection components/instruments, etc.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/691,790 filed Jun. 17, 2005, and U.S. Non-Provisional application Ser. No. 11/370,414 filed Mar. 8, 2006, each hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention is drawn to a load bearing panel member formed by a method of injection molding.
BACKGROUND
There are numerous known systems for plastic injection molding. In conventional plastic injection molding systems, plastic pellets are melted in an injection molding machine and advanced by a screw ram through an injection nozzle and into a mold cavity. The mold cavity is preferably formed between two mold halves. The molten plastic material in the cavity is allowed to cool and harden in the cavity. When the plastic material has cooled and sufficiently hardened, the two halves of the mold are separated or opened and the part is removed, typically by one or more ejector pins.
Some injection molding systems utilize a gas in the injection molding process and are commonly known as “gas-assisted injection molding” systems. In these systems, the gas is injected into the molten plastic material through the plastic injection nozzle itself, or through one or more pin mechanisms strategically positioned in the mold. It is also possible to inject the gas directly into the molten plastic in the barrel of the injection molding machine. The gas, which typically is an inert gas such as nitrogen, is injected under pressure and forms one or more hollow cavities or channels in the molded part.
Gas-assisted injected molding produces a structure having a hollow interior portion which results in saving weight and material, thereby reducing costs. The pressurized gas applies an outward pressure to force the plastic against the mold surfaces while the article solidifies. This helps provide a better surface on the molded article and reduces or eliminates sink marks and other surface defects. The use of pressurized gas also reduces the cycle time as the gas is introduced and/or migrates to the most fluent inner volume of the plastic and replaces the plastic in those areas which would otherwise require an extended cooling cycle. The pressure of the gas pushing the plastic against the mold surfaces further increases the cooling effect of the mold on the part, thus solidifying the part in a faster manner and reducing the overall cycle time.
SUMMARY
The present invention provides a method for producing a structural or load bearing injection molded panel member. According to a preferred embodiment, the panel member is a floor panel for a van having retractable rear seats wherein the panel member is adapted to cover the rear seats when fully retracted and act as a load floor. The panel member preferably includes a first portion, a second portion and an interior surface portion. The present invention will hereinafter be described according to the preferred embodiment wherein the interior surface portion is a carpet material; however, it should be appreciated that according to alternate embodiments the interior surface portion could also include, for example, a vinyl material or a textile material.
The preferred method of the present invention includes placing the carpet material into a mold cavity configured to produce the panel member. The mold cavity preferably includes a first chamber adapted to form the first portion of the panel member, and a second chamber adapted to form the second portion of the panel member. After the carpet material is inserted into the mold, molten plastic material and pressurized gas are injected into the first chamber of the mold cavity. After the molten plastic material is injected into the first chamber of the mold, molten plastic material is injected into the second chamber of the mold cavity. A sequential gating process is used to achieve this sequence of operations. The molten plastic is then cooled until it solidifies. After the molten plastic is sufficiently cooled, the pressurized gas is vented and the panel member is removed from the mold.
It should be appreciated that the order in which the steps of the preferred embodiment are performed may be varied according to alternate embodiments. For example, according to one alternate embodiment of the present invention, the molten plastic material may be injected into the second chamber of the mold cavity before molten plastic material is injected into the first chamber of the mold cavity. According to yet another alternate embodiment, molten plastic may be injected into the first and second chambers of the mold cavity simultaneously.
The present invention also provides a structural or load bearing panel member and a product by process. The load bearing panel member preferably includes a generally rectangular first portion, a generally rectangular second portion, and a carpet material. The carpet material is attached to the first portion and the second portion such that the carpet material forms an integral or living hinge at a gap therebetween. The first portion of the panel member defines a plurality of solid horizontally disposed ribs and a plurality of solid vertically disposed ribs. The first portion of the load bearing panel member also includes a plurality of hollow ribs formed by the gas assisted injection molding process. The hollow ribs are generally located around the periphery of the first portion of the load bearing panel member as well as in an X-shape originating at the center of the first portion and extending toward the corners thereof. The solid ribs and hollow ribs are adapted to increase strength and rigidity and provide substantial structural or load-bearing capability
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom view of a load bearing panel member in accordance with the present invention;
FIG. 2 is a block diagram illustrating a method of the present invention;
FIG. 3 is a sectional view of the panel member taken along line A-A of FIG. 1 ;
FIG. 4 a is a schematic sectional view of an injection molding nozzle and a plurality of valves; and
FIG. 4 b is a schematic plan view of a mold cavity.
DESCRIPTION
Referring to the drawings, wherein like reference numbers refer to like components, FIG. 1 shows a panel member 10 produced according to a method of the present invention. The panel member 10 will hereinafter be described as a floor panel for a van having retractable rear seats (not shown), wherein the panel member 10 is adapted to cover the rear seats when the seats are fully retracted and also to act as a load floor. It should be appreciated, however, that the method of the present invention may be implemented to produce other conventional panel members as well.
The panel member 10 includes a generally rectangular first portion 12 , a generally rectangular second portion 14 , and an interior or appearance surface portion 16 (shown in FIG. 3 ). The present invention will hereinafter be described according to the preferred embodiment wherein the interior surface portion 16 is carpet material; however, it should be appreciated that according to alternate embodiments the interior surface portion 16 could also include, for example, a vinyl material or a textile material. According to a preferred embodiment, the carpet material 16 is a polypropylene material with a polyester backing. The carpet material 16 is attached to the first portion 12 and the second portion 14 such that the carpet material 16 forms an integral or living hinge 18 at a gap 19 between the first portion 12 and the second portion 14 . The first portion 12 of the panel member 10 defines a plurality of solid horizontally disposed ribs 20 and solid vertically disposed ribs 21 . The solid ribs 20 and 21 are normal to each other so as to increase strength and rigidity and provide substantial load-bearing capability. According to a preferred embodiment of the present invention, the second portion 14 of the panel member 10 includes a plurality of up-standing clip attach members 22 .
The clip attach members 22 preferably each retain a metallic attachment clip (not shown) configured to mount the second portion 14 of the panel member 10 to a seat assembly (not shown). When the seat assembly is in an upright position, the hinge 18 allows the second portion 14 of the panel member 10 to fold underneath the first portion 12 and below the seat.
When the seat assembly (not shown) is fully retracted, the first portion 12 of panel member 10 is rotatable about the integral hinge 18 from an open position exposing the seat assembly to a closed position at which the seat assembly is covered. When the seat assembly is fully retracted and the first portion 12 of panel member 10 is in the closed position, the carpet material 16 (shown in FIG. 3 ) is exposed and the seat assembly is completely hidden. In this manner, the panel member 10 is adapted to provide an aesthetically pleasing carpeted interior when the seat assembly is retracted, and also provide substantial floor-strength.
Referring to FIG. 2 , a method for manufacturing the panel member 10 according to the present invention is shown. At step 50 , the carpet material 16 is placed into a mold cavity 70 (shown in FIG. 4 b ) configured to produce the panel member 10 . Optionally, at step 50 , metal inserts such as bars and/or tubes (not shown) can also be placed into the mold cavity 70 with the carpet material 16 to produce a panel member 10 with increased strength and rigidity. The mold cavity 70 of the present invention preferably includes a first chamber 72 (shown in FIG. 4 b ) adapted to form the first portion 12 of the panel member 10 , and a second chamber 74 (shown in FIG. 4 b ) adapted to form the second portion 14 of the panel member 10 . The first and second chambers 72 , 74 are preferably separated by an insert or feature 75 (shown in FIG. 4 b ) configured to produce the integral hinge 18 (shown in FIG. 3 ). At step 52 , molten plastic material 76 (shown in FIG. 4 a ) is injected into the first chamber 72 of the mold cavity 70 . The molten plastic material 76 is preferably injected in a conventional manner, such as, for example, by a reciprocating screw type injection device (not shown), through an injector nozzle 40 (shown in FIG. 4 a ), through a valve gate 42 a (shown in FIG. 4 a ), and into the first chamber 72 of the mold cavity 70 .
At step 54 , an inert gas 80 (shown in FIG. 4 b ) such as nitrogen is injected into the first chamber 72 of the mold cavity 70 (shown in FIG. 4 b ) through a plurality of gas pins 82 (shown in FIG. 4 b ) positioned at locations predefined by the desired locations of the hollow ribs 30 . The gas 80 preferably does not mix with the molten plastic material 76 , but takes the path of least resistance through the less viscous portions of the plastic melt. The molten plastic 76 is therefore pushed against the wall portions of the mold cavity 70 , which forms channels 31 and produces the hollow ribs 30 (shown in FIGS. 1 and 3 ).
Referring to FIG. 3 , a sectional view taken through section A-A of FIG. 1 is shown. It can be seen in FIG. 3 that the hollow ribs 30 define an internal Channel 31 through which the gas is injected. Referring again to FIG. 1 , the gas 80 (shown in FIG. 4 b ) is preferably injected through the gas pins 82 (shown in FIG. 4 b ) into the first portion 12 of the panel member 10 at the gas injection locations 32 . According to a preferred embodiment, the hollow ribs 30 are generally located around the periphery of the first portion 12 of the panel member 10 as well as in an X-shape originating at the center of the first portion 12 and extending toward the corners thereof. It has been observed that the hollow ribs 30 formed in the manner described increase the rigidity and strength of the first portion 12 of the panel member 10 . The increased strength and rigidity is particularly advantageous for the preferred embodiment wherein the panel member 10 is implemented as a load bearing floor panel.
Referring again to FIG. 2 , at step 56 molten plastic material 76 (shown in FIG. 4 a ) is injected into the second chamber 74 of the mold 70 (shown in FIG. 4 b ). The molten plastic material 76 is preferably injected through the injector nozzle 40 (shown in FIG. 4 a ), through a valve gate 42 b (shown in FIG. 4 a ), and into the second mold chamber 74 .
A sequential gating process is preferably implemented to perform previously described steps 52 and 56 . Referring to FIGS. 4 a - 4 b , the valve gates 42 a and 42 b , which are adapted to feed the first and second mold chambers 72 , 74 , respectively, are opened using the sequential gating process. In other words, the sequential gating process is implemented to control the timing of the gates 42 a , 42 b and to coordinate the operation of valve gate 42 b with the operation of valve gate 42 a . According to a preferred embodiment, the valve gates 42 a and 42 b are configured to open and close at a predetermined time. The predetermined time at which the valve gates 42 a and 42 b open and close is generally based on the needs of the specific part to be molded and type of material being used. Alternatively, the valve gates 42 a and 42 b may be opened and closed based on the position of a screw type injection device (not shown).
Referring again to FIG. 2 , at step 58 the molten plastic material 76 (shown in FIG. 4 a ) that was injected into the first and second chambers 72 , 74 of the mold cavity 70 (shown in FIG. 4 b ) at steps 52 and 56 is allowed to cool and solidify. Thereafter, at step 60 , the pressurized gas 80 (shown in FIG. 4 b ) that was injected in to the first chamber 72 of the mold cavity 70 at step 54 is allowed to vent through the gas pins 82 (shown in FIG. 4 b ). At step 62 , the finished panel member 10 is removed from the mold cavity 70 .
It should be appreciated that the order in which the steps 50 - 62 of the preferred embodiment are performed may be varied according to alternate embodiments. For example, according to one alternate embodiment of the present invention, step 56 at which the molten plastic material 76 (shown in FIG. 4 a ) is be injected into the second chamber 74 (shown in FIG. 4 b ) of the mold cavity 70 (shown in FIG. 4 b ) may be performed before step 52 at which molten plastic material 76 is injected into the first chamber 72 (shown in FIG. 4 b ) of the mold cavity 70 . According to yet another alternate embodiment, steps 52 and 56 may be performed simultaneously such that molten plastic 76 is injected into the first and second chambers 72 , 74 of the mold cavity 70 simultaneously.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
|
A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of rib members forming a grid pattern on the first portion and another plurality of rib members extending toward the periphery of the first portion which may be non-orthogonal to each other and to the rib members forming the grid pattern. A tubular cavity may be formed within each of the non-orthogonal rib members by injecting a gas into the rib member during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.
| 4
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims as priority date provisional applications filed by the same inventor: (1) Application #61/744,277 filed on Sep. 24, 2012 entitled: “Innovation Package G29” and (2) Application #61/724,916 entitled “Hybrid Coins” filed on Nov. 10, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] The newly emerging digital money mints require a careful design and construction of procedures and implements to allow for the digitally minted money to spread into the hands of the trading public. Such procedures and implements are the subject of this invention.
SPECIFICATIONS
[0005] Continuation in Parts of Utility patent application Ser. No. 14/035,921
BRIEF DESCRIPTION OF DRAWINGS
[0006] FIG. 1 : string inside and string outside trading options for hybrid coins. —demonstrating the distinction between passing a string that is contained inside a hybrid coin, and a string that is without. In part (a) Alice passes the hybrid coin to Bob, which corresponds to cloud-based accounting action: transferring the coin denomination value from Alice's account to Bob's account. In part (b) Alice also passes a hybrid coin to Bob. This time the coin contains the digital money inside itself. There is no corresponding account transfer anywhere.
[0007] FIG. 2 : Anatomy of Hybrid Coin Payment environment: Depicting the functional elements in a hybrid coin payment environment. The elements include the memory module where the digital money is written, and where it is accessible to a read/write processor module that responds to a crypto processor. The crypto processor will be connected to a display window to show the current amount in the coin. The crypto processor will carry out a dialogue protocol with the payment terminal that engages the hybrid coin, allowing for the coin to pay, or be reloaded. The hybrid coin will engage with an external payment system via a hook-up apparatus.
[0008] FIG. 3 : Appearance of a hybrid coin: depicting the front and rear elements typical of a hybrid coin, including coin-id, and a running meter of residual digital value. Items (a,a′,a′) represent a mini USB female port, (b) represents the covered slot for a coin battery, (c) represents the residual value display window. In the drawing it shows $8.75, indicating that the coin has lost its gold status (lost its virginity), was already partially drained (in the mount of $1.25), and the residual value of the coin is $8.75. On the back face, item (d) represents the mint-assurance window. The display on the window changes frequently as computed by the crypto processor inside the coin
[0009] FIG. 4 : This figure depicts the “nut design” for the hybrid coin. Part (a) shows the top side of the cap; part (b) shows the flat surface of the cap, and part (c) shows the slit where a USB protrusion fits. The cap-matching part (the “heart”) shows its corresponding flat surface (d), the USB protrusion (e), and it opposite part (I where a USB active slit (g) is visible. The “nuts” may be chained together through loops (h,i,j,k). The “nuts” coins may be attached through “threading” the USB protrusions to USB female connections at the cap side of the nut. This will amount to creating the equivalent of a single hybrid coin of the same denomination as the sum of the threaded coins.
[0010] FIG. 5 : Cracked Hybrid Coins: (a,b,c) are up, side, and down views of a plastic cast coin housing a micro SD (or similar) device that contains money in the form of a digital string (bit string). The coin may be constructed from composite or any other suitable material. (d) depicts such a hybrid coin subject to a hammer blow (or a nut-cracker squeeze) resulting in a cracked coin (e) where the cracking is clearly visible. The coin owner will pull the micro-SD (f) from the cracked hybrid coin, and then connect the micro SD with a phone (g) or any connectivity device to communicate with the digital mint website, validate and upload the money from the coin.
[0011] FIG. 6 : Drainable Hybrid Coin (Elements): This figure shows the elements that comprise a drainable hybrid coin: it contains the money bits—bits which together reflect the monetary value of the coin; it contains additional data (meta data), (b), that is being used by the payment circuitry system (PCS), (c) to effect the drained payment; it contains the coin erasure circuitry (d) which is the security apparatus designed to wipe out the coin data (the money bits) when attempts to tamper with the coin are being detected. The coin is fitted with a payment port (e) which is a latching fixture to be latched to a corresponding payee port. Alternatively, the port may be “touch-less” using technology like NFC or Bluetooth to effect the payment. The various elements of the drainable coin are being enclosed in a secure enclosure that is sealed, and in most cases is not designed for re-opening.
[0012] FIG. 7 : Tamper-Proofing a Drainable Hybrid Coin: Illustrating various security measures: (a) a light sensor that is designed to be activated in the event that the otherwise darkened internal environment is flashed with light as a result of drilling a hole, or cracking the enclosure. Once activated the coin erasure circuitry is activated and wipes out the coin content; (b) is a pressure sensor that is triggered when the pressure inside the enclosure changes beyond some preset threshold—either for higher, or for lower values. The pressure sensor may be applied for the case of creating a vacuum in the enclosure and upon drilling or cracking the internal pressure returns to normal, or in the case where the set pressure in the enclosure is higher than atmospheric, and upon drilling or cracking the pressure comes down to normal. Once activated the coin erasure circuitry is activated; (c) is an emitter of electromagnetic radiation that is fired across the internal volume of the enclosure to be captured and metered at the other end (d) where the level of radiation absorption is being monitored. Any tampering and exposure of the enclosure to the outside environment will result in a change in the gaseous composition of the internal volume, and a consequential change in the rate of radiation absorption—such change will trigger the erasure circuitry to wipe out the digital coin within the enclosure. The absorbing cocktail will be kept a secret to make it intractable for the assailer to beat this defense.
[0013] FIG. 8 : Pizza coin: an illustrating of one of many decorative ways to present, a gift, say, of electronic cash. In the illustration 8 coins are built as pizza slices that fit to be a complete pizza. The money in each such crackable coin is the same: $10, but it could be different. This alludes to the many creative ways in which crackable hybrid coins can be configured, while still maintaining their utility.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention is described in two parts:
1. Mint Array Design (Core Mint v. Front Mints) 2. Hybrid Coins
1. Mint Array Design
[0017] The Core BitMint projects to any number of front BitMint entities, and the relationship may be one or a mix of the following:
[0018] Royalties Payment
[0019] System
[0020] Dead Coins
[0021] Live Coins
[0022] Each front mint may take the role of the Core, and project to its own front entities. In this way one may define a mint-tree (hierarchy).
[0023] This relationship will allow front mint to be consistent with parameters and regulations prevailing in their domain, while enjoying technical and functional support from the Core BitMint.
[0024] Royalties Payment:
[0025] In this mode Front BitMints pay use royalties to the Core for using its technology, and no further relationship or obligation exists.
[0026] System:
[0027] In this mode the Core delivers, installs, and provides training and maintenance to the front—or any part of this list. In its full implementation the Core provides a ready-to-mint system, maintains it, and trains its operators.
[0028] Dead Coins:
[0029] In this mode the Core delivers to the front valueless minted-coins per the front request. The front would then ‘charge’ these dead coins, and ‘bring them alive’ versus its customers. It would be the Core responsibility to insure the integrity of the bits and their identity, and to equip each coin with the headers and trailers as needed. The Core would identify the core mint, the front mint, any other parameters requested by the front, and then add, say, as trailers, any cryptographic parameters as needed.
[0030] Live Coins:
[0031] In this mode the Core will deliver live, charged coins to the front mint. The front mint will pay, or promise to pay for these live coins, and then, if necessary, process these coins to serve for the purpose of the front.
[0032] The responsibility and involvement of the Core with the business of the front entities is minimal in the royalties mode, a bit greater but still limited in the system mode, also limited in the dead-coins mode, and the highest in the live-coins mode.
[0033] In the system mode the Core is responsible for the integrity of the delivered system, but not for its use. In the dead-coins mode, the Core is responsible for the quality of the bit identities of the coins; but not for its money value or use. In the live-coins mode the Core is responsible for the money value of the coins. This responsibility may be of two categories:
[0034] front-limited
[0035] front-extended
[0036] In the front-limited mode the Core has a contract with the front whereby the front pays or promises to pay for the delivered coins, and the Core agrees to redeem these coins when submitted by the front for redemption. The Core will not be involved in any business arrangement between the front mint and its customers, and will not interact with those customers. In the front-extended mode the Core will interact with the customers of the front, even directly redeem its coins to them.
[0037] Basically, the idea of live coins, is to alley the customers apprehension with regard to the trustworthiness of the front mint. The live-coins setup will give the front customers the peace of mind that their money is kept the trustworthy Core.
[0038] For example, customers may be reluctant to trust their money to an unknown Front company that offers them money transfer, micropayment, charity contribution, etc. However, if the terms of the coin are such that if the Front does not pay, or goes out of business, the coin can be redeemed at the Core.
Buffer: Layered Mint Operation
[0039] It may be advisable to construct a buffer between the entity that mints the coins and the entity that trades them with the public (its customers). Such in the case in the “live coin” Core-front business setup. A buffer will allow a Core mint to mint coins that may either be traded as is by the front mint (in this case this entity is not much of a mint), or it may be first processed by the front mint, with both the header and trailer possibly adjusted, added-to, to serve the purpose of the front. The value bits will be minted by the Core based on the Core's recognized trustworthiness. For example the front could add cryptographic parameters to the trailer.
[0040] Illustration: the add-on header information (added by the front) will include payment terms according to which the Front will redeem the coin in favor of its customer. The trailer add-on may contain a signed hash to identify the coin as re-minted by the Front.
Bit-Masking Trade Tracing
[0041] This procedure is based on the notion that a BitMint coin is constructed from a large number of ordered bits. So much so that anyone who knows the identity of, say, 80% of the bits is not likely to have guessed it right but is overwhelmingly likely to have been given the bits. Accordingly Alice could pass a BitMint coin to Bob, and mask the identity of a small number of bits, say, selected randomly. Bob will have knowledge of the identity of sufficient number of bits to claim that he is in possession of the coin, but the identity of the masked bits will connect Bob to Alice, as the payer of the coin. If Bob had received the coin from Carla, then it is virtually impossible for Carla to randomly select the very same bits as Alice for the purpose of masking their identity as she passes the coin to Bob. Hence the identity of the masked bits points to the source of the coin. Bob, on his part may pass the coin to David—masking some additional bits. The identity of the bits that Bob masked will point to him as the source of the coin. And so on, when David passes the coin to Eve he masks some more bits. And on it goes. If Alice will examine a coin held by Eve she will be able to determine that it was a coin she held because the bits that she masked giving the coin to Bob are all masked. And since the number of masked bits is so small compared to the number of bits in a coin, the chances that all of Alice masked bits are masked by someone else are very slim.
[0042] The selection of bits to mask may be done via a selection algorithm that takes into consideration any information on the coin, its value bits and all the other coin information (header and trailer). So for each coin the selected bits are different, but given a coin the selection algorithm may be readily replayed.
[0043] If an approval hierarchy is used then it is advisable that the number of masked bits is smaller than the number of masked bits between layers on the approval tree.
Samid Cipher RFID
[0044] Samid cipher U.S. Pat. No. 6,823,068 may lend itself to RFID technology. The key may be hard-wired as matrix of bits where every two bits represents one of the four letters: X, Y, Z, and W. The cipher will operate on basic knowledge where the plaintext comprised of a non-repeat series of X, Y, Z and W letters guides a traveling path on the key, and produces a traveling trace marked as a sequence of Up, Down, Right, and Left. The stream comprised of U, D, R and L letters will constitute the ciphertext. The plaintext may be hard-wired, firmware, or software. Upon triggering from the outside the plaintext will be fast processed through the key (the matrix) to yield the ciphertext as output. Conversely, the ciphertext may be resident in the RFID, and upon initialization, the ciphertext will be processed via the key (the bit matrix) to yield the plaintext as output. In both cases the Samid cipher will be implemented.
[0045] There are various uses for this arrangement:
[0046] Hiding content of the RFID: an RFID tag may contain information that needs to remain private. In a regular ID any reader would activate the RFID and read the information in it. That information may be encrypted and be interpreted through an exhaustive look-up table. But an easier alternative is to fit the secret RFID information as software, firmware or hardware in the tag, and refer to it as plaintext. The Samid key will such that the size of the output ciphertext will be much larger than the size of the plaintext. And also there will be a great deal of degree of freedom for the encryption process to yield any of a large variety of ciphertexts, all of them decrypt back to the same plaintext, if the decryptor has possession of the right key.
[0047] So, in this arrangement only the key will have to be known to the reader of the RFID, and a large number of related or unrelated RFID tags will be sharing the same key. Each tag will contain some specific and unique content. Upon activation, reading, the content will be processed through the Samid cipher key, and yield an output to be read by the decoder/reader. The reader will have the key in its reading device, and will be able to instantly decrypt the ciphertext, and display and interpret its contents. An unauthorized reader, will activate the RFID, but will be unable to interpret its output because of not having the key.
[0048] What is more: the size of the ciphertext will vary, and so the hacker will not be able to conclude from the size of the ciphertext, how much contents (plaintext) is stored in the device. Also the activation will be able to include random data from a clock or from the environment, and that data will guide the encryption each time to a different ciphertext, a further difficulty for the cryptanalyst.
[0049] Similar setup could be done with Flash technology. A flash memory may contain a content X (may be a digital money string or anything else). The device that holds this memory card, activates the device, so that X is encrypted via a well defined firmware, say key, and produces Y. A verifier attests to the presence of X in the drive on account of detailed examination of Y.
AutoKey Authentication
[0050] Alice holds string X, and wishes to signal and prove that holding to Bob. If she sends X in the clear, Eve, the eavesdropper will catch it. If she had a shared key with Bob she could use it to encrypt X and send it to Bob. Otherwise she could use diffie Hellman or any other cryptography between strangers—with all the weaknesses thereto. So instead she could use an Auto-Key, based on the crypto-cipher and crypto addition presented by this inventor before. Accordingly Alice will separate from the string t bits as described in the crypto cipher, use these bits to find where to dissect the rest of the string, and then use one part so dissected as plaintext and the other as a Samid cipher key. Then Alice will encrypt the plaintext using her derived key applying the Samid cipher. She will communicate the result to Bob the verifier. Bob who knows X will repeat Alice process to check if Alice ciphertext agrees with his calculations, and if so, he is rest assured that Alice has X. This verification happened without any exchange of any key. Eve, the hacker will not be able to reverse Alice ciphertext, Y to the original string because as it has been shown there, there are infinite number of strings that process to the same Y.
2. Hybrid Coins
Off-Line Digital Money
Gideon Samid, Provisional Application U.S. PTO #61/724,916 Nov. 10, 2012
[0051] Digital money is native to online applications, and inherently problematic in off-line circumstances where one suspects that the same digital string was used earlier, elsewhere, or even later, putting the payment in doubt. We propose effective means to manage such risks and operate a viable off-line digital payment solution. The central concept is that of a ‘hybrid coin’ or say, a ‘dynamic coin’—a physical device containing, dispensing, and in some cases, accepting digital cash. The device, the coin, will be tamper-resistant to a degree commensurate with its capacity. Security will be safeguarded by insuring that the cost to counterfeit exceeds the maximum money content of the coin. Different coin denominations will have different tamper-resistant measures, and these measures will be dynamically adjusted to protect against increasingly more sophisticated counterfeit measures. The use of the coins will be either via the regular hand-over, or by ‘draining’: namely, one could pass to the payee a bunch of coins trusted for their declared money content, or one would connect the coin to a recipient device, and drain, pay off a portion of the stored value. We distinguish between the following coins: (1) “gold coins” which are minted by digital currency mint, and their seal is intact, indicating they were never bled, drained, and hence satisfying the recipient that these coins carry their nominal (mint stamped) value. (2) “silver coins” which are gold coins that have been partially used (drained), and now contain less money than the originally minted amount. (3) “bronze coins” which have been drained, or bled, but which have also be replenished from another coin. The coins are optionally battery operated, marked by a unique serial number, and they may be shaped like regular coins. The digital money in the coins can be defined in terms of dollars, Euros, Yuan, or any other currency, as well as defined against gold, or any other commodity valuable. Hybrid coins may be uploaded to online use, and altogether facilitate an important facet of normal civil trade practice. Hybrid coins provide continuity of habit relative to regular coins, and respond to every day functionality needs. Hybrid coins may also be found useful in mass emergencies, when power lines are down, communication networks collapsed, and off line payment is the only way.
Introduction
[0052] There are several solution options for online digital money. Yet to prevail in the marketplace it seems necessary for a solution to be extendible to off-line circumstances. For centuries people have been paying each other by handing over a physical token, a representative of value. For behavioral continuity this is a must. In practice there are two categories of situations where the off-line payment option is critical: (1) immediacy and simplicity, and (2) emergency—short-lived, or durable. Nothing electronic, or computer-based can compete with the immediacy and simplicity of hand to hand coin transfer. In many daily circumstances resorting to an electronic gadget, having to punch buttons, and having to participate in a person-machine dialogue, is too much of a burden. Electronic transactions inevitably rely on electric power supply: be it a battery, or be it the grid. Both may be interrupted, impaired and become dysfunctional—disabling payment altogether. Our modern societies are comprised of very crowded urban areas where millions of strangers share a territory and public resources, and a payment mechanism is the only way to get such a crowd into a mutually beneficial cooperation. We cannot risk the loss of the payment option, exactly when it is needed most.
[0053] We conclude then that we must allow for a seamless back and forth motion between the online payment mode and the offline payment mode, and the concept of Hybrid Coins proposes a solution for this challenge.
[0054] Let us first define and characterize digital money.
[0055] Digital Money is money that expresses its value via digitized data in a medium-un-tethered fashion. Since all data can be reduced to an equivalent binary string, we can further narrow the definition to say that digital money is money that expresses its value via a bit string, or, say a ‘binary string’ where the identity of the string bits {0,1} carries the monetary value regardless of the medium through which these binary digits are written or expressed.
[0056] The logic, mechanism algorithm or concept that associates a given binary string with a monetary value is of no importance for our matter herein. A hybrid coin should extend to off line payment any digital money solution where a bit string represents value, regardless of the concept, formula, logic, mechanism that establishes the value of the string.
The Hybrid Coin Concept
[0057] A hybrid coin is a physical device that by handing it over, one carries out a payment corresponding to the face value of this device, where the face value is reflected by a bit string that changes ownership from the payer to the payee as the coin is handed over. Ownership is expressed as the right to use, dispose, pass-on this string as the owner sees fit.
[0058] According to the above definition the bit string—the digital money—does not have to be inside the coin, or passed along with the coin. All that is needed is for the ownership of the associated bit string to be exchanged between payer and payee. Obviously, if the coin contains the string, the ownership passes on. In the “no-string-inside” option the coin may serve as “proof of ownership” which can be used in some subsequent protocol in which the money is actually transferred. FIG. 1( a ) depicts the “no string inside” option, and FIG. 1( b ) depicts the “string inside” option.
[0059] In FIG. 1( a ) “no string inside: Alice passes to Bob a $10.00 hybrid coin, and this act confers a transfer of ownership of a bit string that resides in the clouds of elsewhere outside the coin. As the coin is transferred from Alice to Bob, the respective ownership of the corresponding bit string is also passed from Alice to Bob. Passing the string from Alice to Bob, does not necessarily erase the string from Alice memory. This leads to the fundamental issue of double spending, namely Alice, by mistake or by fraudulent intent may re-transfer ownership to the same bit string to a third person, thereby violating the association between the bit string and the socially accepted sense of value. Since the bit string represents value in the context of some comprehensive solution to digital currency, we may assume that the issue of double spending is resolved and taken care of in the context of that solution.
[0060] FIG. 1( b ) “string inside” represents the case where the physical device, the hybrid coin, contains the digital money, and hence, the passing of the coin amounts to passing the string—the money itself.
[0061] A string-inside hybrid coin is produced and manufactured, and also optionally distributed by an entity referred to as the mint. The mint assumes the responsibility to the monetary value of the coin it issues, mints.
[0062] In addition to the standard hybrid coins described above the mint may wish to construct: (1) empty coins, and (2) networked coins. Empty coins are simply bit-money containers that may be filled with bit-money by traders to dispose of them at a later time either by feeding their bits to a payee or by passing the coin to a trusting payee. Networked coins are hybrid coins with a phone-like connection to networks. Such “live hybrid coins” may have their contents instantly, and continuously verified by the continuously connected mint.
String Imide Hybrid Coin.
[0063] The string-inside case may be categorized as follows: (1) Gold coins: a pristine, virgin coin that has not been broken-into, meaning not ‘opened’, nor tampered with, relative to the state in which it was issued by the mint. (2) Silver coins: a gold coin that has been worked on, and its inside money string was at least partially exposed; (3) bronze coins: a silver coin to which a money bit string has been inserted from a source other than the mint.
[0064] Gold coins are transacted on account of the evidence of the authenticity of the declared mint, and on account of their virginity, namely by convincing the payee that the handed-over coin has not been tampered with since it was minted, and hence its declared face value is inside the coin with the full faith of credit attached to the mint itself. The evidence of virginity may be ‘self evident’—judged by simple visual inspection, or it may be instrument based—verified by a testing device relying on scientific principle that is used by the coin. A combined measure is also possible.
[0065] A silver coin may be totally drained, and hence worth nothing, or it may be partially drained, and in that case a reader may be needed to establish its residual value, and confirm that the digital money still there is indeed the original money put there by the mint, and not a refill from an unknown source.
[0066] A bronze coin will also need a reader to read the digital money residing in the coin, but in addition the payee will require means to authenticate the present string as its source may be questionable.
[0067] Silver coins must be born from gold coins, and ‘give birth’ or transform into bronze coins, but bronze coins don't have to have silver status ancestry. A trader could construct his own bronze coin, and fill it with digital currency on his or her own. If the coin is characterized and identified as ‘bronze’ then the recipient would not care whether the coin originally was a gold coin, or it started as a bronze status. The security implications are the same. The mint might issue ‘empty coin’—which are essentially empty containers for digital currency, expecting the trader to fill us these containers on his or her own. In this case the mint will have no liability as to the ill use of such coins by fraudsters.
[0068] The reader of contents for each hybrid coin may be built into the coin, and the result is electronically computed in the coin itself. In that case the present value of the coin may be communicated electronically to an electronic device with which the coin communicates, and/or it may be displayed on the coin for the payee to read without any instrument. The reading circuitry of residual value will have to be trustworthy and tamper resistant.
String not Inside Hybrid Coin
[0069] In this mode possession of the coin, once verified by the authority that manages the bit money string, will be declared as given to the holder of the coin. When the coin holder passes the coin further to a subsequent trader then the string management authority reconfirms the new holder of the coin, and registers the new possessor of the coin as the new owner of the string. A bit money string owner can redeem it, or download it, or dispose of it as he sees fit according to the operating rules of the mint.
[0070] “String not inside” may be operated mainly with gold coins. The monetary value of the string-not-inside must be commensurate with the security and trustworthiness of the technology that is used to confirm the possession of the hybrid coin that is associated with the particular string.
[0071] The advantage of the ‘string not inside’ mode is that payment may be conditional. A ‘string inside’ coin, say denominated for $100, will allow the holder of the coin to trade it as a physical object for its nominal $100 value, and will allow him to break it open, suck out its bits and use them as un-tethered cash. A ‘string not inside’ gold coin for the same denomination, would be clearly marked with a payment code, or say a payment condition code that would indicate to the recipient that this coin does not contain money per se, but its possession will allow one to claim the denominated sum if, and only if a set of conditions indicated by the marked code is fulfilled. The recipient then will accept the coin as a gold coin for its nominal value, if he can satisfy the payment conditions indicated by the code. (Or, if he or she believes they can trade it further to a complying recipient). The possessor of a gold ‘string not inside’ coin may break it up, connect it electronically to the mint—prove to the mint that the respective coin is in his possession, and when so, the mint will demand prove of satisfaction of the other payment conditions, and upon a satisfying proof, the mint will communicate the denominated sum to the claimant.
[0072] So for our $100 ‘string not inside’ coin, once broken-in and hooked through a phone to the mint, the mint might launch a challenge-response dialogue with the coin. The coin will be tamper resistant and have a chip inside with unique data and logic to satisfy the challenge-response dialogue issued by the mint. The mint will then be satisfied that the particular coin is in possession of the claimant, and will then ask for a proof that the claimant belongs to, say, a club, by asking for a club membership PIN to be communicated to the mint, or to be demonstrated for having possession of the PIN using a challenge-response dialogue. And only when the two conditions are met, the digital money worth $100 is sent down the electronic channels for the claimant to use as cash.
Technology of Hybrid Coins
[0073] We discuss the following technological challenges:
Mint Assurance Virginity Assurance Silver and Bronze Coins Value Determination Construction technology
[0078] In each case the technology will have to correspond to the denominated value of the coin, aiming to insure that the cost to counterfeit or violate the coin will be at par or more with its denominated value. Coins with large denominations will allow for more expensive technology.
[0079] Unlike the case with ordinary coins, hybrid coins allow the mint to (1) monitor counterfeit activity, and (2) effectively fight it strategically. Coins may be minted with a built-in expiration date. By that date the coin will have to be cracked open, and its content redeemed. This will expose the number of coins that circulate while being counterfeit. Also, if a major counterfeit action happens, the mint can wholesale invalidate the type and denomination of the violated coin, and ask owners of such coins to redeem them electronically by breaking them up, and testing the validity of the money within. This can be done in combination with a strategy of manufacturing the coins with expensive machines that become economical only for large quantifies. Counterfeiters will also have to invest in expensive counterfeit machinery, which will become useless the moment the mint invalidates that type of coins.
Mint Assurance
[0080] Traders need to be assured that the coin they trade with was manufactured by the mint, and not by a counterfeiter. For that reason any hybrid coin will come embossed or written with a serial number, allowing a trader to verify the coin. Naturally verification will occur more frequently for high denomination coins. The mint will use technology to create confidence about its coins. The mint assurance technology will be of two kinds or combination: (1) visible measures, (2) device tested measures. The mint might use embossing, imprinting, type-casting, and exotic materials to make it difficult to copy and counterfeit. The higher the denomination, the greater the measures of visible uniqueness. The mint may also embed indicators that would require an inspection device to probe. The device tested technology might be based on electromagnetic phenomena, or on chemical reaction.
[0081] As an example the coin may be covered with color changing plastic that changes its color upon shining on it with a special range of electromagnetic radiation. This technology is used in sunglasses that become dark upon sunlight, and return to sheer status in room situation
[0082] Various holographic techniques can be used to build a sophisticated coin that will frustrate amateur counterfeiters, and all others except top professionals, and will also require the counterfeiter to counterfeit only high denomination coins.
[0083] A simple mint assurance will be given by the serial number and minting date imprinted on each coin. A recipient trader will be able to text the serial number and date to the mint (or pass it on otherwise), and the mint will respond either with an authentication—yes, such a serial number corresponding to the sent date is a the serial number and a date of a valid coin. It is not a very good assurance, of course, but it has some base value.
[0084] One special way to provide mint assurance is the cryptographic window method. See below.
[0085] The above address the issue of mint assurance—assurance of authenticity of the coin as being issued by the declared mint—with respect to Gold coins. Once opened, broken-in, the assurance of the mint will be taken care of through the electronic exchange with the computing device that would be connected to the coin. There are various common cryptographic means to assure the validity of the declared manufacturer of a device. Such ‘silver coin mint assurance’ is a different challenge from the ‘gold coin mint assurance’.
[0086] Cryptographic Window Mint Assurance:
[0087] This method is more attractive for high denomination gold coins. The gold coin is fit with a dynamic display window, LCD or similar display technology. The small display will feature some sequence of alphanumeric characters based on some cryptographic protocol. The recipient of the coin will communicate to the mint the serial number of the coin, and the current display string. The mint will respond with an OK, if the communicated display string is the expected one, and “not-ok” otherwise.
[0088] This crypto window may be implemented using any of the prevailing techniques used by hardware devices that compute keys, display them and change the display every 60 seconds or so. Such devices are used to authenticate a user to an approached bank, and they could also be used to authenticate a coin, especially of high denomination.
[0089] The coin so fitted will have two separate electronic circuitry. One is the circuitry that is used once the coin becomes silver, and is communicating value and money transfer with the hosting computing device, and the other circuitry will be for mint authentication as a gold coin status, with virginity intact.
[0090] The mint assurance circuitry can easily be implemented using hardware oriented cipher, like a typical LFSR stream cipher, or the cipher described in U.S. Pat. No. 6,823,068. Every so often the time count by a built in clock will be used as plaintext, and the corresponding ciphertext will be displayed on the crypto window. The coin recipient, or say, the coin verifier, will text the code to a mint number, and get a text back: OK, or not-OK, status because the mint will know from the serial number what is the tamper-resistant key in the coin and compute the corresponding display (ciphertext).
[0091] Any other mechanism where the coin will display a seemingly random display that changes frequently enough, will serve as a means to assure the identity of the mint.
Virginity Assurance
[0092] “Gold coins” must be traded with the confidence that they are ‘virgin’—unopened, unused. Virginity may be based on basic old fashioned technology of ‘scratchable pads’. A simple heavy stock paper ticket will certify the denomination of the coin, and will feature a scratchable stripe. Upon scratching the stripe, the bar-coded digital coin will be exposed, and be entered via a bar-reader into a payment oriented electronic computing device. Once scratched it is clearly not virgin anymore, and no one would be fooled to regard it as such. This solution may be a bit inconvenient since it requires a bar code reader.
[0093] The pharmaceutical industry is using a variety of technologies to prove the ‘virginity’ of packages of medications. These wrappers etc. may be copied for assuring the virginity of coins.
[0094] Coins may be wrapped with a plastic cover fitted with a ‘breaking line’. Upon a slight blow, like with a heavy book, or a small hammer, the plastic cover will break along the breaking line, and the virginity will be clearly lost. The coin exposer will then be able to connect the coin with a payment oriented computing device and use the money therein.
Silver and Bronze Coin Value Determination.
[0095] A silver coin will have to provide first mint assurance, and then “no bronze” assurance, namely assurance that the coin has not be refilled with bits, but that all the bits to represent money therein are originally minted by the mint. Mint assurance and residual value assurance will be provided through the communication protocol between the coin and the payment oriented computing device with which the coin will be connected.
[0096] One common way to provide assurance of mint and residual value is for the coin to be tamper resistant and communicate with the connected computing device by encrypting all outgoing data from the coin using a private key put there by the mint, to allow the computing device to read it using the corresponding published mint public key. There could be a large variety of private-public key pairs that are distributed and used according to denomination, date of minting, etc.
[0097] There are several common hardware solutions to insure that the file that holds the money bits of the digital currency is not a refill but an original mint-placed bits.
[0098] Bronze coins require no assurance, they simply serve as bit money container, and the validity of the money will have to be ascertained outside the coin.
Construction Technology
[0099] Construction Technology will be discussed by topics:
circuitry power options Hook-up technology shape, size and form
Circuitry
[0104] The basic circuitry of the hybrid coin may be comprised of the following functions: memory—where the digital money is housed, a processing unit that reads/writes into the memory and optionally erases parts thereof, a value display unit that is connected to the processing unit, a crypto processor that is connected to the processing unit on one hand and to a hook-up apparatus on the other hand. The hook-up apparatus is connected to the payment oriented computing device that communicates with the hybrid coin. See FIG. 2 . The hook-up mechanism may be touch-based, swipe based, or distance based including NFC, BLUETOOTH, INFRARED, WiFi, phone connection, etc. The latter are trademarks representing various means for communications based on modulating electromagnetic waves.
[0105] The coin comes with its coin data in memory. The memory may also include various mint data to help authenticate the coin itself. The crypto processor has a built in keys and operates through a variety of optional protocols, to help hinder counterfeiting. One such protocol is to encrypt all coin data that is processed by the processing unit and fed into the crypto processor, by the crypto processor, and send it out as a ciphertext. The payment oriented computing device over the hook-up apparatus will use the mint public key corresponding to the coin's private key, to ascertain that the coin is authentic.
Power Option
[0106] The hybrid coin can be power-less and operated only through the power of the device it is being hooked to. Or it can have a tiny built in battery only for the secondary circuitry to authenticate the mint, or it may have a built in battery to power up the silver operation for display of value, if such a window is presented (normally in the high value denomination coins), and for the dialogue with the hooked computing device. The battery could be replaceable and latched through a small slit at the side of the coin.
Hook-Up Technology
[0107] The coin could allow for one or more hookup options including touch hook up, nominally via a USB cable with the coin being equipped with a mini USB female port. Or with swipe option where the coin is being equipped with a magnetic card, or with a distance based communication, which is less secure.
Shape Size, and Form
[0108] The basic hybrid coin will be round and thin, to emulate the familiar quarters or dollar coin. Its fabric will be reminiscent of a regular coin. Its edge might be jagged. See FIG. 3 : items (a,a′,a′) represent a mini USB female port, (b) represents the covered slot for a coin battery, (c) represents the residual value display window. In the drawing it shows $8.75, indicating that the coin has lost it gold status (lost its virginity), was already partially drained (in the mount of $1.25), and the residual value of the coin is $8.75. On the back face, item (d) represents the mint-assurance window. The display on the window changes frequently as computed by the crypto processor inside the coin. That display number if computed based on a built in clock, and on the serial number of the coin, and on built-in hardware constructed cryptographic key. The recipient trader will text or otherwise communicate to the mint the serial number of the coin, and its display number, and the mint will text back whether this coin is bona fide or counterfeit because the mint will have the data in all its coins, and could follow the computation of the coin, and verify the displayed code.
[0109] Other shapes, rectangular, credit-card like will be also available. Different shapes will accommodate different options for proof of virginity and mint assurance. The round coins have the advantage of behavioral continuity.
[0110] There might be a distinction in the size of the coin based on the denomination, so that larger denomination coins will be of a larger size.
Use of Hybrid Coins
[0111] We discuss use according to the two main categories of use:
Fast cash-and-carry transactions Emergency Use
[0114] We also discuss briefly the economics of hybrid coins. On top of the expenses needed to mint the digital money per se, there will be cost for manufacturing the coins. This cost may be handled by a purchase commission computed for each denomination based on the actual cost of the coin. In special cases where a coin represents the exact fair for a ride, for example, then the train or bus authority may bear the cost of the coin, so that commuters pay only the face value. The train or bus system will save on fare handling and will find it advantageous to pay the coin commission.
Use of Fast Common Cash Transactions
[0115] We discuss fast common cash transaction use according to the following topics:
denomination shape and format distribution life cycle purpose online-offline interplay security power supply coupons and non-dollar representation acceptability
Denomination
[0126] We expect hybrid coins to first extend from regular coins, namely to be used in denominations starting from $1.00 to $10.00. These small denominations will require corresponding simple counterfeit technology, and hence the cost to be born to produce them will be small. These coins are expected to be long lasting before their virginity is tampered with because of their low denomination. Higher denominations will be gradually more and more in demand, as people get accustomed to these coins, and begin to trust them as carriers of value. One may envision hybrid coins denominated at various values up to $100, and even up to $1000. Of course, the higher the denomination, the more sophisticated the anti-counterfeit technology involved.
[0127] There are likely to be cases where a common service, like a train ride has a non-round cost, say $23.72. If the number of commuters is large, then riders will be invited to purchase coins denominated exactly for $23.72 cents, and hand them over or slip them in a payment slot in a fast flow through to the train. The train authorities will engage the mint, to issue gold coins for this particular amount. A rider who accumulated these coins and for some reason stopped using the train, could readily use these coin for any other payment need, or he or she will be able to break the virginity of the coin, and upload its contents ($23.72) to their phone or PC for regular use.
Shape and Format
[0128] To extrapolate from present day nominal coins, one will opt for similar round shape and size, and such will be easier to accept and accommodate. But for reasons of storage, counting and otherwise, one can envision a variety of shapes and format. See for example the nut option ( FIG. 4 ). Of particular interest are the flat, card-like coins: they will serve as an extrapolation of the familiar credit card. We have on-card flat chip technology that could accommodate the hybrid coins. Credit-card like coins will have the advantage of a large surface area that can be used for branding, for colorful text and graphics for advertising purposes, etc.
Distribution
[0129] Because hybrid coins are meant to be easily transferable, they are naturally un-tethered to a particular owner, and if lost, anyone could find and use them. Same for theft and robbery. So much as people are reluctant to hold and be in possession of large number of cash, so they would not wish to hold a large quantity of hybrid coins. People will stuff their wallets, their glove compartment, their desk with a small amount of money in small denominations, and would probably opt for gold coins that are the easiest one to trade, and command the greatest measure of trust. Traders will get these coins in their bank; they will exchange coins in stores, and they will buy coins in automatic kiosks where they will pay with their credit card, or old fashioned cash, and receive the coins.
Life-Cycle
[0130] The hybrid coin is minted as a ‘gold coin’—virgin, pristine, and it may transact indefinitely as ‘gold’. At some point the gold coin is either returned to the mint for redemption, or it turns into a ‘silver coin’ namely a coin that has lost its virginity, and has been partially drained, which means some of its digital value has been removed from it. The silver coin may be traded as silver in which case the authenticity and the integrity of the coin is maintained by the coin valuation mechanism that keeps track over how much of the original value of the coin is still in it. For example, if a coin was minted as ‘gold’ in a $25.00 denomination, then after being traded as virgin, gold $25.00 coin, it is eventually ‘opened’ and $7.00 are paid off through the coin drainage mechanism, leaving the value of the coin at $18.00, with status ‘silver’. The silver coin may be traded about for its current face value of $18.00, and the payee will trust first the mint the issued the respective gold coin, and second, the value tracking mechanism within the coin that assures the recipient payee that he indeed receives a payment of $18.00. Eventually one of four things happens: (1) the silver coin is handed back to the mint for redemption, (2) the silver coin is drained to residual value of $0.00 and discarded, (3) the silver coin is rendered into a bronze coin, namely some non-Mint source of digital money pumps digital money into it and the residual tracking mechanism reflects this. The coin can then start to drain again, or it may be redeemed at the mint, or it may be re-pumped and re-used as above indefinitely. (4) the coin is lost, abandoned, it breaks down physically either by a blow, or by a strong force, or by getting excessively wet, or by some chemical interaction, or otherwise. Please note that if the coin is stolen, it can still be used unless it has proper security feature. Regular hybrid coins are presumed to be owned by their holder.
Purpose
[0131] The main purpose for hybrid coins is the desire to conclude a simple ordinary transaction with minimum of hassle and complexity. When you pick a daily paper at the counter, it's too much to pull out your phone hit a series of buttons, or slide the screen here and there. The newspaper may cost $2.50, and you wish to be able to pull a coin from your pocket, flip it over to the seller, pick your copy and move on. A $2.50 gold coin will be perfect for this use. The anonymity that is inherent to this use is another purpose, even for more expensive deals. You want to buy books without ‘big brother’ watching you and profiling you based on the books your buy or the movies you watch, or the food you eat, so paying with modern cash—hybrid coins seem a suitable satisfactory solution. Hybrid coins may prove useful in an Internet cafe and otherwise for online purposes. Of course in this use the gold coin must be broken-in, and used as a reservoir of bit money. One would expect Internet Cafe operators to hold a supply of hybrid coins for customers, who may even buy them with credit card, counting on the hope that the cafe owner is not keeping tab of which coin went to which customer. A third purpose is to avoid the burden of carrying a heavy load of regular cash in your pocket. Hybrid coins may carry a large denomination on a single coin, which is not feasible with regular coins. A fourth purpose is to avoid currency exchange when you cross a national border. The bits are usable online from any place, from any location. And so even local brick and mortar stores who may not legally and conveniently accept dollars in a foreign country, will gladly accept bit representation of dollars because it is tradable all over.
[0132] A special purpose of the hybrid coin will be as a silver category over-distance payment. See below.
Offline-Offline Interplay
[0133] It seems essentials to be able to shift from online mode to offline mode and vice versa in a seamless way. Using bronze coins a trader could replenish his original coin but decrease its security and therefore make the trade with the coin a bit more cumbersome as the recipient needs to verify the paid coin. Every coin may be opened, broken-into, (disrupting its virginity), and its content may be streamed into any phone, pc, or otherwise an electronic container from where this money can be used in any online application. So bronze coin trading allows for a back and forth flow of bits without any limitation. When trade is limited to gold and silver coins then the flow of hybrid coin money is only one way: towards the online use.
Security
[0134] Security of gold coins may be assured by simple visual inspection, or by use of some authentication technology to be applied to the coin. Coins of low denominations will be inspected quickly and visually, but coins of high denominations might attract more scrutiny, and the payee may wish to use a verifier device before he or she is convinced of the gold status of the coin. Silver coins may be trusted by the coin declaring itself silver and proclaiming the value of the residual money in it. But one might expect some payee being extra cautious, especially for coins of large denominations: they will wish to authenticate the coin contents at the mint. To do that they will have to connect the silver coin to a phone or a PC. Of course “live hybrid coins” that are continuously connected to the mint are an easier option.
Power Supply
[0135] Gold coins may not require any power supply, but silver and bronze coins may be needing a power source to operate. The power may be coming partly from an outside source to which the coin is connected. In that case the silver and bronze coins will be blind—showing no indication as to how much money is left and even not as to their status, silver or bronze. They will have all that data in their ‘blind memory’ and when connected to a phone a PC or any other well powered computing device their data will be read and displayed on the connecting device. Otherwise silver and bronze coins may operate with a battery that would power the computation needed for it status determination (silver or bronze) and for computing its residual digital money. Power is also needed to display the residual money value and its status. The battery that supplies this power may be built in, and its power rated to be sufficient for the expected life time of the coin. If the built-in battery dies, the coin can be returned to the mint for replacement. Otherwise the battery may be snapped in and out, and easily replaced.
Coupons and Non-Dollar Representation
[0136] The hybrid coins may be issued to represent value other than US dollar or other national currency. Much as digital money may reflect any valuable, so is the case for hybrid coins. So hybrid coins may represent discount money in selected store, or money that is tied for a purpose, say food. One might find the coin-like appearance of the hybrid coin more appealing than the traditional cards or printed rolls of paper.
Acceptability
[0137] Acceptability of hybrid coins will probably be tied to the acceptability of the underlying digital money, and will be much appreciated as an extension thereto.
[0138] Over-Distance Payment Use Options:
[0139] Silver coins fitted with over-distance payment options may find a variety of important use cases. Over-distance payment may be carried out via NFC, BLUETOOTH, IR, or any other electromagnetic radiation regimen. Payment will be possible as an alternative to physical hook-up or swipe option, but also for new uses. For example an over-distance silver coin could replace today ‘Easy-Pass’—the payment devices that are attached to the windshield and communicate with road-side or road-top readers to accomplish a toll payment for a tall road, for example. A silver coin will use the over-distance technology to actually send over the money owed, as a cash transfer, instead of accounting data for a future payment. Drivers would like this, because these silver coins can be purchased everywhere, and because drivers would be able to make a payment but maintain their anonymity.
[0140] Movie goers will be able to put in their shirt pocket an over-distance payment silver coin, and never stand in line to buy a ticket, but rather walk directly to the theatre, a door-placed reader will extract the ticket amount as they walk in.
[0141] In a restaurant a diner will place a silver coin on the table, and the waiter will point to it a hand held payment extractor, and get paid.
[0142] Parking may be paid by simply displaying the silver coin on the dashboard. Every parking stop will have a distant money reader instead of the old fashioned money collector.
[0143] A special case of over distance payment refers to internet live, or phone connection, which allows for coin verification in real time, and long distance coin payment.
Hybrid Coins Use in Emergency Payment Circumstances
[0144] We consider two categories of emergencies:
networks emergency liquidity emergency
[0147] The former refers to a situation where the global or zone connectivity is disrupted, the cloud collapses, connection with the mint or its agencies is broken, and normal network enabled communication are not feasible. The latter case refers to a crisis or a disaster situation where the banks are dysfunctional, people cannot retrieve and activate their money assets, and the area is hard hit by an earthquake a powerful storm, flood, or snowfall, or perhaps a terrorist act. Areas of urban populations present a big challenge to the rescue operation and a lot depends on mutual help. Yet, one cannot expect a gas station owner to pump gas to his customers and rely on them showing up to pay for the gas when the flood is over. Cash money activates the community and allows for useful trade to help resolve the situation.
[0148] Networks emergency can clearly be helped by trading gold coins, but also by trading silver coins where the coin is battery operated, and so is the recipient of the money bits, if they are transferred to him or her. One prepares for such emergency with plenty of stored batteries.
[0149] Liquidity emergency may be handled by the disaster management authority (DMA) by distributing gold hybrid coins to the suffering population. A proper distribution of denomination previously prepared by the DMA will greatly alleviate the situation. People will then be able to trade these coin in a silver status, using the accompanied supply of batteries. This situation calls for preparation of active digital coins to be so distributed. Another, more sophisticated way to handle payment regimen in a crisis situation is to use hybrid coins of crisis money. Crisis money is money that comes alive when a disaster happens, and it fades away after the disaster is over.
[0150] Hybrid Coins for Crisis Money:
[0151] Payment requirement in a crisis situation may be handled by using ephemeral money. Ephemeral money is money that appears at a given moment—out of thin air, and at a subsequent moment it vanishes into complete disappearance. Between this birth and death points the money is active, traceable and satisfies a requirement set upon it. In general ephemeral money may vanish in a way that its holder is simply losing it. In that case the purpose of the ephemeral money is to effect some lasting changes during its live time, but the trade is such that whoever is left with it at its vanishing point, is losing its value without compensation. Such ephemeral money is used in money games and game-trades designed for digital money. But for crisis management the planned ephemeral money will be traded against some form of lasting money so that the holder of ephemeral money will end up with an equivalent or corresponding amount of durable, and lasting money.
[0152] Ephemeral money may be traded in a form of digital money prepared in hybrid coins which may or may not be distributed ahead of time. Unlike nominal money, ephemeral money is of no value until the proper authority announces its “birth”. So unlike regular money the people who receive it to prepare for a pending crisis cannot use it before its birth date, and so it will be available to them when the crisis hits. If the ephemeral money in hybrid coins is distributed through a proper range of denominations with a proper amount of coins then the coins can be traded as ‘gold’ which is the least time consuming under the duress of the crisis. Otherwise, using battery operated devices, if necessary, the people affected by the crisis will be using silver coins for their trade.
[0153] When the crisis is over the ephemeral money may be traded against nominal money under some exchange protocol. This is important for the people to be willing to accept the ephemeral money. The crisis management authority may deduct the value of the originally distributed ephemeral money from any amount of ephemeral money that people will submit for redemption. If people in the crisis zone will end up with less money than they were given then per an authoritative decision, either the shortfall will be forgiven or it will become debt to the government. Either way the ephemeral money will relieve the banks from the requirement to struggle to remain open despite the crisis, and at the same time it will allow the many strangers in the disaster zone to cooperate and collaborate in ways that would encourage many to work their hardest, and be recognize for their efforts.
Hybrid Coin Options
[0154] The basic hybrid coin is comprised of a physical enclosure, capsule, in which a digital coin is placed, recorded on any bit-recording media.
[0155] We distinguish between two categories of hybrid coins:
[0156] Crackable
[0157] Drainable
[0158] Crackable coin is built to be cracked open, allowing the digital media where the coin is written to be exposed and used for the coin's full value. A drainable coin is designed to be drained bit-wise, and pay off directly from the coin at any given rate, driven by time or by events. A crackable coin is designed to be paid in full, (passed from payer to payee in tact), a drainable coin is designed as a one-way wallet, paying any required sum, up to the contents of the wallet.
Crackable Coins
[0159] Crackable coins may be featured in forms reminiscent of the traditional coin, and in forms shaped by artistic input in order to impart a sense of beauty. The shape of a coin may be reflective of its value, same for its colors and size. Coins can be fitted on a decorative structure to effect a cash gift with a sense of beauty and celebration. Coins may have a handling ears attached to them so that they can be strung together. They may be made to dove-tail fit into each other. A round colorful coin may be placed in the center of a flower head made out of decorative material, so that one can give “flowers” as gifts, which amounts to cash. Cracked coins may be fitted with a pre-recorded message by the giver for the recipient.
[0160] Crackable coins can be manufactured in two stages: (i) dead coin, and (ii) live coin. The dead coin will be comprised of a string of random bits written on some electronic media, and housed in the physical coin. The physical coin is imprinted with an identification code (an Id), but the contraption is not money, it is simply a well-housed string of random bits. This will allow a manufacturer of a hybrid coin to be focused on (i) securing high quality random bits, and on (ii) constructing an effective physical coin of the right shape, fabric, weight, size etc.
[0161] The dead coin may also serve as a randomness capsule for any purpose randomness may be used for (see below). Such dead coins can be activated, by some front mint. We will regard the entity that manufactures the dead coin as the core mint, which will deliver the dead coin to the front mint which will activate it by passing it on to its customer (a trader) against a sum $x, and then record in its book that the coin of the indicated id was sold to a trader. There are two options, either the image of the randomized bits within the coin are passed to the front mint, or they are not. If they are passed, then the front mint will have the image and the id of the coin, and when anyone submits the coin for redemption, the front mint will verify that the identified bits are all right per that coin Id, and if so, pay off the coin. To submit a coin for redemption the submitting trader will have to crack it, upload its bit contents to the network and submit it to the mint. If the coin image is not passed to the front mint then the core mint will have to be given the redemption data and approve or disapprove the submission.
[0162] If the coin value is based on the count of its bits, then it is possible for one to crack the coin, then upload the coin bits to a computer, then to chop off any number of bits and assign them a value which is a straight proportion of the total value of the coin. The chopped off bits could be paid electronically or be redeemed by the front mint.
[0163] The core mint may manufacture its dead coins according to the specific order of the front mint, as to id, size, color, shape, or with any of the other higher level security features mentioned herein.
[0164] The dead coin's may be manufactured in a standard fashion, namely they will all have the same number of coin bits, (say t bits). The front mint will assign each such coin (comprised oft value bits) its trade value. If the coin is set up to be cracked and then have its bit contents traded electronically base on its bit count then, the coin Id will have to include its characteristic value-per-bit parameter. So a coin of a standard 1 million bits when traded at a par value of, say 10$, will operate with a bit value of 100,000 bits per 1US$. The next 1 million randomized bit coin may be traded as 1000$, and in the case the bit value will be 1000 bits per dollar. Once this bit value is indicated, then both the payer and the payee will know how to par out any sum lesser than the value. For example a transaction of $2.00 will include transfer of 200,000 bits in the first instance, and transfer of 2000 bits in the second instance. Of course, all this transferring occurs after the coin is cracked and the value bits are extracted from the physical coin.
[0165] The Front mint will be able to maintain a fixed $/bit value, and in that case the number of value bits, v, will be determined by the denomination of the coin. As long as v t the coin will simply designate the starting bit, s, and the ending bit, e such that (e−s=v), and the rest of the t-v bits will be ignored.
[0166] Tethered Hybrid Coins:
[0167] Hybrid coins may be tethered in many ways.
[0168] Tethering a hybrid coin to a given group: The manufacturer of the coin may assign the coin to be tradable within a well defined group, and only a member of that group will have the right to redeem it.
Randomness Capsule
[0169] A randomness capsule is a dead coin comprised of some r randomized bits enclosed in a physical enclosure, as is the case for a dead coin, described above. Only that the randomness capsule is not a coin, it is a container of a particular image of random bits, marked with a given Id. Such capsule can be used anywhere randomness is in use.
[0170] For example, one could buy two identical capsules, send one such capsule to a friend, using regular mail, say, and then the two will use that randomness to carve out shared cryptographic keys and the like. Or alternatively, Alice will buy a random capsule in a store, then pass its id to Bob, or contact the core mint (now acting as a randomness capsule manufacturer) and request an identical capsule to be sent to Bob. If Bob gets the capsule physically intact he is quite assured that its contents was not seen by a hacker, and only he, Alice and the Mint have the randomness image.
Operational Suit Upload
[0171] The electronic media within a crackable coin may include more than the digital coin per se. It may include operational software such that when uploaded to a phone, for example, it will install there the application that is designed to handle the money of the coin. The uploaded media may include a suit of applications for money management. By doling out attractive physical coin with a nominal value, it would be possible to induce traders to install the operational software for that mint onto their phones.
Loyalty Money
[0172] Crackable coins are very well suited for loyalty money applications. These coins may be hidden in boxes of products of a given store, and the money within may be tethered to that store. Store managers could hand off decorative coins to pacify irate customers who were mistreated, or wait too long in line etc. The tangibility and the beauty of the coins will have a special effect.
Drainable Coins
[0173] Drainable coins are designed to ‘spit out’ one bit at a time and that way exercise payment to the entity that receives the bits, which may be another trader or the entity that sold the bits. The payment involves emitting the bit from the drainable coin, and forgetting (discarding) that bit. Such bit draining can occur on a time basis (like when paying for parking), or on event basis, (say, upon receiving a measure of electrical charge). The hardware will insure (using common means) that the emerging bits are erased from the bit stock in the coin.
[0174] The drained coin will also have an id, which will be marked without and within. So any payment session based on such draining will start by the coin notifying the payee what is its Id.
[0175] Drainable coins may be controlled by a combination of events, circumstances and time. So one can receive a drainable coin wired to emit (‘spit out’) no more than $50 a day for 100 days (so the coin initially is valued as $5000). And this $50 is to be paid per pages read on the Internet, per browsing time, etc. A tethered coin will not release its bits to a recipient it was not programmed for.
[0176] Such drainable coins will have to withstand a fraudulent attempt to crack them, release all the money (in the above example the full $5000), and use that money for any purpose. This will require some technology for a secure enclosure. Such coins may be engineered with a proper draining port to facilitate the payment. The specially shaped draining port will have to fit the payment port of the intended payee.
Draining Port
[0177] A USB stick is an example for an effective bit transfer between a male and a female pair of counter ports. For the drainable coin we may wish to eliminate any bit stream to the coin, and effect only an egress of bits to the payee port. Different payees may be fitted with a unique geometry of a port (male or female) so that the counter port that fits it will be the only possibility for payment to take place. This will eliminate errors and fraud and insure that each coin is paying only for what it was designed to pay.
Secure Enclosure
[0178] There are various methods to be designed to secure the money enclosure (the hybrid coin). They are based on volatility of the coin bearing media, such that when at attempt to breach its integrity is detected, the money information inside the coin is instantly erased (the coin data disappears).
[0179] The question is how to detect whichever way one may try to crack the coin. A simple way is to trigger the erasure of the coin by an electronic circle based on light. Another is pressure based, and the most secure is based on radiation absorption.
Use of Secure Enclosure Drainable Coins
[0180] Secure Enclosure Drainable Coins (SED-coins) are characterized by having both the digital money as a randomized bit series, or in equivalent form, and payment control circuitry (PCS). The PCS insures that the coin is drained as agreed upon in the payment arrangement.
[0181] The key idea here is that payment conditions (tethering) which nominally would be recorded in the mint, can this way be recorded in the secure physical coin—either as in addition to the mint recording or in lieu of it.
[0182] For example, a government support money for people in distress may be given through an SED coin delivered physically to the recipient, and containing financial support for a prolonged time, say, several months. The money giver intends to allow for that support to be doled out at a given measured daily rate. The PCS will be hard programmed to effect this restriction so that not more than the allotted daily expenditure can be spent. This will insure that the support lasts for the intended period, and is not spent in a splurge over a short time.
[0183] The PCS could also be programmed to recognize an id-type given to it from the payee to check that it is a qualified recipient.
[0184] It is expected that the holder of such a slow dispensing coin will be most eager to break in, and make use of the bulk of money inside right away, and that's where the security measures will be tested.
[0185] For an implementation where the money dispensed from the SED coin is untethered the incentive to crack the coin is greater, since all the money within translates directly to cash, and there is nothing in the mint that will prevent that money from redemption. So fraud-resistance depends on the integrity of the physical coin.
[0186] The incentive to crack the SED coin is of course proportional to the value it carries. Since it is being envisioned that the SED coin will be an efficient way for support agencies to exercise their support effectively and without frequent laborious contact, there will be a pressure to offer very high denominations digital coins so no more human attention will be needed to insure the money is well spent (at the intended pace)—technology will so guarantee.
[0187] Some use cases, call for an SED coin to be impressed with the identity of the rightful owner (especially for high denominations drainable coins). The rightful owner will have to use it in person, latching the coin through its port into the fitting port of the payee. Such ports can be made unique so that only a rightful (intended) payee will be able to extract money bits from the SED coin. The payee will verify that the SED coin carries the name or the image of the person trying to use it. Biometrics may also be used. The payer will have a fingerprint cushion to lay his thumb upon, as he or she presents himself or herself before the payee. Such measures will be economically justified for high denomination coins.
Methods of Securing the Coin Enclosure
[0188] The basic idea is to carry the coin data (bit identities) in a volatile format, readily erasable. This can be done by activating a securely built-in battery that either works at low energy all the time, keeping the information alive, and is cut off when a break-in effort is being detected. Or the battery is activated when a breach attempt is being detected, and wipes out the value bits in one of the commonly used ways.
[0189] The challenge is to detect whatever method is used to pry open the coin. Since the efforts to break the coin are likely to be commensurate with the minted, or remaining value of the coin, a corresponding investment in security measures is called for.
[0190] The erasure circuitry could be activated by light, since the coin is locked into an internal darkness. The light will trigger the erasure mechanism. Alas, fraudsters could pry open the coin by doing so in the darkness—if they know that security is based on light.
[0191] The other way may be based on capturing a non-atmospheric pressure in the internal sealed volume of the coin. If the coin is pried open, the pressure inside becomes atmospheric, right away, and this change triggers the wipe-out mechanism. This has the advantage in as much as the attacker may not be aware of the randomized pressure used to protect the coin, so he can't (easily at least) place the coin in an external pressure of the same value (over or under atmospheric as the case may be), and the pressure gap between the inside of the coin, and the outside which will be exposed as the coin is tampered with, will quickly dissipate as the pressure inside the coin equalizes with the pressure outside, and this change of pressure triggers the erasure mechanism. The hacker could drill first a small hole resisting a quick pressure equalizer. The “drill” will measure the pressure inside the coin, and then will adjust the external “hood” pressure to allow complete opening of the coin.
[0192] Another method is to set up a constant electro magnetic radiation circuitry that is fixed up to erase the data when the absorption of the gaseous environment in the coin changes above a given threshold. The hacker will be hard pressed to guess the randomized proportion of gases used in the SED coin. Each combination of gases will have to be fitted with a corresponding wave length of radiation bandwidth.
SED Coin Construction
[0193] The SED coin is comprised of the money bits and the meta bits that accompany the money bits, and the circuitry that controls the payment according to pre-defined terms. The circuitry (PCS) includes a clock to insure time based payment terms, and any other terms. The money bits, the meta bits and the PCS are enclosed in an enclosure that is sealed. The seal may be designed for some eventual procedural opening, but in most cases it would be a seal that is not designed for re-opening. That means that one will have to break, cut, drill the enclosure to reach into its content. And hence the enclosure will be linked to a data erasure mechanism (any commonly used mechanism will do) that will be triggered when the seal is tampered with. The erasure mechanism may be any combination of the above identified methods. The built in randomness (as to pressure or vacuum rating, or gas composition), will pose a formidable challenge to the attacker.
Tethering Drainable Coins
[0194] Drainable coins may make payments with untethered money as well as with tethered money. This refers to tethering (restricting) money at the mint level where redemption is exercised only if any valid tethering terms are satisfied. However, the drainable coin may shift some tethering functions to the coin itself. The physical hybrid coin will have circuitry built in (PCS) that will insure that the prescribed tethering terms are satisfied. Thus, for example, the coin will have to be activated by an activation code that is input to it via some key pad or a similar input device. Or the coin will be equipped with biometric protection, say a fingerprint.
[0195] The coin may be issued to a particular person and be replaceable upon loss or theft. The owner will notify the mint, and have a replacement coin shipped to him or her, while the lost or stolen coin will be voided. If the loss or theft occurred when part of the coin money has been drained, then only the remainder will be replaced. This practice may be limited to some reasonable number of times, to foil any repeating attempts to crack the coin, and upon failure, request a replacement.
[0196] Such coin built-in tethering may take some load off the mint. Namely, from the mint perspective the money is free from any tethering. All payment terms are exercised within the tamper-resistant drainable coin.
Encoding
[0197] Describing the “Dual Bits” encoding (DBE): a digital coin may be comprised of money value bits (MVB), and any other data, (meta data), like mint identification, coin-identification, payment terms, coin history, cryptographic keys, etc. One may distinguish between the MVB and the non-MVB in the following way:
MVB: encode “0” as “00”; encode “1” as “11” Non-MVB: encode “0” as “01”; encode “1” as “10”
[0200] This will allow any meta data to be encoded in any way expressible in bits, ands will eliminate any confusion between the MVB and the non-MVB. DBE will double the size of the bit size of coin as the price of this distinction.
[0201] Example: a coin is expressed through 7 value bits randomized to: 1001101, and is ‘embraced’ with a header H=1011 and a trailer, T=0011 indicating the nature of the coin and its mint. The coin, in normal encoding will look like:
coin (bit encoding): 1011-1001101-0011
[0203] Of course, the ‘dashes’ don't appear in the code itself, so somewhere else it would have to be specified that the right most 4 bits, and the leftmost 4 bits represent header and trailer respectively. And if for some reason the header or the trailer will grow in size then the specification (outside the coin) will have to so indicate.
[0204] In the DBE the same coin is encoded as:
coin (dual bit encoding) 10 01 10 10 −11 00 00 11 11 00 11 −01 01 10 10
[0206] So that if for some reason there will be a requirement to add more information, say, to the trailer to become T′=0011000, then the coin will readily be adjusted to look as follows:
coin (dual bit encoding) new trailer: 10 01 10 10 −11 00 00 11 11 00 11 −01 01 10 10 01 01 01
[0208] And the recipient of the coin will readily interpret the coin as intended because the trailer bits are written in meta data encoding. This means that the payment management system will be able to dynamically add information to the paid coin through a header, a trailer, or even inside the MVB bits, if so desired, without incurring any confusion as to whether a bit is a money value bit or a meta data bit.
Summary of Specifications
[0209] (1) We described here a system named “drainable digital coin” comprised of a secure enclosure, fitted with a payment port, containing (i) a digital coin payable in any desired resolution, (ii) a payment control circuitry (PCS), and (iii) tamper-resistant apparatus, that enables payment (drainage) from the drainable digital coin, according to the terms programmed into the PCS; the coin resisting attempts to compromise its integrity, and use the contained money in ways inconsistent with the prescribed terms programmed into the PCS
(2) More specifically, we described here a system as in (1) where the secure enclosure is manufactured without intended means for re-opening, such that any attempt to have access to the contents of the digital coin will involve cracking, drilling, or otherwise harming the integrity of the enclosure in ways detectable by one of various detection systems placed in the coin for that purpose, like: light detection system to be activated to wipe out the coin data upon sensing light in the otherwise dark internal of the enclosure; pressure detection system that is activated by a change of the pressure in the internal volume of the enclosure; absorption detection system activated when electro-magnetic radiation emitted at one point inside the enclosure, is detected in the opposite point of the enclosure, and the detection apparatus is activated when the absorption of the radiation changes above a preset threshold, as a result of a change in the gaseous composition of the space between the radiation emitter and the radiation detector, and where upon such detection, the contents of the coin is wiped out; such activations operate over the coin data which is kept in the coin in a volatile state.
(3) And also we describe here a system as in (1) where the PCS includes a preset limitation of the amount of money spent within a specified time interval, such that a digital coin of nominal value of $X, if allowed to be used for paying $y per a time interval (e.g. day, week, month), will be usable for payments for x/y time intervals.
4. A system as in (1) where the coin requires authentication of its user to be an intended payer using this coin; either as being a member of an authorized group, or as being a particular individual; such authentication may be exercised via requirement of a preset authentication code to be input via a dedicated numeric pad, or via a biometric port, and where such a coin may be tethered to its authorized users, such that if lost, or stolen, the coin issuing mint will replace it with the portion of the unused money.
|
This invention describes a set of related procedures designed to co-operate with mints of digital money in order to allow for said money to be properly, securely, and conveniently traded by, various size and various type of trading crowds. The procedures refer mainly to distribution of responsibility. This invention also specifies the construction of digital coins encapsulated in a physical housing to amount to off-line tradable digital coins.
| 6
|
FIELD OF THE INVENTION
[0001] The invention concerns a porous paper machine clothing for dewatering a paper web in a paper machine, in particular as a paper machine felt or dryer fabric, having a yarn layer made up of at least one ply of longitudinal yarns and at least one ply of transverse yarns crossing the longitudinal yarns.
[0002] Porous paper machine clothings are long and wide belts which circulate in various sections of a paper machine and on which the paper web is transported through the paper machine. In the first, so-called sheet-forming section, a fiber pulp is applied onto the paper machine clothing, causing a web of fibrous material to form. This is dewatered through the paper machine clothing. The paper machine clothing comprises a textile yarn structure which is sufficiently porous that the liquid coming out of the web of fibrous material is carried off through the paper machine clothing in response to gravity and vacuum. In the subsequent press section, the paper web and paper machine clothing are passed through roller presses so that the liquid still present in the paper web is pressed out through the paper machine clothing. As a rule, the paper machine clothing is embodied as a felt having a substrate made of a textile yarn structure. In the subsequent drying section, the paper web and paper machine clothing are guided over heated rollers, causing further dewatering—or, more accurately in this case, drying. Once again, paper machine clothings (i.e. dryer fabrics) made up of yarn structures are preferably used in the drying section; these are once again porous so that vapor can escape through the pores.
[0003] The textile yarn structures are embodied principally as woven fabrics. Also known, in addition, are so-called yarn layers, in which the yarns are not engaged into one another, i.e. are not interwoven or meshed with one another. U.S. Pat. No. 3,097,413 discloses one such paper machine clothing. It has a yarn layer made up of one ply of longitudinal yarns that extend parallel to and at a distance from one another and are not connected to one another. Applied onto the ply is a nonwoven fabric that encloses the longitudinal yarns and is needled to them.
[0004] A paper machine clothing of this kind has only a little transverse strength, however. For that reason, a transition has been made to combining the longitudinal yarn ply with a transverse yarn ply (DE-A-1 802 560; EP-B-0 394 293). Here modules comprising a yarn ply and a needled-on nonwoven fabric are first formed, and those modules are brought together and needled again. This manufacturing approach is not suitable for paper machine clothings made of only one yarn structure. For that situation, U.S. Pat. No. 4,555,440 proposes connecting the individual yarn plies to one another with binding threads.
[0005] In the paper machine clothings of the species described above, resistance to displacement between the individual plies in particular, and thus the dimensional stability, is unsatisfactory. If binding threads are used, these represent foreign elements and greatly complicate the manufacturing process. To eliminate these disadvantages, U.S. Pat. No. 5,888,915 proposes laying the plies of longitudinal and transverse yarns directly onto one another and fusing them together at the crossing points by heating. A prerequisite for this, however, is that bicomponent yarns be used in which the yarn core has a higher melting temperature than the yarn sheath. Fusing is accomplished by heating to a temperature above the melting point of the yarn sheath and below the melting point of the yarn core.
[0006] The dimensional stability of the paper machine clothing is improved because of the direct connection of the yarns of the individual plies. It is disadvantageous, however, that special yarns, namely bicomponent yarns, must be used; these are expensive and their material properties cannot always be optimally adjusted to conditions in the respective section of the paper machine.
SUMMARY OF THE INVENTION
[0007] It is the object of the invention to configure a paper machine clothing having a yarn layer in such a way that high dimensional stability can be obtained therewith regardless of the type of yarn, and so that it is suitable for all sections of a paper machine. A second object is to make available a method for its manufacture.
[0008] The first object is achieved, according to the present invention, by the fact that the longitudinal and transverse yarns are connected positively to one another at crossing points, in which context each connection can comprise an orifice in the one yarn and a projection fitting thereinto on the crossing yarn, or mutually aligned orifices at the crossing points and pegs, e.g. studs or rivets made of plastic or metal, passed through them. The invention thus creates the possibility of effecting a direct connection between the longitudinal and transverse yarns at the crossing points, regardless of the material of the yarns. There is thus no further need to resort to bicomponent yarns (although the basic idea of the invention also encompasses such yarns), but instead single-component yarns can be connected directly to one another.
[0009] The result is to make available for the first time a paper machine clothing having a yarn layer that is distinguished by excellent dimensional stability and—when single-component yarns are used—low manufacturing costs. “Single-component yarns” are understood here to mean those yarns that homogeneously comprise one material; that material can also be a copolymer, provided homogeneity exists.
[0010] The paper machine clothing according to the present invention has the advantage over woven and knitted fabrics of greater flexibility in terms of the number of plies, yarn density, and material selection. Manufacture also does not require complex textile machinery such as looms and knitting machines, which moreover limit the width of the paper machine clothing that can be produced on them. Such a limitation does not exist with yarn layers; in other words, they can be manufactured in practically any width. In addition, with yarn layers it is possible to dispense with the thermosetting operation necessary with woven fabrics, if the yarns have previously been adequately heat-treated.
[0011] An embodiment of the invention provides for an adhesive additionally to be present at the crossing points that are to be connected. An adhesive of this kind contributes to the immobilization of the longitudinal and transverse yarns at the crossing points. In addition, the adhesive can adhesively bond the parts engaging positively into one another, for example the orifices and projections or pegs. Suitable adhesives are hot-melt adhesives whose melting temperature is less than that of the yarns, contact is adhesives, diffusion adhesives, and/or reaction adhesives.
[0012] Immobilization at the crossing points can be improved by the fact that the longitudinal and transverse yarns and/or the parts connecting them, e.g. the pegs and orifices, are additionally fused to one another at crossing points as a result of heating confined to those crossing points. The temperature of the remaining regions of the yarns remains below the melting point of the yarn material. It therefore undergoes no change in structure or shape, so that the overall yarn structure defined by the superposition of the plies is retained.
[0013] It is particularly preferred to configure the longitudinal and transverse yarns as flat yarns having a rectangular cross section. The result is to create a planar contact at the crossing points, and the area over which the yarns can be fused to one another is considerably increased and therefore stronger. The yarn shape furthermore promotes formation of the positive connection. A range from 2 to 20 mm, preferably 8 to 12 mm, has proven advantageous as the width for the longitudinal and transverse yarns. The thickness should be between 0.3 and 2 mm, preferably 0.6 to 1.2 mm, and the transverse yarns should have, at maximum, the same thickness as the longitudinal yarns.
[0014] In order to guarantee sufficient permeability for water or vapor, especially with very wide flat yarns, passthrough openings can be provided in the longitudinal and/or transverse yarns. The permeability can be controlled as desired by way of their size and number; the possibility also exists of configuring the permeability differently over the width of the paper machine clothing, e.g. greater at the center than in the edge regions, or vice versa. The passthrough openings can be embodied as round holes or as oblong slots.
[0015] The paper machine clothing according to the present invention can have any desired number of plies, such that a ply having longitudinal yarns and a ply having transverse yarns alternate respectively, i.e. are in each case adjacent to one another. An advantageous number is two or three plies; in the former case a lower longitudinal yarn layer is combined with an upper transverse yarn layer, and in the latter case a ply having transverse yarns is enclosed on each side by a ply of longitudinal yarns. A longitudinal structure is formed thereby on the upper and lower sides. The possibility of course exists of proceeding conversely, so that a transverse structure is created on the upper and the lower side by the transverse yarns present there.
[0016] The permeability of the paper machine clothing can also be adjusted within wide limits, for example, by way of the width dimensions of the longitudinal and/or transverse yarns and/or their yarn density. It is also possible in this context to arrange the longitudinal yarns, in at least one ply, in such a way that they have a different yarn density in the center region than in the edge regions, in particular have a lower density in the center region than in the edge regions.
[0017] With the yarn layer according to the present invention it is also possible, in simple fashion, to produce eyelets at the ends of the paper machine clothing by bending back longitudinal yarns to constitute loops, so as to form an inserted wire seam with them. This can be done as follows: at the ends of the paper machine clothing, end pieces of longitudinal yarns of a first ply are bent back, forming loops, onto the side facing away from that ply of the ply having transverse yarns, and are attached to several of those transverse yarns, preferably to at least five transverse yarns. Attachment can also, however, be performed to the longitudinal yarns themselves. Attachment can be accomplished in both cases in positive fashion, e.g. by means of studs or rivets made of plastic or metal.
[0018] The loops should preferably be formed with only a portion of the longitudinal yarns, so that the two end edges can engage into each other in comb fashion with their loops and thus form a continuous conduit for an inserted wire. It is preferable if alternately at least one end piece is bent back to form a loop, and at least one end piece ends at the outer transverse yarn edge without forming a loop. To ensure that permeability in this region is not degraded, longitudinal yarns from the second ply in contact against the ply having transverse yarns should be adjacent against the ends of the end pieces, i.e. these longitudinal yarns butt in blunt fashion against the end pieces so that they do not overlap them, so that a greater density of longitudinal yarns does not occur in this region.
[0019] As regards the material of the yarns, there are fundamentally no limitations: it should possess high tensile strength, low elongation, and a high initial modulus. PET, PA in all its modifications, PPS, PEK, PEKK, elastic polyester, PBT or PTT, or combinations thereof, are, for example, suitable. The yarns can be reinforced, e.g. with fibers such as glass fibers, carbon fibers, and/or ceramic fibers; the fibers can also be present as shortcut fibers.
[0020] The paper machine clothing according to the present invention can be used in every section of a paper machine, and because of its flexibility can be optimally adapted to the requirements in each of these sections. For use in the sheet-forming and drying sections, the most suitable embodiments are those in which the paper machine clothing comprises only the yarn layer; this does not exclude combining the yarn layer with other components, for example a nonwoven fabric. For the press section, it is recommended to use the yarn layer according to the present invention as a substrate and to equip it on one or both sides with a fiber layer, for example applying nonwoven fabrics or spun-bonded fabrics by needling or lamination.
[0021] For manufacturing the paper machine clothing described above, the invention proposes a method in which the longitudinal and transverse yarns are connected positively to one another at the crossing points, for example by mutual engagement in each case of a projection on the one yarn and a complementary orifice on the crossing yarn, or by insertion of a peg, for example a stud or a rivet, into mutually aligning orifices in the yarns.
[0022] The connection between the yarns can be further improved by the fact that the longitudinal and transverse yarns are fused at crossing points to one another and/or to connecting elements by a heating operation to melting temperature that is confined to the crossing points, the heating being accomplished by way of laser energy, high-frequency energy, and/or inductive energy. It is possible here to use two alternative methods with which heating can be concentrated onto the crossing points. On the one hand, the energy can be applied in single-point fashion, i.e. in a manner physically confined to the crossing points, for which purpose lasers are especially suitable because of their focused laser beam. As an alternative to this, however, the energy can also be applied in wide-area fashion over a plurality of crossing points to be fused, for example over the entire width and a certain length of the paper machine clothing, if the crossing points are previously equipped with an additive that promotes energy absorption. As a result of this additive, energy uptake is concentrated on the crossing points in spite of the wide-area application, so that only those points are heated to melting temperature and consequently are fused to one another. Wide-area energy application is easier to implement in terms of apparatus, since there is no need to focus onto the plurality of crossing points to be connected.
[0023] The additive usable in each case should be adapted to the type of energy application. If a laser, for example a diode laser, is used, the additive should be a light-absorbing colorant, e.g. black dye, or a photoactive substance, the yarns located thereabove being transparent. For the utilization of high-frequency or inductive energy, metals, and in this case principally powdered iron, which can be present in the form of a paste, dispersion, or powder, are especially suitable. The additive can be applied between or onto the yarns, application only onto the yarns of one ply of each pair of adjacent plies being sufficient in the latter case. Instead of application at a later time, the additive can also be added to the yarn material in single-point fashion, e.g. during the extrusion operation.
[0024] According to a further feature of the invention, it is proposed that the longitudinal and transverse yarns be additionally connected to one another at crossing points by using an adhesive. Connection at the crossing points is thereby further strengthened.
[0025] Manufacture of the yarn layer can be accomplished specifically by first stretching longitudinal yarns parallel to one another, for example between two parallel yarn trees, and then laying transverse yarns, individually or in groups, successively onto these longitudinal yarns and connecting the transverse and longitudinal yarns positively to one another at the crossing points, for example by inserting connecting studs into holes that align at the crossing points, or by pushing a projection on the one yarn into a complementary orifice in the other yarn.
[0026] In order to achieve even better connection of the yarns at the crossing points, the yarn layer can be continuously transported in the longitudinal direction through a fusing apparatus and then rolled up. Simultaneously or later, transverse yarns can also be attached onto the other side of the longitudinal yarns. It is understood that a ply having longitudinal yarns can also in turn be applied in corresponding fashion onto the exposed side of the transverse yarns.
[0027] The invention further provides that after fusing at the crossing points, the plies are pressed against one another for a time until the connection has hardened and cooled.
[0028] If a felt is to be produced, for example for use in the press section of a paper machine, a fiber layer should be applied onto one or both sides of the yarn layer and attached thereto. Attachment can be effected by needling, adhesive bonding, or fusing.
[0029] It is understood that the transverse yarns need not extend perpendicular to the longitudinal yarns, but rather that with the method according to the present invention it is also possible to manufacture yarn layers in which the transverse yarns extend obliquely with respect to the longitudinal yarns. It is also possible to provide two plies of transverse yarns, in which the transverse yarns of the one ply cross the longitudinal yarns at a different angle than those of the other ply.
DESCRIPTION OF THE DRAWINGS
[0030] The invention is illustrated in further detail, with reference to exemplary embodiments, in the drawings, in which:
[0031] [0031]FIG. 1 is a plan view of a schematically depicted paper machine clothing with a fusing apparatus;
[0032] [0032]FIG. 2 is an magnified plan view of a portion of the paper machine clothing according to FIG. 1;
[0033] [0033]FIG. 3 is a partial cross section through the paper machine clothing according to FIGS. 1 and 2;
[0034] [0034]FIG. 4 is a side view of the seam region of the paper machine clothing according to FIGS. 1 through 3;
[0035] [0035]FIG. 5 is a plan view of the seam region of the paper machine clothing according to FIGS. 1 through 3;
[0036] [0036]FIG. 6 is a longitudinal section through the seam region of the paper machine clothing according to FIGS. 1 through 3, showing the prolongation of a longitudinal yarn beyond the right end of the paper machine clothing;
[0037] [0037]FIG. 7 is a cross section through the seam region of the paper machine clothing according to FIGS. 1 through 3, showing the prolongation of a longitudinal yarn beyond the left end of the paper machine clothing according to FIGS. 1 through 3; and
[0038] [0038]FIG. 8 is a plan view of the seam region of the paper machine clothing according to FIGS. 1 through 3, which differs from the embodiment of FIGS. 4 and 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Paper machine clothing 1 depicted in FIG. 1 comprises a yarn layer whose lower ply 2 is constituted by longitudinal yarns (labeled 3 by way of example). Longitudinal yarns 3 have a rectangular cross section and equal spacing from one another. For the manufacturing process, they are wound with their left ends (in a manner not visible here) onto a yarn tree. Provided on the right side (and also not visible here) is a second tree onto which the finished paper machine clothing 1 is wound. Paper machine clothing 1 moves in this direction (arrow A).
[0040] An upper ply 4 having transverse yarns parallel to one another (labeled 5 , 6 , 7 by way of example) is laid onto lower ply 2 . Transverse yarns 5 have a wide spacing corresponding substantially to the spacing of longitudinal yarns 3 , transverse yarns 6 have a narrow spacing in order to reduce the permeability of paper machine clothing 1 , and transverse yarns 7 also have a narrow spacing but a substantially narrower width than transverse yarns 5 , 6 . It is understood that in an actual paper machine clothing these differences are not present, i.e. identical transverse yarns, equally spaced from one another, are used. The depiction is intended merely to symbolize the fact that the method according to the present invention makes possible a very wide variety of types of longitudinal and transverse yarns 3 , 5 , 6 , 7 and yarn densities. The same applies to longitudinal yarns 3 , the additional possibility existing here of varying their spacings across the width, e.g. providing a lower yarn density in the center region than in the two edge regions, or vice versa.
[0041] FIGS. and 3 show portions of paper machine clothing 1 according to FIG. 1. At the crossing points (labeled 8 by way of example), longitudinal and transverse yarns 3 , 5 are connected positively to one another, specifically by way of connecting studs (labeled 10 by way of example) that each pass through mutually aligned holes (labeled 11 , 12 by way of example) in longitudinal and transverse yarns 3 , 5 . Instead of this, however, connecting studs 10 can also be shaped onto longitudinal yarns 3 or transverse yarns 5 , so that only the respective other yarns need to have holes into which the connecting studs are then pressed.
[0042] For the manufacture of paper machine clothing 1 , longitudinal yarns 3 are stretched between the two trees and transverse yarns 5 , 6 , 7 are then laid over longitudinal yarns 3 . This can be done in mechanized fashion, for example using a transverse table apparatus whose principle is known from U.S. Pat. No. 3,097,413. Longitudinal and transverse yarns 3 , 5 , 6 , 7 are then connected positively by inserting connecting studs 10 into holes 11 , 12 that align at crossing points 8 . For additional immobilization, longitudinal and transverse yarns 3 , 5 , 6 , 7 are adhesively bonded to one another at crossing points 8 . Adhesive can be applied onto longitudinal and/or transverse yarns 3 , 5 , 6 , 7 either in single-point fashion or over an area.
[0043] A fusing apparatus 9 spans paper machine clothing 1 like a bridge. Its purpose is to cause the material of longitudinal and transverse yarns 3 , 5 , 6 , 7 , and of connecting studs 10 , to melt at crossing points 8 so that they fuse to one another there. Laser, high-frequency, and/or induction apparatuses are suitable as the fusing apparatus. To ensure that the melting of the material of longitudinal yarns 3 and transverse yarns 5 , 6 , 7 remains confined to crossing points 8 , an additive has been applied to crossing points 8 that promotes absorption of the energy generated in fusing apparatus 9 . The energy impingement is then adjusted so that longitudinal and transverse yarns 3 , 5 , 6 , 7 melt only at crossing points 8 because of the additive present there, and consequently fuse to one another and/or to connecting studs 10 , while the other portions of longitudinal and transverse yarns 3 , 5 , 6 , 7 are heated either not at all or only slightly, and in any event not to melting temperature. After leaving fusing apparatus 9 , crossing points 8 cool off so that the molten regions harden and a permanent connection is created between longitudinal and transverse yarns 3 , 5 , 6 , 7 . This can be further promoted by pressing the two plies 2 , 4 together, for example using rollers or plates that are carried along as paper machine cloth 1 moves.
[0044] If connecting studs 10 fit very tightly into holes 11 , 12 , the positive connection may also be sufficient, and a subsequent fusing process is then not necessary.
[0045] In FIGS. 4 and 5, the end regions of paper machine clothing 1 are depicted partially, i.e. reduced in width to five longitudinal yarns 3 . Transverse yarns 5 are connected via connecting studs 10 to longitudinal yarns 3 ; on the left side, connecting studs 10 that are square in cross section were used, and on the right side connecting studs 10 that are round in cross section. This depiction is provided solely in order to demonstrate that different cross sections can be used for connecting studs 10 . Connecting studs 10 that all have the same cross-sectional shape will usually be used in a paper machine clothing 1 .
[0046] At both ends 31 , 32 of paper machine clothing 1 , every second longitudinal yarn 3 protrudes in such a way that longitudinal yarns 3 of the two ends 31 , 32 engage into one another in comb fashion, i.e. wherever a longitudinal yarn 3 projects at the one end 31 , that longitudinal yarn 3 does not project at the other end 32 , so that a gap is created for the portion of longitudinal yarn 3 projecting at end 31 . The projecting portions of longitudinal yarns 3 are looped over and back to form loops (labeled 33 by way of example). They thereby form loop openings (labeled 34 by way of example) that all align with one another and thereby form a conduit through which a coupling wire 35 is inserted. This coupling wire 35 connects ends 31 , 32 of paper machine 1 , thus yielding an endless paper machine clothing 1 . Paper machine clothing 1 can be opened again by pulling out coupling wire 35 , for example in order to pull paper machine clothing 1 into a paper machine or remove it therefrom.
[0047] As is evident in particular from FIG. 5, the turned-over loop ends (labeled 36 by way of example) are laid back down onto the associated longitudinal yarns 3 and joined to it via connecting studs 10 in the same way that transverse yarns 5 are joined to longitudinal yarns 3 . FIG. 4 illustrates a connection of loop ends 36 using two connecting studs 10 in each case, but FIG. 5 illustrates the use of only one connecting stud 10 . The variant according to FIG. 4 is suitable for transferring particularly large tensile forces.
[0048] In the exemplary embodiment according to FIGS. 6 through 8, paper machine clothing 1 has a form of connection of ends 31 , 32 that differs from the embodiment according to FIGS. 4 and 5. Longitudinal yarns 3 are prolonged in the same way as in the embodiment according to FIGS. 4 and 5, i.e. they engage in comb fashion into one another. They are not, however, turned back to form loops; instead they extend out flat and end in the vicinity of transverse yarns 5 of the respective other end 31 or 32 .
[0049] Yarn strips (labeled 37 by way of example) are laid onto the projecting portions of longitudinal yarns 3 in such a way that mutually aligning openings 38 are produced. Coupling wire 35 is inserted through these openings 38 . On either side of coupling wire 35 , yarn strips 37 are connected to the projecting portions of longitudinal yarns 3 by means of connecting studs 10 . In the variant shown in FIGS. 6 and 7, four connecting studs 10 —two on either side of coupling wire 35 —are used for this in each case, so that large loads can be handled. If the loads are smaller, two connecting studs 10 —one on either side of coupling wire 35 —are sufficient in each case, as depicted in FIG. 8.
|
The invention concerns a porous paper machine clothing ( 1 ) for dewatering a paper web in a paper machine, having a yarn layer made up of at least one ply ( 2 ) of longitudinal yarns ( 3 ) and at least one ply ( 4 ) of transverse yarns ( 5, 6, 7 ) that cross the longitudinal yarns ( 3 ), which is characterized in that the longitudinal and transverse yarns ( 3, 5, 6, 7 ) are connected positively to one another at crossing points ( 8 ).
The invention further concerns a method for manufacturing a porous paper machine clothing of this kind.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to hand held lighting devices and more particularly pertains to a hand held, battery operated, kinematic optical emitter which may be utilized for entertainment, attracting attention, and general novelty lighting applications.
2. Description of the Prior Art
The use of hand held lighted wands and kinematic display lighting is known in the prior art. More specifically, hand held lighted wands heretofore devised and utilized for the purpose of entertainment and attracting attention are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
For example, in U.S. Pat. No. 4,924,358 to Von Heck a safety-sparkler wand with chemiluminescent or electric-light illumination is disclosed. The Von Heck invention comprises a hand held intrinsically lighted wand having a multiplicity of highly flexible optical fiber strands conveying light from an electrically or chemically stimulated internal source to various conically enveloped volumes wherein the emergent light proceeds into free space with a given optical fiber termination as an apex. Movement of the device holding hand stimulates movement of the optical fibers and, consequently, viewers perceiving the light emitted from the fibers observe a random blinking or sparkling effect. The present invention differs markedly in having one or more electric motors powering a plurality of light emitters which are substantially fixed in position on a series of radially disposed arms. The light sources move in a substantially circular path thereby generating an effect in hand held wand light sources far removed from the capabilities of the Von Heck patent.
In U.S. Pat. No. 5,097,394 to Friedlander a dynamic light sculpture wherein an externally illuminated, elongated, flexible element is driven in multidimensional motion by one or more electric motors is described. The various oscillations, nodal formations, and occasional chaotic behavior of the illuminated flexible element are observable and are purportedly pleasing in effect. The present invention differs from the Friedlander patent in employing a plurality of kinematic illumination sources wherein each illumination source is rigidly affixed to a stiff radial member extending from a motor driven central hub. The Friedlander invention is not readily adaptable to battery power and is unsuitable for a hand held wand configuration.
In U.S. Pat. No. 5,041,947 to Yuen et al. a display device is disclosed wherein a plurality of light sources arranged in a pattern are rotated by two rotating means in one or more planes to achieve unique optical effects. The Yuen et al. invention has no provision for single axis rotation of a radially arranged array of lights as in the present invention and is not disclosed having an embodiment which is adaptable to a hand held, battery powered, kinematic light apparatus.
In U.S. Pat. No. 4,364,106 to Lama light display with travelling balls and compound rotation is disclosed. The Lam invention comprises a rigid assembly of hollow tubes rotated simultaneously about horizontal and vertical axes, wherein each tube contains a free ball illuminated from below by an external light source. The present invention differs from the Lam invention in having moving sources of light and thereby being independent of reflected light and the complexities introduced by having an external light source. Additionally, the Lam patent omits any hand held or wandlike configuration and is not renderable to forms amenable to holding in ones hand.
In U.S. Pat. No. 3,916,181 to Smith an illuminated propeller decorative light is disclosed wherein a battery powered light source is coupled through a series of small apertures to a multiplicity of transparent propeller blades fixedly attached to a freely spinning hub. The propeller assembly is caused to spin by external influence and light is emitted whenever the apertures are in alignment with the base of a propeller blade. The present invention employs internal electric motors to drive the moving parts which include a series of light sources.
In U.S. Pat. Nos. 4,097,917 and 4,206,495 to McCaslin a rotatable light display is described in which a tube containing a multiplicity of flexible, rod like, light transmitting members illuminated from below is caused to rotate about a central axis in response to sound input. The present invention differs in providing motion to a multiplicity of light sources and in being hand held.
In U.S. Pat. No. 4,600,973 to Mori a light source device is disclosed for the purpose of stimulating photosynthesis in plants. The Mori patent comprises an optical fiber or optical fiber bundle coupled to a light source. An electric motor engages a crank which provides oscillatory motion of a portion of the optical fiber such that the light emerging from the optical fiber is caused to sweep a large area. A disadvantage in this prior art lies in a lack of movement of a light source, the absence of battery power, and the inability to extend to a wandlike configuration.
As illustrated by the background art, efforts are continuously being made to attempt to improve kinematic light sources. No prior effort, however, provides the benefits attendant with the present invention. Additionally, the prior patents and commercial techniques do not suggest the present inventive combination of component elements arranged and configured as disclosed and claimed herein.
Therefore, it can be appreciated that there exists a continuing need for a light twirler wand which can be employed to provide a dramatic hand held kinematic display of light. In this regard, the present invention substantially fulfills this need.
The present invention achieves its intended purposes, objects, and advantages through a new, useful and unobvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing only readily available materials.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types now present in the prior art, the present invention provides an improved hand held kinematic light wand construction wherein the same can be utilized for entertainment, attracting attention, or for communications. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved hand held kinematic light source apparatus and method which has all of the advantages of the prior art hand held kinematic lighting methods and none of the disadvantages.
The invention is defined by the appended claims with the specific embodiment shown in the attached drawings. For the purpose of summarizing the invention, the invention may be incorporated into a tubular wand first portion containing an electric battery power source, switches, and motors; a second portion comprising radially disposed arrays of electric light sources engaging the drive section of a motor in the first portion; and a third portion being a substantial mirror image of the second portion. The tubular wand first portion is held in the human hand and the second and third portions may be caused to spin and emit light thereby creating an unusual visual effect especially if the human holder gyrates or otherwise moves the entire assembly as in twirling a baton.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. In as much as the foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may readily be utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be realized by those skilled in the art that such equivalent methods and structures do not depart from the spirit and scope of the invention as set forth in the appended claims.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
Therefore, it is an object of the present invention to provide a new and improved light twirler wand.
It is another object of the present invention to provide a new and improved light twirler wand which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved light twirler wand which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved light twirler wand which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such light twirler wand economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved light twirler wand which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved light twirler wand which serves a purpose of providing an entertaining optical display.
Yet another object of the present invention is to provide a new and improved light twirler wand which incorporates a self contained kinematic power source which facilitates production of a continuous optical display of long duration thereby providing the user with enhanced attention capture capabilities.
Even still another object of the present invention is to provide a new and improved light twirler wand thereby having a beneficial impact on the kinematic optical display industry in general.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. The foregoing has outlined some of the more pertinent objects of this invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the present invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding may be had by referring to the summary of the invention and the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a light twirler wand.
FIG. 2 is a side elevational view of the light twirler wand.
FIG. 3 is a side sectional view of the light twirler wand taken substantially upon the plane indicated by the section lines 3--3 of FIG. 2.
FIG. 4 is fragmentary perspective view of the light twirler wand.
FIG. 5 is a fragmentary sectional view of the light twirler wand taken substantially upon the plane indicated by the section line 5--5 of FIG. 4.
FIG. 6 is a sectional side view of electrically conductive collector rings attached to the first portion of a light twirler wand.
FIG. 7 is a front elevational view light twirler wand.
FIG. 8 is a fragmentary front elevational view of an alternate embodiment of the light twirler wand.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 1 thereof, a new and improved light twirler wand embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
From an overview standpoint, the light twirler wand 10 is adapted for use by a human to attract attention and generally have an entertaining effect. Light twirler wand 10 comprises a first portion 12 which houses stored energy and engine components, and a rotatably driven second portion 14 having a multiplicity of electric lights 16 mounted on arms 18 converging to a hub 20 wherein hub 20 provides rigid support for an end of each arm 18 and additionally comprises a portion of a co-active rotary electrical transfer device 22, and a rotatable third portion 30 presenting, more or less, a mirror image of second portion 14 by having a multiplicity of electric lights 32 mounted on arms 34 converging to a hub 36 wherein hub 36 provides rigid support for an end of each arm 34 and additionally comprises a portion of a co-active rotary electrical transfer device 40. See FIGS. 1 and 2.
More specifically, it will be noted that the light twirler wand 10 first portion 12 comprises an elongate tubular structure and may be composed of various rigid structural materials such as aluminum or plastic, and furthermore may include various surface treatments such as texturing, ribbing, printing, and color schemes. First portion 12 houses one or more electrical batteries 50 which may comprise disposable dry electrochemical cells, rechargeable electrochemical cells, or any electric current producing cell which is self contained and has an ability to supply adequate power for all light twirler wand functions for extended periods. See FIG. 3.
Electrical batteries 50 are disposed in a series conductive arrangement with switch 52, lights 16, and electric motor 54, and in a separate series conductive arrangement with switch 56, lights 32, and electric motor 58. Alternately, a single switch may be used to control a parallel arrangement of lights 16 and 32, and electric motors 54 and 58. See FIGS. 4 and 5.
Electric motor 54 comprises body 60 and extended shaft 62 wherein hub 20 engages shaft 62 such that hub 20 and shaft 62 rotate as a unit under the influence of the various internal devices of electric motor 54. Electrical power is transferred from batteries 50 to lights 16 by co-active rotary electrical transfer device 22 wherein brushes 70 are maintained in contact with collector rings 72 by springs 74.
FIG. 6 shows a concentric arrangement of two collector rings 72 affixed to motor shaft 62, however, a conductive motor shaft 62, motor housing, and motor bearing can be employed as a substitute for one collector ring. Brushes 70 are shown affixed to hub 20 and collector rings 72 are affixed to first portion 12, however, an alternate arrangement in which brushes 70 are affixed to first portion 12 and collector rings are affixed to hub 20.
Electric motor 58 equivalently comprises a body and extended shaft wherein hub 36 engages the extended shaft such that hub 36 and the extended shaft rotate as a unit under the influence of the various internal devices of electric motor 58. Electrical power is transferred from batteries 50 to lights 32 by co-active rotary electrical transfer device 40 wherein brushes are maintained in contact with collector rings by springs. The brushes may be affixed to hub 36 and collector rings 72 may be affixed to first portion 12, however, an alternate arrangement is feasible wherein the brushes are affixed to first portion 12 and collector rings 72 are affixed to hub 36.
In an alternate embodiment additional arms 80 and optical emitters 16 are affixed to hub 20. See FIG. 7. And furthermore, the length of arms 80 may differ substantially from the length of arms 18. Likewise the assembly comprising arms 34, optical emitters 32, and hub 36 may be modified by inclusion of arms 80.
In another alternate embodiment a plurality of optical emitters 90 are affixed to arms 18, arms 80, and arms 34.
Additionally the light twirler wand may feature only first portion 12 and second portion 14 wherein first portion 12 comprises a housing containing a single motor 54 and switch 52.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. In as much as the present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
|
A light twirler wand including a central portion held in the hand and furthermore containing batteries, motors, switches and an electrical power transfer device; and a series of rotating lighted arms at one or both ends of the central portion. Lights affixed to the arms may be positioned at the tips or a plurality of lights may be dispersed throughout the arm to produce a desirable lighting effect.
| 5
|
TECHNICAL FIELD
This invention relates to a pumpskid useful in conjunction with a remotely operated vehicle for installing and removing suction anchors in deep water installations.
BACKGROUND AND SUMMARY OF THE INVENTION
U.S. Pat. No. 4,318,641 granted to Hogervorst on Mar. 9, 1982, and assigned to Shell Oil Company discloses a suction anchor. Briefly, a suction anchor comprises a length of steel tubing having a relatively large diameter and a relatively long length, for example, a typical suction anchor might be 12 feet in diameter and 60 feet in length. The suction anchor has an open bottom and a top equipped with structure which allows water to be pumped out of the interior of the suction anchor thereby establishing a pressure differential which causes the suction anchor to penetrate the seafloor. The suction anchor is adapted for subsequent removal from the seafloor by pumping water into the interior thereof.
The Hogervorst '641 Patent discloses in FIGS. 1 and 2 a first pumping apparatus and in FIG. 7 a second apparatus which may be used to effect the flow of water out of or into a suction anchor. Although mentioning structure for clamping the pumping apparatus to the suction anchor, the details of the clamping apparatus are not further disclosed. It is not at all clear from the specification of the Hogervorst '641 Patent that the pumping apparatus described therein can be actuated to effect rapid reversal of the direction of water flow relative to the suction anchor which may be necessary to free the suction anchor from the seafloor in the event that the material into which the suction anchor has been installed has become consolidated around the interior and exterior walls thereof. Also, the apparatus disclosed in FIG. 7 of the Hogervorst '641 Patent for guiding the pumping apparatus downwardly from the surface and into engagement with the suction anchor is not considered adequate for use in deep water installations.
The present invention comprises a pumpskid useful in conjunction with a remotely operated vehicle for installing suction anchors in deep water installations. In accordance with the broader aspects of the invention, the pumpskid is provided with structure for securely clamping the pumpskid in engagement with the suction port of the suction anchor. The pumpskid is provided with remotely operable valving apparatus for causing a pump mounted on the pumpskid to pump water either out of or into the suction anchor as may be required. The valving apparatus may be operated to rapidly reverse the direction of water flow relative to the anchor thereby dislodging a suction anchor which may have become too firmly imbedded in the seafloor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a suction anchor;
FIG. 2 is a front view of the suction anchor of FIG. 1;
FIG. 3 is a top view of the suction anchor of FIG. 1;
FIG. 4 is an enlargement of a portion of FIG. 1;
FIG. 5 is a sectional view of the apparatus shown in FIG. 4 taken along the lines 5--5 therein;
FIG. 6 is a top view of a pumpskid incorporating the present invention;
FIG. 7 is a side view of the pumpskid of FIG. 6;
FIG. 8 is an end view of the pumpskid in FIG. 6 in which certain parts have been broken away and more clearly to illustrate certain features of the invention;
FIG. 9 is a view similar to FIG. 8 showing a different operational condition of the pumpskid of the present invention;
FIG. 10 is a diagrammatic illustration of the utilization of the pumpskid of the present invention; and
FIG. 11 is an enlarged partial side view of the apparatus shown in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 through 5, therein is shown a steel suction anchor 70 useful in the practice of the invention. The suction anchor 70 is a right circular cylinder 12 feet in diameter and 60 feet in length, having a wall thickness of 1.5 inches. Skids 71, which may comprise lengths of angle iron or lengths of pipe cut in half longitudinally, are welded to the cylinder comprising the anchor 70 to prevent it from rolling on the deck of an installation vessel.
The suction anchor 70 is open on the lower end 72 and closed at the upper end 74 by a plate 76. A padeye 78, for receiving a mooring line, is attached on an exterior side of suction anchor 70 approximately 40 feet from the top. The top closure plate 76 on the upper end 74 of suction anchor 70 includes ports 82 which allow water to flow through the closure plate 76 as the anchor 70 heaves up and down during lowering to and retrieval from the seafloor. The ports 82 are opened and closed by worm gear actuators 83 which are in turn operated by a manipulator extending from a remote operation vehicle (ROV) 300 which is located relative to the suction anchor 70 by docking posts 84. ROV 300 may comprise a Raycal SEA LION Mk.II heavy work class ROV having 100 horsepower; however any of the various commercially available ROV's having 75 h.p. or more can be used in the practice of the invention.
Vertical alignment of the anchor 70 is determined using a camera on the ROV 300 which observes a bullseye level 85. The ROV 300 also adjusts the horizontal alignment of the suction anchor 70 by checking the suction anchor's heading with a gyrocompass onboard the ROV. If the horizontal alignment is out of tolerance, the ROV 300 rotates the suction anchor 70 by activating thrusters on the ROV. The placement of the ROV 300 on the outer edge of the closure plate 76 ensures that the ROV's thrusters can apply adequate torque to rotate the suction anchor 70 about its axis.
Padeyes 86 are used to connect the anchor to a recovery bridle. An alternate padeye 87 may be used with a single recovery pendant or with double recovery sling. A suction port 88 having a clamp down hub is engaged by the ROV 300 to effect pumping of water into or out of the anchor 70.
A pumpskid 160 comprising the present invention is shown in FIGS. 6, 7, 8, and 9. The ROV 300 is fitted with the pumpskid 160 which is mounted beneath the ROV. The pumpskid 160 includes a centrifugal pump 162, a hydraulic motor 163 which drives the pump 162, pump manifold valve actuators 164 and 165, and latching actuators 166, all powered and controlled by the hydraulic system of the ROV 300. The pumpskid further includes a male connector 168 for the suction port 88. The male connector is provided with O-ring seals 169 to ensure a water-tight connection with the suction port 88. Valves 170 and 172 are operated by actuator 164 and valves 174 and 176 are operated by actuator 165.
As is shown in FIGS. 8, 9, and 10, the ROV 300 docks and latches onto the suction anchor 70 and its suction port 88 by engagement of the male connector 168 and by actuating the latching actuators 166. The latching actuators 166 comprise hydraulic cylinders which are actuated from the ROV 300. Each latching actuator 166 has a piston rod 178 extending therefrom. The distal end of each piston rod 178 comprises a truncated cone 180. The suction port 88 of the suction anchor 70 has a clamp down ring 182 which is provided with a tapered circumferential slot 184 adapted for mating engagement with the cones 180 to securely clamp the pumpskid 160 and the ROV 300 in engagement with the suction anchor 70.
After the latching actuators have been operated to engage the cones 180 with the tapered slot 184 to secure the pumpskid 160 to the anchor 70, the ROV closes the ports 82. The pump 162 of the pumpskid 160 is started and pumps water out of the interior of the suction anchor 70, reducing the water pressure inside relative to the outside pressure. This is accomplished by means of actuator 164 which opens valve 170 and closes valve 172 and actuator 165 which opens valve 174 and closes valve 176, thereby causing water to flow through suction port 88, valve 174, pump 162, and valve 170, and then out through a port 188 which is open to the surrounding sea. As will be understood, the mechanical linkage 190 extending between the actuator 164, the valve 170, and the valve 172 assures that whenever valve 170 is open valve 172 is closed, and vice versa. Likewise, the linkage 192 between actuator 164, valve 174, and valve 176 assures that whenever valve 174 is open valve 176 is closed and vice versa.
The differential pressure under the action of pump 162 acts as a downward force on the top of the suction anchor 70 pushing the suction anchor further into the seafloor to the desired penetration depth. When the desired penetration has been reached, as determined from a depth monitoring system on the ROV 300, the ROV disconnects from the top of the suction anchor 70. This is accomplished by operation of the latching actuators to withdraw the cones 180 from the tapered slot 184. Next the ROV checks the suction anchor penetration by reading the penetration marks at the mudline. When the suction anchor 70 penetration is found to be within tolerance, the ROV 300 closes the suction port 88 so that all openings in the top of the suction anchor are closed. The ROV 300 then disconnects the lowering line from the recovery buoy 146 and is retrieved to the surface.
Whenever removal of the suction anchor 70 is desired, the ROV 300 docks onto the suction anchor top and latches onto the suction port 88. This is accomplished by operating latching actuators 166 to force the cones 180 into the tapered slot 184. As is shown in FIG. 11, the ROV 300 pumps water into the interior of the suction anchor by means of the pump 162. This is accomplished by operating the actuators 164 and 165 to open valve 176, open valve 172, close valve 174, and close valve 170, thereby causing water to flow through port 188, valve 172, pump 162, valve 176 and port 88 into anchor 70.
Due to the pump 162, the water pressure inside becomes greater than the outside water pressure, and the differential pressure results in an upwards force on the suction anchor top. The upwards force, and the pull on the recovery line pulls the suction anchor out of the seafloor. If too much pump pressure is required to pull the suction anchor 70 out of the seafloor, due to too much consolidation of the soil around and inside the suction anchor, the water flow direction from the pump 162 can be reversed instantaneously by changing the positions of valve actuators 164 and 165. By rapidly changing the water flow direction from pumping in to pumping out, the suction anchor 70 will be alternately pulled out and pushed in. When this is done for some time, the soil in contact with the suction anchor cylinder will liquefy, making it easier to pump and pull the suction anchor out off the soil. Suction anchor 70 is raised to the surface by a recovery line and is loaded on an installation vessel using the riser line 50.
The pumpskid 160 is provided with a differential pressure gauge 194 which is connected to the male connector 168 by a pressure line 196. The pressure line 194 indicates the difference in the pressure of the water within the connector 168 with respect to the pressure of the water outside of the suction anchor. The ROV 300 monitors the gauge 194 during suction anchor installation and removal operations to assure that the differential pressure between the inside and the outside of the suction anchor remains within predetermined limits.
The water pumping rate can be adjusted from the ROV 300 by controlling the rate of flow of pressurized hydraulic fluid to the hydraulic motor 163. Reduction in the water flow rate may be required if either the suction anchor penetration rate, or the suction anchor withdrawal rate, or the differential pressure between the interior and the exterior of the suction anchor is too high.
The pumpskid 160 is fitted with syntactic foam buoyancy elements 196 designed for the maximum operating water depth. The buoyancy elements 196 ensure that the pumpskid 160 is slightly buoyant when submerged.
Although preferred and alternative embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements and substitutions of parts and elements without departing from the spirit of the invention.
|
A pumpskid comprises a frame adapted for connection to a remotely operated vehicle for positioning thereby. A male connector mounted on the frame is adapted for engagement with the suction port on a suction anchor. Clamping apparatus is provided for securing the male connector in engagement with the suction port of the suction anchor and thereby clamping the pumpskid in engagement with the suction anchor. A pump mounted on the frame is connected in fluid communication with the male connector by piping sections which include a port open to the surrounding sea. Valves and valve actuators are provided for causing the pump to cause water flow out of or into the suction anchor, as required.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit to a prior filed co-pending U.S. Regular Utility application Ser. No. 10/793,641 filed on Mar. 4, 2004 and entitled COOLED TURBINE SPAR SHELL BLADE CONSTRUCTION by Jack Wilson, Jr. and Wesley Brown, which claims benefit to a prior filed Provisional application Ser. No. 60/454,095, filed on Mar. 12, 2003, entitled COOLED TURBINE BLADE by Jack Wilson, Jr. and Wesley Brown.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to internally cooled turbine vanes for gas turbine engines and more particularly to the construction of the internally cooled turbine vane comprising a spar and shell construction.
2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
As one skilled in the gas turbine technology recognizes, the efficiency of the engine is enhanced by operating the turbine at a higher temperature and by increasing the turbine's pressure ratio. Another feature that contributes to the efficiency of the engine is the ability to cool the turbine with a lesser amount of cooling air. The problem that prevents the turbine from being operated at a higher temperature is the limitation of the structural integrity of the turbine component parts that are jeopardized in its high temperature, hostile environment. Scientists and engineers have attempted to combat the structural integrity problem by utilizing internal cooling and selecting high temperature resistant materials. The problem associated with internal cooling is twofold. One, the cooling air that is utilized for the cooling comes from the compressor that has already extended energy to pressurize the air and the spent air in the turbine cooling process in essence is a deficit in engine efficiency. The second problem is that the cooling is through cooling passages and holes that are in the turbine blade or vane which, obviously, adversely affects the blade or vane's structural prowess. Because of the tortuous path (a serpentine path through the blade or vane) that is presented to the cooling air, the pressure drop that is a consequence thereof requires higher supply pressure and more air flow to perform the cooling that would otherwise take a lesser amount of air given the path becomes friendlier to the cooling air. While there are materials that are available and can operate at a higher temperature that is heretofore been used, the problem is how to harness these materials so that they can be used efficaciously in the turbine environment.
To better appreciate these problems it would be worthy of note to recognize that traditional blade cooling approaches include the use of cast nickel based alloys with load-bearing walls that are cooled with radial flow channels and re-supply holes in conjunction with film discharge cooling holes. Examples of these types of blades and vanes are exemplified by the following patents that are incorporated herein by reference.
U.S. Pat. No. 3,378,228 issued to Davies et al on Apr. 16, 1968 shows a blade for a fluid flow duct and comprises ceramic laminations which may be in two or more parts, where the laminations are held together in compression by a hollow tie bar through which cooling air may be passed, and where the blades are mounted between platform members.
U.S. Pat. No. 4,790,721 issued to Morris et al on Dec. 13, 1988 shows an airfoil blade assembly having a metallic core, thin coolant liner and ceramic blade jacket including variable size cooling passages and a circumferential stagnant air gap to provide a substantially cooler core temperature during high temperature operations.
U.S. Pat. No. 4,473,336 issued to Coney et al on Sep. 25, 1984 shows a turbine blade with a spar formed with a central passageway with cooling holes passing through the spar wall into a cavity formed between an airfoil shaped shell and the spar.
U.S. Pat. No. 4,519,745 issued to Rosman et al on May 28, 1985 shows a ceramic blade assembly including a corrugated-metal partition situated in the space between the ceramic blade element and the post member, which corrugated-metal partition forms a compliant layer for the relief of mechanical stresses in the ceramic blade element during aerodynamic and thermal loading of the blade and which partition also serves as a means for defining contiguous sets of juxtaposed passages situated between the ceramic blade element and the post member, one set being open-ended and adjacent to exterior surfaces of the post member for directing cooling fluid there over and the second set being adjacent to the interior surfaces of the ceramic blade element and being closed-off for creating stagnant columns of fluid to thereby insulate the ceramic blade element from the cooling air.
U.S. Pat. No. 4,512,719 issued to Rossmann on Mar. 24, 1981 shows a turbine blade adapted for use with hot gases comprising a radially inward portion of metal including a core projecting radially outwards on which is supported a ceramic portion of airfoil section enclosing the core. The inner end of the ceramic portion forms a continuous surface contour with the metal inward portion. The ceramic portion extends no more than one-half of the total span of the blade and, preferably, about one-third of the blade span. In a particular embodiment, the wall thickness of the ceramic portion can increase in a radially outwards direction.
U.S. Pat. No. 4,563,128 issued to Rossmann on Jan. 7, 1986 shows a hot gas impinged turbine blade suitable for use under super-heated gas operating conditions has a hollow ceramic blade member and an inner metal support core extending substantially radially through the hollow blade member and having a radially outer widened support head. The support head has radially inner surfaces against which the ceramic blade member supports itself in a radial direction on both sides of the head. The radially inner surfaces of the head are inclined at an angle to the turbine axis so as to form a wedge or key forming a dovetail type connection with respectively inclined surfaces of the ceramic blade member. This dovetail type connection causes a compressive stress on the ceramic blade member during operation, whereby an optimal stress distribution is achieved in the ceramic blade member.
U.S. Pat. No. 4,247,259 issued to Saboe et al on Jan. 27, 1981 shows a composite, ceramic/metallic fabricated blade unit for an axial flow rotor includes an elongated metallic support member having an airfoil-shaped strut, one end of which is connected to a dovetail root for attachment to the rotor disc, while the opposite end thereof includes an end cap of generally airfoil-shape. The circumferential undercut extending between the end cap and the blade root is clad with an airfoil-shaped ceramic member such that the cross-section of the ceramic member substantially corresponds to the airfoil-shaped cross-section of the end cap, whereby the resulting composite ceramic/metallic blade has a smooth, exterior airfoil surface. The metallic support member has a longitudinally extending opening through which coolant is passed during the fabrication of the blade. Simultaneously, ceramic material is applied and bonded to the outer surface of the elongated airfoil-shaped strut portion, with the internal cooling of the metallic strut during the processing operation allowing the metal to withstand the processing temperature of the ceramic material.
U.S. Pat. No. 3,694,104 issued to Erwin on Sep. 26, 1972 shows a turbomachinery blade secured to a rotor disc by a pin.
U.S. Pat. No. 4,314,794 issued to Holden, deceased et al on Feb. 9, 1982 shows a transpiration cooled blade for a gas turbine engine is assembled from a plurality of individual airfoil-shaped hollow ceramic washers stacked upon a ceramic platform which in turn is seated on a metal root portion. The airfoil portion so formed is enclosed by a metal cap covering the outermost washer. A metal tie tube is welded to the cap and extends radially inwardly through the hollow airfoil portion and through aligned apertures in the platform and root portion to terminate in a threaded end disposed in a cavity within the root portion housing a tension nut for engagement thereby. The tie tube is hollow and provides flow communication for a coolant fluid directed through the root portion and into the hollow airfoil through apertures in the tube. The ceramic washers are made porous to the coolant fluid to cool the blade via transpiration cooling.
U.S. Pat. No. 3,644,060 issued to Bryan on Feb. 22, 1972 shows a cooled airfoil in which a shell is secured over a spar by dove-tail grooves.
U.S. Pat. No. 4,257,737 issued to Andress et al on Apr. 23, 1985 shows a Cooled Rotor Blade, where the cooled rotor blade is constructed having a cooling passage extending from the root and through the airfoil shaped section in a serpentine fashion, making several passes between the bottom and top thereof; a plurality of openings connect said cooling passage to the trailing edge; a plurality of compartments are formed lengthwise behind the leading edge of the blade; said compartments having openings extending through to the exterior forward portion of the blade; and sized openings connect the cooling passage to each of the compartments to control the pressure in each compartment.
U.S. Pat. No. 4,753,575 issued to Levengood et al on Jun. 28, 1988 shows an airfoil with nested cooling channels, where the hollow, cooled airfoil has a pair of nested, coolant channels therein which carry separate coolant flows back and forth across the span of the airfoil in adjacent parallel paths. The coolant in both channels flows from a rearward to forward location within the airfoil allowing the coolant to be ejected from the airfoil near the leading edge through film coolant holes.
U.S. Pat. No. 5,476,364 issued to Kildea on Dec. 19, 1995 shows a tip seal and anti-contamination for turbine blades, where a cavity is judiciously dimensioned and located adjacent the tip's surface discharge port of internally cooling passage of the airfoil of the turbine blade of a gas turbine engine and extending from the pressure surface to the back wall of the discharge port guards against the contamination and plugging of the discharge port.
U.S. Pat. No. 5,700,131 issued to Hall et al on Dec. 23, 1997 shows an internally cooled turbine blade for a gas turbine engine that is modified at the leading and trailing edges to include a dynamic cool air flowing radial passageway with an inlet at the root and a discharge at the tip feeding a plurality of radially spaced film cooling holes in the airfoil surface. Replenishment holes communicating with the serpentine passages radially spaced in the inner wall of the radial passage replenish the cooling air lost to the film cooling holes. The discharge orifice is sized to match the backflow margin to achieve a constant film hole coverage throughout the radial length. Trip strips may be employed to augment the pressure drop distribution.
Also well known by those skilled in this technology is that the engine's efficiency increases as the pressure ratio of the turbine increases and the weight of the turbine decreases. Needless to say, these parameters have limitations. Increasing the speed of the turbine also increases the airfoil loading and, of course, satisfactory operation of the turbine is to stay within given airfoil loadings. The airfoil loadings are governed by the cross sectional area of the turbine multiplied by the velocity of the tip of the turbine squared, or AN 2 . Obviously, the rotational speed of the turbine has a significant impact on the loadings.
The spar/shell construction contemplated by this invention affords the turbine engine designer the option of reducing the amount of cooling air that is required in any given engine design. And in addition, allowing the designer to fabricate the shell from exotic high temperature materials that heretofore could not be cast or forged to define the surface profile of the airfoil section. In other words, by virtue of this invention, the shell can be made from Niobium or Molybdenum or their alloys, where the shape is formed by a well known electric discharge process (EDM) or wire EDM process. In addition, because of the efficacious cooling scheme of this invention, the shell portion could be made from ceramics, or more conventional materials and still present an advantage to the designer because a lesser amount of cooling air would be required.
BRIEF SUMMARY OF THE INVENTION
An object of this invention is to provide a guide vane for a gas turbine engine that is constructed with a spar and shell configuration.
A feature of this invention is an inner spar that extends from a root of the vane to the tip, and is secured to the attachment at the root by a pin or rod member.
Another feature of this invention is that the shell and/or spar can be constructed from a high temperature material such as ceramics, Molybdenum or Niobium (Columbium) or a lesser temperature resistive material such as Inco 718, Waspaloy or well known single crystal materials currently being used in gas turbine engines. For existing types of engine designs where it is desirable of providing efficacious turbine vane cooling with the use of compressed air at lower amounts and obtaining the same degree of cooling, and for advanced engine designs where it is desirable to utilize more exotic materials such as Niobium or Molybdenum, the shell and spar can be made out of these materials or the spar can be made from a lesser exotic material with lower melting points that is more readily cast or forged.
Another feature of this invention for engine designs that require higher turbine rotational speeds, the spar can be made from a dual spar systems where the outer spar extends a shortened distance radially relative to the inner spar and defines at the junction a mid spar shroud, and the shell is formed in an upper section and a lower section where each section is joined at the mid span shroud. The pin in this arrangement couples the inner spar and outer spar at the attachment formed at the root of the vane. This design can utilize the same materials that are called out in the other design.
A feature of this invention is an improved turbine vane that is characterized as being easy to fabricate, provide efficacious cooling with lesser amounts of cooling air than prior art designs, provides a shell or shells that can be replaced and hence affords the user the option of repair or replacement. The materials selected can be conventional or more esoteric depending on the specification of the engine.
The forgoing and other features of the present invention will become more apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an exploded view in perspective showing the details of one embodiment of this invention;
FIG. 2 is a perspective view illustrating the assembled turbine blade of the embodiment depicted in FIG. 1 of this invention;
FIG. 3 is a section taken from sectional lines 3 - 3 of FIG. 2 ;
FIG. 4 is a section taken along the sectional lines 4 - 4 of FIG. 3 illustrating the attachment of the shell to the strut of this invention;
FIG. 5 is a perspective view illustrating a second embodiment of this invention; and
FIG. 6 is a section view in elevation taken along the sectional lines of 6 - 6 of FIG. 5 .
FIG. 7 is a section view of a third embodiment of this invention, showing a vane;
FIG. 8 is a sectional view of a fourth embodiment of this invention;
FIG. 9 is a section view of a fifth embodiment of this invention showing another vane.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is described in its preferred embodiment in two different, but similar configurations so as to take advantage of engines that are designed at higher speeds than are heretofore encountered, this invention has the potential of utilizing conventional materials and improving the turbine rotor by enhancing its efficiency by providing the desired cooling with a lesser amount of compressed air, and affords the designer to utilize a more exotic material that has a higher resistance temperature while also maintaining the improved cooling aspects. Hence, it will be understood to one skilled in this technology, the material selected for the particular engine design is an option left open to the designer while still employing the concepts of this invention. For the sake of simplicity and convenience, only a single vane in each of the embodiments for the vane is described although one skilled in this art would know that the turbine rotor consists of a plurality of circumferentially spaced blades and vanes mounted in a rotor disk (blades) or attached to the casing (vanes) that makes up the rotor assembly.
This disclosure is divided into two embodiments employing the same concept of a spar and a shell configuration of a turbine blade, where one of the embodiments includes a single spar and the other embodiment includes a double spar to accommodate higher rotational speeds. FIGS. 1 through 4 are directed to one of the embodiments of the turbine blade generally illustrated as reference numeral 10 as comprising a generally elliptical shaped spar 12 extending longitudinally or in the radial direction from a root portion 14 to a tip 16 with a downwardly extending portion 18 that fairs into a rectangular shaped projection 26 that is adapted to fit into an attachment 20 . The spar 12 spans the camber stations extending along the airfoil section defined by a shell 48 . The attachment 20 may include a fir tree attachment portion 22 that fits into a complementary fir tree slot formed in the turbine disk (not shown). The attachment 20 may be formed with a platform 24 or the platform 24 may be formed separately and joined thereto and projects in a circumferential direction to abut against the platform 24 in the adjacent blade in the turbine disk. A seal, such as a feather seal (not shown) may be mounted between platforms of adjacent blades to minimize or eliminate leakage around the individual blades.
The spar 12 may be formed as a single unit or made up of complementary parts and, as for example, it may be formed in two separate portions that are joined at the parting plane along the leading edge facing portion 30 and trailing edge facing portion 32 and extending the longitudinal axis 31 . Spar 12 is secured to the attachment 20 by an attachment pin 34 which fits through a hole 29 in the attachment 20 and an aligned hole 31 formed in the extension 18 . Pin 34 carries a head 36 that abuts against a face 38 of the attachment 20 and includes a flared out portion 40 at an opposing end of the head 36 . This arrangement secures the spar 12 and assures that the load on the blade 10 is transmitted from the airfoil section through the attachment 20 to the disk (not shown). The tip 16 of the blade 10 may be sealed by a cap 44 that may be formed integrally with the spar 12 , or may be a separate piece that is suitably joined to the top end of the spar 12 . it should be appreciated that this design can accommodate a squealer cap, if such is desired. The material of the spar 12 will be predicted on the usage of the blade and in a high temperature environment the material can be a molybdenum or niobium, and in a lesser temperature environment the material can be a stainless steel like Inco 718 or Waspaloy or the like.
Shell 48 extends over the surface of the spar 12 and is hollow in the central portion 50 and spaced from the outer surface of spar 12 . The shell 48 defines a pressure side 52 , a suction side 54 , a leading edge 56 , and a trailing edge 58 . As mentioned in the above paragraph, the shell 48 may be made from different materials depending on the specification of the gas turbine engine. In the higher temperature requirements, the shell 48 preferably will be made from Molybdenum, Niobium, alloys of Molybdenum or Niobium (Columbium), Oxide Ceramic Matrix Composite (CMC), or SiC—SiC Ceramic Matrix Composite (CMC), and in lesser temperature environments the shell 48 may be made from conventional materials. If the material selected cannot be cast or forged into the proper airfoil shape, then the shell 48 will be made from a blank and the contour will be machined by a wire EDM process. The shell 48 can be made in a single unit or into two halves divided along the longitudinal axis, similar to the spar 12 . As best seen in FIG. 1 , the attachment 20 is made to include a stud portion 88 that complements the contoured surface of the spar 12 and the contoured surface of the shell 48 . Additionally, the shell 48 and the spar 12 carry complementary male and female hooks 60 and 62 . An upper edge 84 of the shell 48 is supported by the cap 44 and fits into an annular groove 82 so that the upper edge 84 bears against a shoulder 86 . A lower edge 88 fits into an annular complementary groove 90 formed on the upper edge of a platform 24 and bears against the opposing surfaces of the groove 90 and the outer surface of the attachment 20 .
As mentioned in the above paragraphs, one of the important features of this invention is that it affords efficacious cooling, i.e. cooling that requires a lesser amount of air. This can be readily seen by referring to FIG. 3 . As shown, the cooling air is admitted through an inlet 66 , the central opening formed in the spar 12 at a bottom face 68 of the attachment 20 , and flows in a straight passage or cavity 70 without having to flow through tortuous paths like a serpentine path. Air that is admitted into cavity 70 flows out of feed holes 72 into a space or cavity 74 defined between the spar 12 and the shell 48 . Again, there are virtually no tortuous passages that are typically found in prior art designs, and hence the pressure drop is decreased requiring lesser amounts of air at a lower pressure, all of which enhances the cooling efficiency of the blade. The air from the feed holes 72 that may be formed integrally in the spar 12 or drilled therein can serve to impinge on the inner wall of the shell 48 but primarily feeds the space 74 . it should be understood that this design can include film cooling holes (as for example holes 71 and 73 ) formed in the shell 48 on both the pressure surface 52 and the suction surface 54 , and may also include a shower head 77 on the trailing edge 58 . the design and number of all these cooling holes (i.e., the shower head, the film cooling holes, feed holes) are predicted on the particular specification of the engine.
Another embodiment is shown in FIGS. 5 and 6 , and is similarly constructed and is adapted to handle a higher rotational speed of the turbine. In this embodiment, a shell 104 that is equivalent to the shell 48 in the first embodiment ( FIGS. 1-4 ) is formed into two halves, an upper halve 106 and a lower halve 108 , and an attachment 110 that is equivalent to the attachment 20 is extended in the longitudinal and upward direction to extend almost midway along the airfoil portion of the blade to form another spar 112 . This spar 112 surrounds the lower portion 114 of spar 12 (like numerals in all figures depict like or similar elements) and is contiguous thereto along its inner surface. A ledge or platen 116 is formed integrally therewith at the top end and extends in the span wise direction. Shell upper halve 106 and shell lower halve 108 are formed in an elliptical-like shape to define the airfoil for defining the pressure surface 52 , the suction surface 54 , the leading edge 56 , and the trailing edge 58 . A groove 115 formed at an upper edge 117 of shell upper halve 106 bears against the outer edge 118 of cap 120 which is the equivalent of cap 16 of the FIGS. 1-4 embodiment except it is a squealer cap. Obviously, when the blade is rotating the shell upper halve 106 is loaded against the cap 120 and this force is transmitted to the disk via the spar 112 and spar 114 . A lower edge 122 bears against the platen 116 and can be suitably attached thereto by a suitable braze or weld. The shell lower halve 108 is similarly formed like the shell upper halve 106 and defines the lower portion of the airfoil. The shell lower halve 108 includes a groove 130 formed in an increased diameter portion 132 of the shell lower halve 108 and serves to receive an outer edge 134 of the platen 116 . A lower edge 136 of the shell lower halve 108 fits into an annular groove 138 formed in the platform 24 . While not shown in these figures, the male and female hooks associated with the spar and shell is also utilized in this embodiment. The stud is like the first embodiment and is affixed to the attachment via a pin 34 .
The cooling arrangement of the second embodiment of FIGS. 5 and 6 is almost identical to the cooling configuration of the first embodiment. the only difference is that since the platen 116 forms a barrier between the shell upper halve 106 and the shell lower halve 108 , the cooling air to the lower portion of the airfoil is directed from the inlet 66 and passage 70 via radially spaced holes 150 consisting of the aligned holes in the spars 112 and 114 that feed space 156 , and holes 152 formed in the upper portion of the spar 112 that feed a space 158 . As is the case with the first embodiment, the shell may include a shower head at the leading edge, cooling passages at the trailing edge, holes at the tip for cooling and discharging dirt and foreign particles in the coolant, and film cooling holes at the surface of the pressure side and the suction side.
The above first and second embodiments of the present invention disclosed a rotary blade having the shell secured to a spar, the spar being secured to rotor disc. In the third, fourth, and fifth embodiments shown in FIGS. 7-9 , the spar and shell construction for an airfoil is used in a stationary vane. The vane in FIG. 7 includes an outer shroud segment 220 and an inner shroud segment 230 with the vane extending between the two shroud segments, as is well known in the prior art. The outer shroud segment 220 includes hooks 224 to secure the outer shroud segment 220 to the casing. The outer shroud segment 220 includes an attachment portion 222 having an opening for a spar 212 . Both the attachment portion 222 and the spar 212 include a hole 234 in which a pin or bolt would be mounted and secured as in the first and second embodiments. The spar 212 and the outer shroud segment 220 are formed as a single piece in this embodiment, and include grooves 290 in which the shell 248 would fit, as in the first two embodiments. A central passageway or cavity 270 supplies the cooling air to cooling holes 272 in the spar 212 and cooling holes 271 in the shell 248 . The inner shroud segment 230 on the spar 212 also includes cooling holes 272 . The principal for securing the shell between grooves in the outer shroud segment and inner shroud segment for the third embodiment is the same as in the first and second embodiments.
The fourth embodiment of the present invention is shown in FIG. 8 and is similar to the third embodiment in FIG. 7 . In the fourth embodiment, the outer shroud 220 and the spar 212 are formed as a single piece, and the inner shroud segment 230 includes the attachment portion 223 having an opening in which the spar 212 passes through. Both the spar 212 and the inner shroud segment 230 includes holes 234 in which a pin or bolt is placed to secure the inner shroud segment 230 to the spar 212 . The outer shroud segment 220 can include a raised portion 225 that formed the attachment portion 220 in the FIG. 7 embodiment in order to provide a strengthened portion on the outer shroud segment to support a load from the spar 212 .
FIG. 9 shows a variation of the vane of the third and fourth embodiments to form the fifth embodiment of the present invention. Here, the outer shroud segment 320 and the inner shroud segment 393 each include an opening in which the spar 312 extends through, and welds 391 to secure the spar 312 to the two shroud segments 320 and 392 . The shell 348 is placed within grooves 390 between the shroud segments prior to welding. As in the previous four embodiments, the spar 312 and the shell 348 each includes cooling holes 372 and 374 for delivering cooling air from a central passageway or cavity 370 to cooling the airfoil. In the fifth embodiment of FIG. 9 , the outer shroud can also, include the hooks like those in FIGS. 7 and 8 to mount the shroud and vane assembly to the casing. The outer shroud can be made of the Molybdenum, while the shell can be made from Molybdenum, Niobium, Ceramic Matrix Composite, or Single Crystal materials. The joint between the inner shroud and the shell is a thermally free joint with a rope seal made from Nextel material which is a continuous ceramic oxide fiber material capable of use in high temperature operating environments.
Although this invention has been shown and described with respect to detailed embodiments thereof, it will be appreciated and understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention.
|
The present invention is a vane for us in a gas turbine engine, in which the vane is made of an exotic, high temperature material that is difficult to machine or cast. The vane includes a shell made from either Molybdenum, Niobium, alloys of Molybdenum or Niobium (Columbium), Oxide Ceramic Matrix Composite (CMC), or SiC—SiC ceramic matrix composite, and is formed from a wire electric discharge process. The shell is positioned in grooves between the outer and inner shrouds, and includes a central passageway within the spar, and forms a cooling fluid passageway between the spar and the shell. Both the spar and the shell include cooling holes to carry cooling fluid from the central passageway to an outer surface of the vane for cooling. This cooling path eliminates a serpentine pathway, and therefore requires less pressure and less amounts of cooling fluid to cool the vane.
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates generally to computer-aided detection. More particularly, the present invention relates to the detection of polyps in the colon.
BACKGROUND
[0002] Colon cancer is the second leading cause of cancer deaths in the United States, with over 100,000 new cases and over 55,000 deaths expected in 2005. Traditionally, the colon surface is examined using colonoscopy, which involves the use of a lit, flexible fiberoptic or video endoscope to detect small lumps on the colon surface called polyps. Polyps are known to be precursors to colon cancer.
[0003] Computed Tomographic Colonography (CTC), under development as a less invasive alternative to colonoscopy, produces 2-d and 3-d images of the colon using computed tomography (CT). In CTC, radiologists examine hundreds of 2-d images and/or 3-d computer graphics renditions of the colonic surface to detect polyps.
[0004] Three-dimensional surface images rendered from an internal perspective (“virtual fly-through” or “virtual colonoscopy”) appear similar to those produced by conventional colonoscopy. However, navigation through a tortuous, complex structure like the colon is challenging and, frequently, portions of the colonic surface may be missed, leading to incomplete examinations. Cylindrical and planar map projections have been proposed to increase the viewable surface during fly-through, but the presentation format is unfamiliar and the physician may still not have a complete view.
[0005] An alternative approach is to mathematically cut the tubular colon surface and lay it out flat for a comprehensive inspection. To do this, planar cross-sections are computed orthogonal to the central path of the colon. The surface is then unfolded using a Polar-to-Cartesian coordinate transformation. However, in high curvature portions of the path, the surface may either be under- or over-sampled, causing surface features to either appear multiple times or be missed completely. Various methods have been proposed to correct for problems caused by non-uniform sampling. However, no matter which method is used, the output is abundant in haustral folds, which occlude polyps and make it difficult for both visual and computer-aided detection of polyps. Accordingly, there is a need in the art to develop a method of unfolding a 3-dimensional image of the colon surface that allows for uniform sampling, attenuates haustral folds, and preserves polyps.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method of unfolding a medical image. With this method, a medical image is deformed to straighten and flatten folds but not polyps, thus allowing polyps to be identified. In a first step, a 3-dimensional deformable model of the medical image is constructed. This model is set to have a high Young's modulus and a low Poisson's ratio. Preferably, the value for Young's modulus is set to be greater than about 40,000 and the value for Poisson's ratio is set to be less than about 1×10 −10 . More preferably, the value for Young's modulus is set to be in a range from about 40,000 to about 60,000 and the value for Possion's ratio is set to be in a range from about 1×10 −12 to 1×10 −10 . In a preferred embodiment, the model is a continuum surface model, preferably a quasistatic continuum finite element model. Once the model has been constructed, it is deformed such that folds are removed but polyps remain, allowing polyps to be identified. Polyps may be identified either manually or with computer-aided detection.
[0007] Any type of medical image may be used according to the invention, including but not limited to computed tomographic images and magnetic resonance images. In a preferred embodiment, the medical images are from computed tomographic colonoscopy, the folds are colonic folds, and the polyps are colonic polyps.
BRIEF DESCRIPTION OF THE FIGURES
[0008] The present invention together with its objectives and advantages will be understood by reading the following description in conjunction with the drawings, in which:
[0009] FIG. 1 shows examples of unfolding phantoms and actual patient data according to the method of the present invention;
[0010] FIG. 2 illustrates the importance of neglecting inertial effects when unfolding models according to the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The present invention provides a method of unfolding medical images by deforming a deformable model based on these images. Preferably, the method starts with creating a triangulated mesh isosurface at the air-mucosa boundary from the image data. Any desired meshing scheme may be used for this purpose. A physics-based model is then imparted to the mesh to physically manipulate it. In a preferred embodiment, a finite element model is used. To construct an FEM model, constitutive equations are written for the mesh material, which describe the relationship between strain (deformation measure) and stress (internal forces). The forces at the mesh nodes are then computed using a discretized version of the constitutive equations.
[0012] To flatten folds but not polyps, it is desirable for the mesh material to be soft under small strains, but become very stiff under large strain conditions. A nonlinear elasticity model is preferred over a linear elasticity model for this purpose due to the large deformations required. A preferred model is a neo-hookean elasticity model.
[0013] Two important material properties, Young's modulus and Poisson's ratio, need to be set to obtain a model in which deformation causes unfolding of folds without distortion of polyps. Young's modulus is the ratio of longitudinal stress to longitudinal strain (with a force applied in the longitudinal direction), and represents the stiffness of the mesh material. The value of Young's modulus is preferably set to a high value, preferably larger than 40,000, more preferably between 40,000 and 60,000, and most preferably 50,000. A high Young's modulus value causes the mesh material to be stiff enough to allow folds to flatten while polyps remain undistorted. Poisson's ratio is the ratio of axial strain to longitudinal strain in response to a longitudinal stretching force which, in all common materials, causes them to become narrower in cross-section while being stretched. To minimize this contraction, Poisson's ratio should be set to a very small positive number, preferably less than about 1×10 −10 , more preferably between about 1×10 −12 and 1×10 −10 .
[0014] The deformation may be any type of deformation but is preferably stretching. Preferably, to simulate stretching of the surface, external forces are applied to the ends of the mesh material. Positions of mesh nodes are then computed at each step of the simulation. The new positions of the mesh nodes are a function of internal forces, which are computed using the constitutive equations and surface deformation model described above.
[0015] In a preferred method, the triangulated mesh material is treated as a particle system. Each node in the mesh is modeled as a particle, having mass, position, velocity, and zero spatial extent, that can respond to various forces.
[0016] The motion of a single particle is described by Newton's second law using
[0000] f=ma.
[0017] Since a=dv/dt and v=dx/dt, this second order equation may be broken down into two first order equations:
[0000]
dx/dt=v
[0000]
dv/dt=f/m,
[0000] where x, v, and f are 3-vectors and denote the position, velocity and force at a single node in the mesh.
[0018] To describe the evolution of a complete deformable surface, the positions, velocities and aggregate forces of all the nodes in the mesh are concatenated into single n-vectors, where n is the number of nodes in the mesh. Thus,
[0000]
dx/dt=v
[0000] dv/dt=M −1 f ( t,x,v )
[0000] where M represents the diagonal mass matrix.
[0019] The force f at each node is the sum of the internal and external forces acting on that node. The external forces are the user-supplied time varying input to the system. Preferably, the external forces are pulling forces applied to the ends of the surface being stretched. Internal forces represent the resistance of the material to the external forces applied.
[0020] In a preferred embodiment, the response of the model to deformation is spatially invariant. Otherwise, polyps located at different spatial locations will be distorted by different amounts. This can be accomplished by using a continuum surface model. Preferably, it is assumed that the mesh has zero mass, thus giving rise to zero acceleration. This assumption is called the quasistatic assumption, since it neglects inertial effects and solves for static equilibrium at each time step. Thus, in a preferred embodiment, a quasistatic continuum finite element model is used.
[0021] If inertial effects are neglected, such that a system has zero acceleration and zero mass,
[0000] f ( t,x,v )=0.
[0022] The quasistatic assumption satisfies this equation by enforcing force equilibrium at every time step, implying
[0000] f ( x k+1 )= f ( x k +Δx k )=0.
[0023] Therefore, at every time step, a linear system must be solved. Preferably, the Newton-Raphson solver is used,
[0000]
f
(
x
k
+
Δ
x
k
)
≈
f
(
x
k
)
+
Δ
x
k
∂
f
∂
x
|
x
k
=
0.
[0024] One can then compute the new nodal positions x k+1 =x k +Δx k , by computing Δx k from,
[0000]
-
Δ
x
k
∂
f
∂
x
|
x
k
=
f
(
x
k
)
.
[0025] Note that at every time step, it is necessary to invert the global stiffness matrix
[0000]
∂
f
∂
x
,
[0000] which is constructed from the contributions of the element stiffness matrices that account for contributions from the individual triangles.
[0026] To tie the stiffness matrix
[0000]
∂
f
∂
x
[0000] to the constitutive model of the material, note that the constitutive model, which typically relates stress to strain, can also be expressed as a relationship between force and strain energy. So,
[0000]
f
=
-
∂
ψ
∂
x
[0000] where ψ denotes the strain energy.
EXAMPLES
[0027] FIG. 1 shows examples of results from deforming phantom and actual patient data that were modeled using the above-described quasistatic continuum finite element model. Each row shows steps in the deformation of a model derived from phantom or actual patient image data. We created mathematical phantoms using MATLAB 7.0.1, with folds and polyps modeled as half sine functions and hemispheres, respectively. FIG. 1( a ), ( b ), and ( c ) shows a phantom 100 with a polyp 102 on a flat portion in addition to a polyp 104 on top of a fold 106 . FIG. 1( d ), ( e ), and ( f ) shows a phantom 110 with a polyp 112 on a flat portion as well as a polyp 114 on the side of a fold 116 . FIG. 1( g ), ( h ), and ( i ) show a subvolume 120 of actual patient data being stretched. For each case, we measured the curvature and size of polyps (diameters) and folds (height) before and after simulated stretching.
[0028] For the phantom in FIG. 1( a - c ), the height and curvature of the fold 106 were reduced by 70% and 86.1%, respectively. The polyp 104 on top of the fold 106 was distorted in the stretch direction causing an increase in its maximum width by 16%, and a decrease of 20.2% in its maximum curvature. The size and the curvature of the polyp 102 on the surface remained unchanged. The phantom in FIG. 1( d - f ) has polyps on the surface ( 112 ) and on the side ( 114 ) of the fold 116 . The height and curvature of the fold 116 were reduced by 70.3% and 73.5%, respectively. The sizes and curvatures of both polyps remained unchanged.
[0029] FIG. 1( g - i ) shows stretching of a subvolume 120 of actual patient data, acquired during a computed tomographic colonography (CTC) scan, containing a 6.9 mm polyp. The height and curvature of fold 126 were attenuated by 54.4% and 36.3%, respectively. The polyp 122 was distorted in the stretch direction causing an increase of 10% in its maximum width, and a decrease of 10% in its maximum curvature.
[0030] FIG. 2 illustrates the importance of the quasistatic assumption on the unfolding simulation. In FIG. 2 , single time points are compared in the simulated stretching of a phantom with polyps and folds, with inertial effects neglected in FIG. 2( a ), but not in FIG. 2( b ). If inertial effects are neglected ( FIG. 2( a )), polyps 202 , 204 , 206 , and 208 are all distorted by the same amount. If inertial effects are not neglected, polyps at different spatial locations are distorted by different amounts, as shown in FIG. 2( b ). Specifically, if the phantom is stretched by pulling at edges 210 , polyps 202 and 208 , which are near edges 210 , are distorted more than polyps 204 and 206 , which are farther away from edges 210 .
[0031] Although the present invention and its advantages have been described in detail, it should be understood that the present invention is not limited by what is shown or described herein. As one of ordinary skill in the art will appreciate, the unfolding methods disclosed herein could vary or be otherwise modified without departing from the principles of the present invention. Accordingly, the scope of the present invention should be determined by the following claims and their legal equivalents.
|
A method of selectively removing folds in a medical image is provided. With this method, a medical image is deformed to straighten and flatten folds but not polyps, thus allowing polyps to be identified. In a first step, a 3-dimensional deformable model of the medical image is constructed. This model is set to have a high Young's modulus and a low Poisson's ratio. In a preferred embodiment, the model is a continuum surface model, preferably a quasistatic continuum finite element model. Once the model has been constructed, it is deformed such that folds are removed but polyps remain, allowing polyps to be identified.
| 6
|
The present invention relates to a device for delivering defined volumes, particularly defined small volumes for use in microscaled analytical or synthetic processes.
A number of related applications have been filed on liquid dispensing systems that use electrode-based pumps including U.S. Pat. No. 5,585,069 (Dkt. No. 11402), U.S. Pat. No. 5,593,838 (Dkt. No. 11402A); Ser. No. 08/454,771, filed May 31, 1995 (Dkt. No. 11402B); U.S. Pat. No. 5,643,738 (Dkt. No. 11402C); U.S. Pat. No. 5,681,484 (Dkt. No. 11402D); (application Ser. No. 08/454,772, filed May 31, 1995, now abandoned; U.S. application Ser. No. 08/454,768, filed May 31, 1995 (Dkt. No. 11402F); U.S. Pat. No. 5,846,396 (application Ser. No. 08/556,036, filed May 31, 1995, Dkt. No. 11402G); U.S. Pat. No. 5,632,876 (Dkt. No. 11717); U.S. application Ser. No. 08/556,423, Nov. 9, 1995 (Dkt. No. 11717A); U.S. application Ser. No. 08/645,966, May 10, 1996 (Dkt. No. 11717B); U.S. Pat. No. 5,603,Dkt. No. 11740); and U.S. application Ser. No. 08/744,386, Nov. 7, 1996 (Dkt. No. 12385A). These patents and applications are hereby incorporated herein by reference in their entirety.
The invention addresses the problem of distributing metered volumes of liquids to a multiplicity of micro-scaled sites such as reaction sites. The invention provides an inexpensive device for distributing multiple small volumes.
Systems are being developed that allow for complex chemistries or other mixing processes to be conducted at large number of sites--for example 100, 1,000 or 10,000 sites--in a relatively small device. Some of the applications for such high density devices for relaying liquids do not require precise metering of the liquids dispensed into a particular site. Other applications, however, place a greater premium on precise metering mixing. In many cases, precise metering is only needed in limited parts of the process, while other parts of the process may only need reliable but less precise pumping of liquid. The high precision device of the present invention, in a preferred embodiment, allows a receiving substrate to be attached to inject metered amounts of liquid to defined positions of the receiving substrate. Several reagents can be dispensed in sequence through this device by clearing the used channels by appropriate use of purging gas or vacuum. The receiving substrate can also be transferred to another device where other liquids, which may or may not be metered, can be added to the defined positions.
SUMMARY OF THE INVENTION
In one embodiment, the invention provides a liquid dispensing device for delivering defined volumes of a liquid, the device comprising: (a) a reagent fill channel; (b) one or more metering capillaries connected to the reagent fill channel and having an exit; and (c) one or more sources of gas connected to the reagent fill channel, wherein after filling the metering capillaries the reagent fill channel can be drained of liquid while liquid is retained in the one or more metering capillaries, and the source of gas can be operated to eject the liquid in the one or more metering capillaries. Preferably, the device has two or more said reagent fill channels connected to the one or more metering capillaries, wherein the liquid dispensing device is adapted to dispense via separate reagent fill channels two or more different reagents. Preferably, the device further comprises, in the reagent fill channel, two or more connections to gas sources, where two or more of the gas sources can be connected to separate gas sources. In an embodiment, the device further comprises a controller for sequentially activating the gas sources to sequentially and linearly pressurize segments of the reagent fill channel.
In another embodiment, the invention provides an aliquoting apparatus comprising: (1) a first liquid dispensing device as described in the preceding paragraph and a second liquid dispensing device (which can be distinct from the above described device); and (2) a transfer device (preferably motorized) for moving a receiving substrate from the first liquid dispensing device to the second liquid dispensing device, wherein the receiving substrate receives liquids ejected from the first or second liquid dispensing devices. The second device can be, for example, a liquid distribution device such as is described in U.S. Pat. No. 5,846,396 (application Ser. No. 08/556,036, filed May 31, 1995, Dkt. No. 11402G). Preferably, the aliquoting apparatus having the first and second liquid dispensing devices comprise mechanical, magnetic, electrical or optical alignment markers and the apparatus is adapted to operate with receiving substrates having mechanical magnetic, electrical or optical alignment markers. Preferably, the aliquoting apparatus further comprises an alignment detection device for determining the relationship between the alignment markers on either the first or second liquid dispensing system and the alignment markers on a receiving substrate and producing corresponding alignment data; and a controller for receiving alignment data from the alignment detection device and operating the motorized transfer device to improve the alignment data.
In still another embodiment, the invention provides a method of dispensing two or more liquids into two or more mixing sites on a receiving substrate comprising: (i) providing a first and a second liquid dispensing device of the invention with the receiving substrate aligned with the first liquid dispensing device; (ii) dispensing, from the first liquid dispensing device, a first liquid to the mixing sites; (iii) moving the receiving substrate to align with the second liquid dispensing device; and (iv) dispensing, from the second liquid dispensing device, a second liquid to the mixing sites. In another option, the invention provides a method of dispensing two or more liquids into two or more mixing sites on a receiving substrate comprising: (i) providing a liquid dispensing device of claim 1, with the receiving substrate aligned therewith; (ii) dispensing, from the liquid dispensing device, a first liquid to the two or more mixing sites; (iii) filling one or more reagent fill channels of the liquid distribution device with a second liquid; and (iv) dispensing from the liquid dispensing device the second liquid to the two or more mixing sites.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a three-dimensional representation of a liquid dispensing device 90A while FIG. 1B shows a liquid dispensing device 90B that further includes a reagent sink channel 17.
FIGS. 2A, 2B and 2C show cross-sectional representations of the liquid dispensing device 90 at various stages of operation.
FIGS. 3A, 3B and 3C show the dispensing device as in FIG. 2 but without mesas at the top or bottom of metering capillaries.
FIG. 4 shows a structural representation of the interior of a liquid dispensing device when viewed from below.
FIG. 5 shows a structural representation of the interior of the liquid dispensing device of FIG. 4 when viewed from a side of the long axis of a reagent fill channel, as indicated in FIG. 4.
FIG. 6 shows a structural representation of the interior of the liquid dispensing device of FIG. 4 when viewed from a side of the long axis of the gas pulse channel, as indicated in FIG. 4.
FIG. 7 shows a schematic top view of a liquid dispensing device for supplying reagents to a 864-well plate.
FIG. 8 shows a schematic top view of a liquid dispensing device for supplying reagents to a 3456-well plate.
FIG. 9 shows an example of a liquid dispensing device.
FIG. 10 shows a schematic diagram of assay plate to show the location of control wells and reaction wells, and the relation of the assay plate to a synthesis plate on which compounds can be synthesized by a combinatorial process.
FIG. 11 shows a structural representation of the interior of a liquid dispensing device when viewed from a side of the long axis of a gas pulse channel and a reagent fill channel of the liquid dispensing device.
FIG. 12 shows a structural representation of the interior of the liquid dispensing device of FIG. 11 when viewed from a side looking into the the gas pulse channel and the reagent fill channel of the liquid dispensing device.
FIG. 13A shows a top view of a mesa having an outlet of a metering channel.
FIG. 13B shows an oblique view of four such mesas.
FIG. 13C shows a side view of such a mesa.
DEFINITIONS
The following terms shall have, for the purposes of this application, the meaning set forth below. In particular, for the purpose of interpreting the claims, the term definitions shall control over any assertion of a contrary meaning based on other text found herein:
capillary dimensions
"Capillary dimensions" are dimensions that favor capillary flow of a liquid. Typically, channels of capillary dimensions are no wider than about 1.5 mm. Preferably channels are no wider than about 500 μm, yet more preferably no wider than about 250 μm, still more preferably no wider than about 150 μm.
capillary barrier
A "capillary barrier" is a barrier to fluid flow in a channel comprising an opening of the channel into a larger space designed to favor the formation, by liquid in the channel, of an energy minimizing liquid surface such as a meniscus at the opening.
mesa
A "mesa" is a protrusion on which the entrance or exit of a metering capillary is located. Preferably, the mesa serves to reduce the surface area adjacent to the entrance or exit at which a liquid can be retained by a wetting phenomenon.
metering capillaries
A "metering capillary" is a channel designed to fill to a known amount of liquid, which amount can then be dispensed with gas pressure.
DETAILED DESCRIPTION OF THE INVENTION
Described elsewhere in co-pending patent applications, such as U.S. Pat. No. 5,846,396 (Ser. No. 08/556,036, filed May 31, 1995, Dkt. No. 11402G), and U.S. application Ser. No. 08/744,386, filed Nov. 7, 1996, (Dkt. No. 12385A) are small-scaled liquid dispensing systems that allow the distribution of liquids to a large number of sites, such as 10,000 sites arrayed on a 4×4 inch glass plate. These devices are useful for example in combinatorial synthesis procedures. The present invention provides additional tools for distributing liquids to small, closely spaced sites.
In FIG. 1A is shown a three-dimensional representation of a liquid dispensing device 90A Solid arrows in the illustration indicate the direction of liquid flow and hollow arrows indicate the direction of gas flow for fluid transfer. Liquid is introduced from a source (not shown) into reagent fill channel 12 through a reagent feed inlet 11. Excess liquid in the reagent fill channels drains through the excess fluid outlet 13. The outlet can connect with a reagent sink channel which can provide a channel of capillary dimensions to enhance capillary flow through the liquid dispensing device 90A. FIG. 1B shows a liquid dispensing device 90B with a reagent sink channel 17. The liquid flow can be the result of capillary flow processes or can be the result of pumping. In flowing through the reagent fill channel 12, liquid enters and fills a series of metering capillaries 14, for example first metering capillary 14A, second metering capillary 14B and third metering capillary 14C. Capillary barriers formed at the exits of the metering capillaries can prevent premature ejection of the liquid from the metering capillaries 14. The dimensions of reagent sink channel can be selected to promote capillary flow through the channel and thereby through reagent fill channel 12, or, in the case where flow into the reagent fill channel is promoted by a pump, the dimensions are selected so that excess pressure is relieved by liquid flow from the reagent fill channel 12 to the excess fluid outlet 13, where such excess pressure might otherwise cause liquid to be ejected from the metering capillaries 14.
FIGS. 2A-2C illustrate the liquid dispensing device 90 formed in a substrate made of three layers of material, namely first layer 21, second layer 22 and third layer 23. The first layer 21 has gas pulse channels 40 and gas pulse feeders 41 leading into the second layer. The second layer 22 has reagent fill channels 12 leading into the structures in the third layer 23. The third layer 23 has metering capillaries 14 with inlets in communication with reagent fill channels 12 in the reagent distribution plate 22 and outlets.
The reagent fill channel 12 is preferably of dimensions that are large enough so that capillary forces do not inhibit draining of the reagent fill channel. Drainage can be enhanced by constructing a second layer 22 of a material that does not wet on contact with the liquids sought to be dispensed. Methods of forming thin, non-wetting coatings of perfluoroalkanes are described in Datta et al., U.S. Pat. No. 4,252,848. Alternatively, the surface energy of a surface of a reagent fill channel can be reduced by coating the surface with a silicone resin or a fluorine-containing resin, thereby reducing wetting. Such resins are described in Mochizuki et al., U.S. Pat. No. 5,652,079. The sides of the reagent fill channel 12 can also be rendered resistant to wetting, for instance, by reacting the surfaces with a reactive organo silane reagent such as SigmCote™, (Sigma Chemical Co., St. Louis, Mo.), dichlorooctamethylsiloxane (C 2 H 24 Si 4 O 3 Cl 2 , Surfa-Sil™, Pierce Chemical, Rockford, Ill.) or modified organo silane such as an octadecyltrialkoxysilane (Aqua-Sil™, Pierce Chemical, Rockford, Ill.).
FIGS. 2A-2C also illustrate an assay plate 30, located below the capillary metering plate 23 with reaction wells 31 of the assay plate aligned with the outlets of the metering capillaries 14. The assay plate can be aligned with capillary metering plate such that the outlets of the metering capillaries open into the corresponding wells in the assay plate. The wells in the assay plate can be used, for example, to conduct assays, syntheses or other chemical processes. The assays may include, for example, tests for inhibitors, inducers or activators of chemical processes such as biological signal transduction reactions, or tests for the presence of a substance such as an immuno-assay, a hybridization assay, or a nucleic acid amplification assay.
The exemplified assay plate 30 can be reversibly and sealably attached to the third layer 23 to form a liquid tight seal, for instance by the use of the seals described in U.S. application Ser. No. 08/744,386, filed Nov. 7, 1996, now abandoned, (Dkt. No. 12385A) and U.S. application Ser. No. 08/630,018, filed Apr. 9, 1996 now U.S. Pat. No. 5,840,256 (Dkt. No. 12098). A gasket may be placed between third layer and the assay plate as described in U.S. application Ser. No. 08/556,036, filed May 31, 1995 (Dkt. No. 11402G) and U.S. Pat. No. 5,840,256 (application Ser. No. 08/630,018, filed Apr. 9, 1996, Dkt. No. 12098). (This latter patent is hereby incorporated by reference in its entirety.) In the illustration, vents 32 are formed adjacent to reactions wells 31. The vents 32 prevent back pressure from interfering in the dispensing of liquids.
Illustrated in FIGS. 2A-2C is the operation of the liquid dispensing device 90A. In FIG. 2A, the reagent fill channel 12 has been filled with liquid, resulting in metering capillaries 14 also being filled. Liquid flow into the reagent fill channel 12 is then curtailed and liquid is drained from the reagent fill channel 12, for example by capillary flow or through the use of gas pressure, so long as the pressure is less than that effective to eject liquid from the metering capillaries. The draining of the reagent fill channel 12 leaves the metering capillaries 14 filled with liquid, as illustrated in FIG. 2B. A pulse of gas can be applied to a gas pulse channel 40 (a portion of which is shown) with sufficient pressure to inject gas, by way of gas pulse feeder 41, into reagant fill channel 12 to cause the metered fluid 50 in the metering capillaries 14 to be ejected into the corresponding wells 31, as illustrated in FIG. 2C. If necessary, gas-flow through the excess fluid outlet 13 can be blocked to maintain the pressure causing fluid ejection from the metering capillaries 14. However, the gas outlet pathways can be sufficiently constricted to allow the formation of sufficient pressure. The dimensions of the metering capillaries 14 and the locations of gas pulse 41 feeders are selected so that the ejection of liquid from a subset does not sufficiently relieve the gas pressure to prematurely end the liquid ejection process.
In one embodiment, the structures housing the metering capillaries 14 as illustrated in FIGS. 2A-2C can protrude into the reagent fill channel 12 and away from the bulk of the flat surfaces of the lower surface of third layer 23 forming upper mesas 15 and lower mesas 16. The upper mesas 15 of the metering capillaries 14 protrude into the reagent fill channel 12 and thereby minimize the amounts of residual liquid in the reagent fill channel that can be inadvertently ejected by gas pressure. The lower mesas 16 minimize the amount of fluid diverted to flow along the bottom surface of the third layer 23. The upper and lower mesas as shown in the illustration are labeled "upper" and "lower" only for a matter of convenience. In some embodiments, mesas can be designed to have differing orientations.
In another embodiment illustrated in FIGS. 3A-3C, a liquid dispensing device 190 also has the first layer 121, second layer 122 and third layer 123 like that of the liquid dispensing device 90A shown in FIGS. 2A-2C. The three layers of the liquid dispensing device 190 also have their component structures as in FIGS. 2A-2C such as gas pulse channel 140, gas pulse feeder 141, reagent fill channel 112, metering capillaries 114. Assay plate 130 with reaction wells 131 can be reversibly attached to the liquid dispensing device. However, the third layer ("capillary metering plate") 123 housing the metering capillaries 114 illustrated in FIGS. 3A-3C does not form mesas. The three panels, 3A, 3B and 3C illustrate a dispensing liquid 150.
In some embodiments, the surface areas surrounding the inlets and outlets of metering capillaries (e.g., 14 or 114) are not susceptible to wetting. For example, these areas can be treated with a reagent that modifies the surface wetting properties of the surface material.
FIGS. 4-6 represent schematic drawings of a liquid dispensing device 290 with assay plate attached as viewed from different angles to show relative positions of various structures and their relationship to each other. FIG. 4 is a schematic drawing of the liquid dispensing device with assay plate attached when viewed from the bottom. FIG. 5 is a schematic drawing of the liquid dispensing device 290 with assay plate 230 mounted on a fixture platen 201, where the liquid dispensing device 290 is viewed from the side of the long axis of the reagent fill channel 212. FIG. 6 is a schematic drawing of the liquid dispensing device with assay plate 230 mounted on a fixture platen 201 when the liquid dispensing device 290 is viewed from the side of the long axis of the gas pulse channel 240. FIGS. 5 and 6 also show the three layers, the first layer 221, second layer 222, and third layer 223 of the liquid dispensing device 290. In one embodiment, gas pulse channels 240 are arranged at right angles to the reagent fill channels 212. Gas pulse feeders 241 connect the gas pulse channels 240 and the reagent fill channels 212 to deliver gas into the latter.
Each well 231 in the assay plate has a vent 232 as can be seen in FIG. 6 to serve as an outlet for excess gas or liquid during operation of the liquid dispensing device or to provide an outlet for solutions during rinsing process. The fixture platen 201 on which the liquid dispensing device 290 with the assay plate 230 is mounted can have vent slots for venting fluids from the vents 232.
In the illustrated embodiment, reagent fill channel 212 has one or more reagent feed inlets 211 and one or more excess fluid outlets 213 (shown in FIG. 5). The excess fluid outlets 213 can be adapted to be connected to a vacuum source to evacuate liquid in the liquid dispensing device 290. For example, the liquid evacuation channels 213 connected to a vacuum source can be used to rapidly and evenly dry the liquid dispensing device 290 after each operation or rinsing of the liquid dispensing device. In the illustration, the gas pulse channels 240 are arrayed above the reagent fill channels 212, but this like other illustrated features is not a requirement; other design choices will be apparent to those of ordinary skill having benefit of this disclosure.
FIGS. 4 and 5 also include dimensions used in one embodiment However, the dimensions and relative positions can be varied so as to adapt to a given dispensing system and receiving substrate. In this embodiment, the dimensions of each gas pulse channel 240 in the first layer 221 are 450 μm wide by 150 μm deep. Similarly the reagent fill channels 212 in the second layer 222 are 300 μm wide by 100 μm deep. The metering capillaries 214 in the third layer 223 have a uniform length of 2.0 mm and a uniform diameter of 270 μm (which is, for example, 2 mm in length). The diameter of the gas pulse feeder 241 is 25 μm. In preferred embodiments, the size of this gas pulse feeder 241 is selected to minimize liquid flow into the gas pulse channels 240. The size of the each of the reaction wells 231 in the assay plate 230 is 1 mm by 1 mm by 0.3 mm, and pitch between wells is 1.5 mm. Another illustrative embodiment has 1.5 mm by 1.5 mm by 0.3 mm reaction wells. In some embodiments, the size of the reaction wells is selected to allow collection of all effluent from a cleavage step conducted in reaction cells of a liquid distribution system such as is described in U.S. Pat. No. 5,480,256 (Dkt. No. 11402G). Such cleavages preferably cleave a synthetic product from a solid support such as beads.
One aspect of the present invention is the use of an aliquoting apparatus having two or more liquid dispensing devices each with a specific capacity (i.e., volume dispensed per ejection into a well) liquid dispensing system and one or more receiving substrates. In one embodiment, for example, a first liquid dispensing device 390 has numerous reagent fill channels 312 (solid lines) and gas pulse channels 340 (dotted lines) designed to dispense into 864 wells as shown in FIG. 7. First gas pulse channel 340A, second gas pulse channel 340B, third gas pulse channel 340C, and fourth gas pulse channel 340D are specifically identified in the Figure. First alpha reagent fill channel 312A1, second alpha reagent fill channel 312A2 and third alpha reagent fill channel 312A3 are also specifically identified. Each such set of three reagent fill channels 312 is fed by a reagent fill inlet 311, such as first reagent fill inlet 311A, second reagent fill inlet 311B, and third reagent fill inlet 311C. The same triplets of reagent fill channels 312 are evacuated by excess fluid outlets 313, such as first excess fluid outlet 313A, second excess fluid outlet 313B, and third excess fluid outlet 313C. Note that the excess fluid outlets can flow upwards, instead of downwards as illustrated earlier, since negative pressure or a capillary flow system can be used to draw the excess liquid out of the reagent fill channels. In this embodiment, for example, the pitch between wells can be for example about 3 mm, such that the illustrated liquid dispensing system dispenses liquid to about 864 wells in an assay plate located on 4.5 inch by 3 inch substrate.
In another embodiment, for example, a second liquid dispensing device 490 has numerous reagent fill channels 412 (solid lines) and gas pulse channels 440 (dotted lines) designed to dispense into 3456 wells as shown in FIG. 8. In this embodiment, for example, the pitch between wells is for example 1.5 mm, such that the illustrated liquid dispensing system dispenses liquid to about 3456 wells in an assay plate located on a 4.5 inch by 3 inch substrate. The illustrated liquid dispensing device 490 has first control reagent fill channels 461, second control reagent fill channels 462, and third control reagent fill channels 463, along with the more numerous sample reagent fill channels 412 and gas pulse channels 440. The control wells into which the control reagents are injected can be used to conduct different reaction controls, for instance, controls without test sample. For example, in an enzyme assay testing inhibitory effect of potential inhibitors on the enzyme, the first control reagent fill channels may dispense liquids with no test sample but with all other assay reagents including the enzyme, the second control reagent fill channels may dispense no test sample but with all other assay reagents plus a known inhibitor, and the third control reagent fill channel may dispense no test sample and no enzyme but with all other assay reagents. The sample reagent fill channels can be used to dispense liquids with all the ingredients such as the test sample, the enzyme, the inhibitor and all other assay reagents required to test for inhibition of the activity.
In another aspect, gas is delivered to gas pulse channels of the liquid dispensing devices 390 and 490 in a sequential fashion starting with the first gas pulse channel and then the second gas pulse channel, and so on, which results in gas pressure being sequentially received at a reagent fill channel at a first gas pulse feeder, a second gas pulse feeder, a third gas pulse feeder, etc. This sequential fashion can be termed "linearly" pressurizing segments of a reagent fill channel. Linear pressurization can proceed in one or both directions from a starting point in a reagent fill channel. In the liquid dispensing device 390, for example, gas pressure is sequentially delivered to a first gas pulse channel 340A, then a second gas pulse channel 340B, a third gas pulse channel 340C, and so on.
To control the delivery of gas an electronic controller such as an electrical processor can be used, for example in connection with electromechanical devices like switches, solenoids and the like. Remotely operated electromechanical devices can be used to open and close valves connected to the gas sources.
In FIG. 8, the liquid dispensing device 490 has gas pulse channels at two levels in the substrate so that gas can be delivered to sample reagent fill channels 412 and first and second control reagent fill channels 461 and 462 through gas pulse channels 440 (shown as dotted lines) formed in one level of the first layer while gas can be delivered to the perpendicularly oriented third control reagent fill channels 463 through gas pulse channels formed in a second level of the first layer.
The liquid dispensing device 590 of FIG. 9 is described below in Example 1.
For illustrative purposes, FIG. 10 shows two kinds of receiving substrates such as reaction plate composite 600 and assay plate 700. Reaction plate composite is made up of six reaction plates 601. Reaction plate composite 600 has evenly sectored reaction wells 631, the sectors separated by junction seams 634. Likewise, the assay plate 700 also has evenly sectored reaction wells 731. The reaction wells of the assay plate 700 map directly with the reaction wells of the reaction plate composite 600 but the portions of assay plate 700 that would map to the junction seams 634 of the reaction plate composite 600 are instead filled with control wells 733.
For example, the reaction plate composite 600 can be the plate composite on which a combinatorial array of test compounds was synthesized, for example, using the liquid distribution systems of U.S. Pat. No. 5,846,396 (application Ser. No. 08/556,036 filed May 31, 1995, Dkt. No. 11402G) or application Ser. No. 08/744,386, filed Nov. 9, 1996, now abandoned, (Dkt. No. 12385A). Or, the reaction plate composite 600 can be a replica plate matching the product outputs of a combinational synthesis. The junction seams 634 match, for example, the areas of a preferred liquid distribution system that are used for ancillary functions such as gas or liquid feed lines. This extra space can be taken advantage of to disperse control wells within the assay plate 700.
In an enzyme assay, for example, the different types of reagents that are required, in the assay plate 700 wells to conduct the assay, can be added from a single first liquid dispensing device. Or, the assay plate 700 can be transported, by hand or by means of a motorized transfer device such as a robot, to a second liquid dispensing device to add different reagents.
In one embodiment, a first liquid dispensing device 390 with the dispensing system illustrated in FIG. 7 is used to dispense solvents such as DMSO (Dimethylsulfoxide) into an alpha assay plate of 864 wells to dissolve chemicals (such as the products of a combinatorial process) used in an assay with the chemicals or reagents of the 864 wells dissolved. Pin devices such as the Biomek High Density Replicating Tool sold by Beckman Instruments, Fullerton, Calif. can be used to copy the 864 wells onto 1/4th of the wells in a beta assay plate having 3456 wells (situated with 1/2 the cell pitch used with the alpha plate). Reagents from three additional alpha assay plates can be used to load unique reagents into the rest of 3/4 of the wells of the beta assay plate. The beta assay plate can be transferred to a second dispensing device 490 with sample and control reagent fill channels as illustrated in FIG. 8 for further dispensing as required to complete an assay with different controls.
Given the small volumes involved, in some embodiments care is taken to assure mixing of separate fluids added to a well. For example, a plate 490 can be subjected to ultrasonic vibration to assure mixing.
Another liquid dispensing device 890 (FIGS. 11 and 12) is similar to that of the liquid dispensing device 290 described above. The liquid dispensing device 890 also has the first layer 821, second layer 822 and third layer 823. The three layers of the liquid dispensing device also have their component structures such as gas pulse feeders 841 connecting the gas pulse channels 840 and the reagent fill channels 812, reagent feed inlets 811, excess fluid outlets 813, and metering capillaries 214. The component structures of assay plate 830 include one or more wells 831, and each well in turn having a vent 832. These features, further including fixture platen 801, function analogously to those described in FIGS. 4-6, except that the gas pulse channels 840 and reagent fill channels 812 are aligned in parallel.
The embodiment in which the gas pulse channels are parallel to the reagent fill channels is particularly preferred when one wishes to dispense in sequential rows from the metering capillaries. The gas pulse channels are located directly above (or below) the reagent fill channels. When a pulse of gas is introduced into one of the gas pulse channels, dispensing occurs in an entire row of metering capillaries. By sequentially stepping the pulsed gas from one row to another the assay plate receives the reagent in a row-scan fashion until the plate is entirely addressed. This embodiment is desirable for the following reasons: (1) it can reduce the complexity of the off-chip reagent supply system, (2) it can reduce the complexity of the detection system, especially for instrumentation for kinetic assays.
In operation, a device of the invention can, for example, deliver a 8 nL volume (with a metering capillary channel of diameter=100 μm and length=1.0 mm), a 46 nL volume (with a metering capillary channel of diameter=200 μm and length=1.5 mm), or a 42 nL volume (with example a metering capillary channel of diameter=300 μm and length=2.0 mm) to multiple sites. In the case of the first example of a 8 nL metering channel, it is anticipated that a feed volume of about 200 μL to about 300 μL can be used to deliver this volume to each of 3,456 wells. The depth of each well is, in one preferred embodiment, no greater than 300 μm (and holds, for example, a 300 nL volume). Where appropriate to the application, liquid flowing through the excess fluid outlet can be recycled.
It will be recognized that the liquid dispensing device can be manufactured to adapt to the viscosity, capillary flow and other physico-chemical properties of a class of liquids, such as aqueous solutions or non-aqueous solutions. For example, a particular design might be appropriate for dispensing aqueous solutions and ethanol solutions, while another design taking into account the low viscosity and surface tension of the distribution channels can be used for dispensing other organic solutions.
Materials to fabricate the liquid dispensing device can be chosen from group resistant to the chemicals used for distribution and assaying. A preferred material is amenable to micro-fabrication, etching and replication (for example molding plastic replica plates). The layers of the liquid dispensing device are, for example, formed of a material that can be chemically etched, reactive ion etched, laser drilled or replicated from molds or tools made from these processes to form the needed structures, such as glass, quartz, silicon, doped silicon, or polymers in the case of replication. The replicated layers are formed of a moldable plastic such as polypropylene, polystyrene or Teflon™ (tetrafluoroethylene polymer). Preferred materials used for assay plates can be plastics such as polypropylene or Teflon™. Preferably, the thickness of the plates or layers making up the device is from about 1.0 mm to about 6.0 mm, more preferably from about 1.5 mm to about 3.0 mm.
To fabricate a device of the invention in glass, channels can be formed along the boundaries of glass plates that are joined together. Channel fabrication can be accomplished by etching techniques such as for example by chemical or reactive ion etching or laser ablation. Channels formed through plates are preferably formed by laser ablation. Preferably, the major surfaces of glass plates are roughened prior to drilling such channels by laser ablation, and in particular it is preferred to roughen the side of the plate at which the outbreak will occur. The roughening helps limit the scope of any fracturing that occurs at the outbreak site. Following laser ablation, the rough surface can be ground and polished.
Where fine features are desired, highly accurate techniques such as dry chemical ion etching are preferred. Dry chemical etching is discussed, for example, in S. M. Sze,"Semiconductor Devices, Physics and Technology", John Wiley & Sons, New York, 1985, pp. 457-465. In one such technique, plasma-assisted etching, an electrical field can be used to direct the plasma etchant along a given axis, thereby increasing the crispness of the etch boundaries. Following the formation of such plate-traversing channels, the surfaces of the plates can be lapped and polished. When the plates are sufficiently smooth, they can be permanently joined to other plates of the liquid dispensing device, for example using the anodic bonding technique described in U.S. Pat. No. 5,747,169 (application Ser. No. 08/745,766, filed Nov. 8, 1996, Dkt. No. 11865). (This patent is incorporated herein by reference in its entirety.) The anodic bonding technique can be used, for example to join plates of glass, glass and silicon (See U.S. Pat. No. 5,846,396, Dkt. No. 11402G).
To fabricate a device of the invention in plastic, molding tools are fabricated usually in silicon using the same processes above. The tools are made with reverse features to produce a molded replications that have appropriate features.
In a further aspect of the invention, the aliquoting apparatus with liquid dispensing devices is preferably provided with an alignment detection mechanism. The alignment detection mechanism preferably has alignment markers on the device and the receiving substrate such as an assay plate. The alignment markers are preferably formed along the margins of the lower surface of the liquid dispensing device and the upper surface of the assay plate. The alignment markers may be for example mechanical markers such as notches, mesas, ridges, furrows, pins or holes. Other alignment markers such as magnetic, electrical or optical markers may also be used. The different alignment markers can be used either singly or in combinations. Preferably, the alignment markers of the liquid dispensing devices are adapted to engage with corresponding markers on the assay plates such that several assay plates requiring the same reagents or different reagents to be dispensed can be aligned precisely with a liquid dispensing device in a sequential fashion or a single plate can be aligned precisely, first with a first device and then with a second device.
The alignment detection mechanism further has an alignment detection device for determining the relative positions of the alignment markers of the liquid dispensing devices with respect to that of the assay plates. The alignment detection device preferably produces alignment data and transfers the alignment data to a controller. Preferably, the controller can be operated not only to transfer the assay plates between the liquid dispensing devises but also to adjust the alignment of the markers of the assay plates with the corresponding markers of a liquid dispensing device after receiving the data from the alignment detection device
The present invention is further supported by the following non-limiting examples.
EXAMPLE 1
Fabrication of a liquid dispensing device
The liquid dispensing device 590 as shown in FIG. 9 is fabricated as follows. A first heat-resistant borosilicate glass plate (such as Pyrex™ glass) (3.5 inch by 5.0 inch by 30 mil) is etched to form on its bottom surface 10 parallel gas pulse channels 540 (450 μm wide by 150 μdeep). All etchings of the first glass plate are conducted with chemicals. A second heat-resistant borosilicate glass plate (3.5 inch by 5.0 inch by 30 mil) is etched on its bottom surface to form two parallel reagent fill channels 512 (300 μm wide by 100 μm deep). At the ends of each reagent fill channel, reagent feed inlets 511 (300 μm diameter) are etched. The second plate is designed to be oriented above the first plate. Gas pulse inlets 542 (300 μm diameter) and gas pulse feeders 541 (25 μm diameter) are etched through the second plate. A silicon plate (3.5 inch by 5.0 inch by 40 mil) is reactive ion etched using an electric field to form crisp metering capillaries 514 (only the cross-sections are shown in the illustration) (the capillaries are 270 μm diameter by 1 mm long). The first glass plate, second glass plate and silicon plate were aligned as indicated in FIG. 9 and anodically bonded. To bond the two glass plates, a silicon layer (300 nm thick) is applied by evaporation under inert atmosphere (to prevent oxidation) to the under interface side of the second glass plate. The silicon-coated surface is then matched with the underside of the first glass plate, and the plates are anodically bonded. The silicon plate is directly anodically bonded to the second glass plate (i.e., without using a silicon coating). Shown in the drawing, for illustrative purposes, is an indication of the outlets of the metering capillaries aligned with reaction wells 531 (which are 1 mm by 1 mm by 0.3 mm deep) of an assay plate. In another example, the plate-traversing holes arc laser drilled.
EXAMPLE 2
Formation of Mesas
Metering cappilaries and mesas were formed on and in a silicon plate (3.5 inch by 5.0 inch by 40 mil) by reactive ion etching using an electric field. FIG. 13A shows a photograph of a top view of a 600 μm wide by 200 μm high mesa in which a 75 μm wide hole has been laser drilled. FIG. 13B shows an oblique view of four of the mesas shown in FIG. 13A. FIG. 13C shows a side view of one of the mesas. Photolithography techniques were used to create 600 μm wide areas covered by a mask (which was a photoresist layer) centered at the anticipated location of the mesas. An electric field was used to direct the etchant, directly down on the silicon plate. This reactive ion technique assured that only a minimal amount of lateral etching occurred. Holes were laser drilled through the tops of the mesas. The resulting mesas are those pictured in FIGS. 13A-13C.
While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred devices and methods may be used and that it is intended that the invention may be practiced otherwise than as specifically described above.
|
Provided is a liquid dispensing device for delivering defined volumes comprising (a) a reagent fill channel, (b) one or more metering capillaries connected to the reagent fill channel and having an exit, and (c) one or more sources of gas connected to the reagent fill channel, wherein after filing the one or more metering capillaries the reagent fill channel can be drained of liquid while liquid is retained in the one or more metering capillaries, and the source of gas can be operated to eject the liquid in the metering capillaries.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE01/03466, filed Sep. 7, 2001, which designated the United States.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention lies in the field of semiconductors. The invention relates to a semiconductor component having a substrate and an epitaxial layer situated thereon, at least a first and a second bipolar component being integrated in the layer, the first and second bipolar components having a buried layer and different collector widths.
[0003] In the case of bipolar transistors it is customary to connect the collector by a buried, highly doped layer, a so-called buried layer. The buried layer is produced by subjecting the substrate to an ion implantation before the application of the epitaxial layer at the desired location. The lightly doped epitaxial layer is subsequently applied. The base, emitter, and collector wells are subsequently produced on the side of the epitaxial layer that extends to the first main side of the semiconductor component. One possible process sequence in the fabrication of a bipolar transistor is described, for example, in the textbook “Technologie hochintegrierter Schaltungen” [Technology of Large Scale Integrated Circuits] by D. Widmann, H. Mader, H. Friedrich, Springer Verlag, 2 nd edition, table 8.13 (page 326 to page 334).
[0004] The phrase collector width denotes that region of the epitaxial layer that is located between the well of the base located in the epitaxial layer and the buried layer. The collector width is consequently determined by the layer thickness of the epitaxial layer, minus the part of the buried layer that extends into the epitaxial layer, and minus the depth of the well of the base layer that is introduced from the first main side.
[0005] The dimensioning of the collector width determines the properties of the bipolar transistor. Bipolar transistors that are intended to be optimized for high limiting frequencies must have a small collector width and an increased doping in the collector. These bipolar transistors are referred to as so-called HF bipolar transistors. By contrast, high-voltage transistors (HV bipolar transistors), which are optimized toward high breakdown voltages, have a large collector width because the space charge zone must not reach the buried layer at maximum operating voltage. The typical collector width of such a bipolar transistor is approximately 450 mm, for an operating voltage of approximately 5 V. The epitaxial layer usually forms the collector in an HV bipolar transistor. The collector doping thus corresponds to the doping of the epitaxial layer, usually 10 16 .
[0006] Many integrated circuits require both bipolar transistors having a high limiting frequency and bipolar transistors having a high breakdown voltage. On account of the fabrication methods existing heretofore, it is necessary to find a compromise with regard to the properties in the case of the integration of bipolar transistors having different limiting frequencies and bipolar transistors having different breakdown voltages. This means that the performance of the semiconductor component cannot be utilized optimally.
[0007] However, if bipolar components having different collector widths are intended to be integrated together in a semiconductor component, then there are currently two possibilities in fabrication: firstly, the depth of the well in the epitaxial layer can be realized differently in the first and second bipolar components. As a result of the increased base width, the limiting frequency of that component whose well (base) extends more deeply into the epitaxial layer is reduced. Furthermore, it is necessary to use an additional mask for producing the base wells of different depths.
[0008] Another possibility is for the thickness of the lightly doped epitaxial layer to be implemented differently in the first and second components. However, the fabrication of a second epitaxial layer is associated with high costs, on one hand, and, on the other hand, the manufacturing outlay is thereby increased considerably.
[0009] On account of the complicated procedure and a generally identical epitaxial layer, i.e., the epitaxial layer has the same thickness at all points. A compromise is, therefore, sought with regard to the high limiting frequencies and the high breakdown voltages.
SUMMARY OF THE INVENTION
[0010] It is accordingly an object of the invention to provide a semiconductor component and method for fabricating it that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that realizes bipolar components having different collector widths in a simple manner.
[0011] With the foregoing and other objects in view, there is provided, in accordance with the invention, a semiconductor component including a substrate, only one epitaxial layer disposed on the substrate, at least a first bipolar component and a second bipolar component integrated in the epitaxial layer, the first bipolar component having a first buried layer having dopant in a first dopant concentration, and a first buried layer thickness, and a first collector with a first collector width, the second bipolar component having a second buried layer having dopant in a second dopant concentration substantially identical to the first dopant concentration, a second buried layer thickness larger than the first buried layer thickness, and a substance influencing diffusion of dopant in the second buried layer, and a second collector with a second collector width different from the first collector width.
[0012] With the objects of the invention in view, there is also provided a semiconductor component including a substrate, only one epitaxial layer disposed on the substrate, at least a first and a second bipolar component integrated in the epitaxial layer, the first and second bipolar components having a buried layer and different collector widths, the buried layer of the second bipolar component having a larger layer thickness than the buried layer of the first bipolar component, the buried layer of the first bipolar component and the buried layer of the second bipolar component having dopant with identical dopant concentrations, and at least the buried layer of the second bipolar component having an additional substance influencing diffusion of the dopant in the buried layer.
[0013] The invention provides for the buried layer of the second bipolar component to have a greater layer thickness than that of the first component, precisely one epitaxial layer being provided. The wells forming the base in the epitaxial layer may, but need not, have an identical depth.
[0014] The invention is based on the insight that the outdiffusion of the dopant of the buried layer can be influenced by other substances. This enables an extremely simple fabrication method because the buried layers of the first and second components are firstly implanted into the substrate with an identical dopant concentration. An additional substance is subsequently introduced into the buried layer of the second component, which additional substance influences the diffusion of the dopant in the buried layer of the second component. By way of example, the additional substance can be introduced by a mask technique and by ion implantation. The epitaxial layer is subsequently applied in a customary manner in a single step.
[0015] The invention has the advantage that only an additional mask technique and an additional implantation are necessary for an additional transistor variant, that is to say, for a bipolar transistor having a varying collector width. The costs in comparison with an additional epitaxial layer, as is provided for example, in the prior art, are, therefore, relatively low.
[0016] Because the collector always ends at the highly doped buried layer of the bipolar component, the transistor properties, thus, change to a lesser extent with an increased collector-emitter voltage than in contrast to a thicker (lightly doped) collector layer.
[0017] The semiconductor component according to the invention can be realized both with NPN transistors and with PNP transistors. In the case of NPN transistors, arsenic or antimony is advantageously used as the dopant of the buried layers. Phosphorus is used, at least in the buried layer of the second component, as an additional substance that influences the diffusion of the aforementioned dopant in the desired manner.
[0018] If the bipolar component is a PNP transistor, then boron is preferably used as the dopant of the buried layers. The additional substance used at least in the buried layer of the second component is, advantageously, nitrogen.
[0019] The substance in the buried layer of the second component can also be fluorine.
[0020] In accordance with another feature of the invention, the first bipolar component has a first well forming a base in the epitaxial layer, the first well has a given depth, the second bipolar component has a second well forming a base in the epitaxial layer, and the second well has a depth substantially identical to the given depth.
[0021] In accordance with a further feature of the invention, it is also conceivable that a respectively different concentration of the substance that influences the diffusion of the dopant is introduced both into the buried layer of the first bipolar component and into the buried layer of the second bipolar component.
[0022] In accordance with an added feature of the invention, in an advantageous refinement of NPN bipolar transistors, the additional substance at least in the buried layer of the second component is provided only in the region of the emitter located in the first well (base). Such a fabrication step can be realized by the mask covering the bipolar transistor such that an ion implantation with the additional substance is effected only in the region of the well of the emitter.
[0023] If the additional substance is introduced only in the region below the emitter, the collector width changes only below the active transistor. The collector width remains unchanged over the remaining area of the buried layer, which is referred to as passive region. If the collector width is reduced by the additional substance in the region of the emitter well, then a region with an increased collector width remains on the remaining region of the buried layer. As a result, it is possible to realize a bipolar component that has reduced capacitances and increased breakdown voltages in this region.
[0024] In accordance with an additional feature of the invention, the second bipolar component has a well and an emitter disposed in the well and a second substance is in the buried layer of the second bipolar component only in a region outside the emitter.
[0025] Such a refinement can be realized for PNP bipolar transistors by introducing a further additional substance into the buried layer outside the emitter region, the further additional substance inhibiting the outdiffusion. By way of example, nitrogen inhibits the outdiffusion of boron.
[0026] In accordance with yet another feature of the invention, there is provided a selectively implanted collector in the epitaxial layer, the collector disposed in a region below the emitter.
[0027] With the objects of the invention in view, there is also provided a method for fabricating a semiconductor component including the steps of applying an epitaxial layer to a substrate in a single step, integrating at least a first and a second bipolar component in the epitaxial layer, the first and second bipolar components each having a buried layer, implanting each of the buried layers into the substrate with an identical dopant concentration, introducing an additional substance at least into the buried layer of the second bipolar component, the additional substance influencing diffusion of dopant in the buried layer of the second bipolar component, and forming a base, an emitter, and a collector in the epitaxial layer by producing wells in the epitaxial layer.
[0028] With the objects of the invention in view, there is also provided a method for fabricating a semiconductor component including the steps of applying an epitaxial layer to a substrate in a single step, integrating at least a first and a second bipolar component in the epitaxial layer by implanting buried layers of the first and second bipolar components into the substrate, the buried layers having an identical dopant concentration, introducing an additional substance at least into the buried layer of the second bipolar component, the additional substance influencing diffusion of dopant in the buried layer of the second bipolar component, and forming, in the epitaxial layer, a base, an emitter, and a collector for at least one of the first and second bipolar components by producing wells in the epitaxial layer.
[0029] In accordance with yet a further mode of the invention, at least one of the first and second bipolar components are covered with a mask to effect ion implantation of the additional substance only at a location of the well of the emitter.
[0030] In accordance with a concomitant mode of the invention, at least one of the first and second bipolar components are covered with a mask only at a location of the well of the emitter and an ion implantation is effected with a second additional substance outside the emitter region but in the region of the buried layer.
[0031] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0032] Although the invention is illustrated and described herein as embodied in a semiconductor component, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0033] 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 DRAWINGS
[0034] [0034]FIG. 1 is a fragmentary, cross-sectional view of a semiconductor component according to the invention with a first and a second bipolar component; and
[0035] [0035]FIG. 2 is a fragmentary, cross-sectional view of an alternative configuration of a bipolar component that can be used in the semiconductor component according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a sectional illustration of a semiconductor component according to the invention, having a first bipolar component 11 and a second bipolar component 11 ′. The first and second bipolar components 11 , 11 ′ are disposed in an epitaxial layer 2 located on a substrate 1 . Situated on a first main side I of the semiconductor component are the active components, that is to say, the base, emitter, and collector wells located in the epitaxial layer 2 . In principle, the bipolar transistors are formed in accordance with a conventional. Such a bipolar transistor having a buried layer is described for example in the textbook “Bauelemente der Halbleiter-Elektronik” [Components of Semiconductor Electronics”] by R. Muller, Springer Verlag 1991, 4 th edition, pages 245, 246.
[0037] The following brief description of the construction of a bipolar component is limited to the first component 11 . In the epitaxial layer 2 , a first well 3 , serving as base, is provided in a manner adjoining the first main side I. Disposed in the first well 3 is a second well 4 , which likewise extends to the first main side I and forms the emitter of the bipolar component. In this case, the second well 4 is completely surrounded laterally by the first well 3 . Provided adjacent to the first well 3 is a third well 5 , which is located in the epitaxial layer 2 in a manner extending to the first main side I.
[0038] The first well 3 has a predetermined depth 8 in the epitaxial layer 2 . The thickness of the epitaxial layer 2 of the semiconductor component is designated by 7 . A buried layer 6 extends below the first well 3 and the third well 5 , the buried layer 6 having been introduced into the substrate 1 by ion implantation before the application of the epitaxial layer 2 . The distance 9 , which is formed between the first well 3 , that is to say the base, and the buried layer 6 , represents the collector width 9 of the bipolar component. The property of the bipolar component is set by the collector width. If the bipolar component has a small collector width and high collector doping, then the bipolar component is suitable in particular for high limiting frequencies, but not very suitable for high breakdown voltages. High breakdown voltages can be obtained by a large collector width and low collector doping. The bipolar component 11 that is illustrated on the left-hand side of FIG. 1 is, therefore, preferably suitable for high voltages, while the bipolar component 11 ′ located on the right-hand side is optimized toward high frequencies.
[0039] The depths 8 , 8 ′ of the respective first well 3 , 3 ′ (base) in both bipolar components 11 , 11 ′ may be formed in identical fashion. The thickness of the epitaxial layer 7 , 7 ′ in both bipolar components 11 , 11 ′ is formed in identical fashion. The epitaxial layer has the same doping in both cases because it is applied in a single method step. The epitaxial layer is preferably lightly doped.
[0040] The special feature of the semiconductor component according to the invention as illustrated in FIG. 1 is that the bipolar components 11 , 11 ′ are located in a single epitaxial layer 7 , 7 ′, but the collector width 9 , 9 ′ is formed in varying fashion. Such a semiconductor component can be realized by a procedure wherein, before the application of the epitaxial layer 2 and the production of the base, emitter, and collector wells located therein, the buried layer 6 ′ of the second bipolar component 11 ′ was provided with an additional substance (not visible in FIG. 1) that influences, that is to say, intensifies, the outdiffusion of the dopant of the buried layer 6 ′.
[0041] A modification of the fabrication method used heretofore is limited to performing only a single additional mask step with a subsequent ion implantation. Consequently, the semiconductor component according to the invention, which can be optimized in terms of its electrical properties by comparison with the prior art, can be fabricated in an extremely simple manner.
[0042] The collector of the second bipolar component 11 ′ (HF transistor) can additionally be doped more highly than the epitaxial layer through a dedicated implantation—so-called selectively implanted collector (well 14 ′). The increased doping reduces the width of the space charge zone and the breakdown voltage. At maximum operating voltage of the HF transistor 11 ′, which is lower than the maximum operating voltage of the HV transistor 11 , the space charge zone no longer reaches the buried layer 6 ′, i.e., the space charge zone ( 14 ′ a ) is then smaller than the collector width 9 ′. Consequently, the region of the collector without space charge zone ( 14 ′ b ) is only parasitic resistance. The reduced collector width reduces this region and, thus, the parasitic resistance.
[0043] The bipolar components 11 , 11 ′ can be embodied both as NPN transistors and as PNP transistors. In this case, the two components 11 , 11 ′ may be of the same transistor type or else of different transistor types. If the bipolar component is an NPN transistor, then arsenic or antimony is preferably used as dopant of the buried layer 6 , 6 ′. This dopant is introduced in the same, that is to say, identical, concentration during fabrication in both components 11 , 11 ′. The addition of phosphorus in the buried layer 6 ′ of the second component 11 ′ intensifies the outdiffusion of arsenic or antimony. In a PNP transistor, the buried layer is composed of boron, for example, in which case the outdiffusion can be reduced by nitrogen and intensified by fluorine.
[0044] It is conceivable for the additional substance to be added only to the buried layer 6 ′ of the second component; however, it is also possible, of course, to add the additional substance in the buried layers 6 , 6 ′both of the first and of the second component 11 , 11 ′. A different collector width 9 , 9 ′ can nevertheless be realized by choosing a different concentration of the additional substance.
[0045] [0045]FIG. 2 shows an alternatively configured bipolar component that can be integrated in a semiconductor component together or alternatively with the bipolar components 11 , 11 ′ shown in FIG. 1. In the fabrication of the bipolar component shown in FIG. 2, the mask for the implantation of the additional substance was formed such that, in the case of an NPN component, only the second well 4 , forming the emitter, remains spared, while in the case of a PNP component, the second well 4 is covered and the rest of the buried layer remains spared. As a result of the subsequent ion implantation of the additional substance (phosphorus in the case of an NPN component, nitrogen in the case of a PNP component), only the outdiffusion of the dopant of the buried layer 6 in the region below the emitter 4 is intensified (NPN component) or inhibited (PNP component). The buried layer 6 , thus, has a step-like course 10 , 10 ′. The collector width below the third well 5 (collector) and also in parts of the first well 3 (base), thus, remains unchanged. The bipolar component illustrated in FIG. 2 enables reduced capacitances and increased breakdown voltages in the region 12 of the buried layer. The selectively implanted collector 14 ′, already described with respect to FIG. 1, is disposed below the emitter 4 in the epitaxial layer 2 .
[0046] The thickness of the epitaxial layer 2 of the component in accordance with FIG. 2 corresponds to the thickness of the epitaxial layer 2 in the semiconductor component of FIG. 1. Likewise, the depth 8 of the first well 3 (base) of FIG. 2 is identical to the depth 8 of the first well 3 , 3 ′ of the bipolar components from FIG. 1.
[0047] Optimization of the electrical properties of a plurality of bipolar components in a semiconductor component that is conventionally fabricated is possible in a simple manner by an additional substance varying the diffusion of a dopant of the buried layer of a bipolar transistor. Such a process makes it possible to set the collector width that determines the electrical properties.
|
A semiconductor component and a method for fabricating it includes a substrate and an epitaxial layer situated thereon and integrating at least a first and a second bipolar component in the layer. The first and second bipolar components have a buried layer and different collector widths. The buried layer of the second component has a larger layer thickness than that of the first component; exactly one epitaxial layer is provided. The different collector widths produced as a result thereof are influenced by the outdiffusion of the dopant of the buried layers by other substances.
| 7
|
[0001] The present invention relates generally to optoelectronic devices, and particularly to a circuit interconnect for controlled impedance at high frequencies.
BACKGROUND OF THE INVENTION
[0002] An optoelectronic device, such as a laser diode or a photo diode, is generally enclosed in a transistor outline (TO) package, which provides a conductive housing for the optoelectronic device. A laser diode converts an electrical signal into an optical signal for transmission over a fiber optic cable, while a photo diode converts an optical signal into an electrical signal. In order for a laser diode to convert an electrical signal into an optical signal, the electrical signal must be sent through the TO package of the laser diode. Similarly, an electrical signal from a photo diode must be sent through the TO package of the photo diode to external electrical circuitry. For high frequency operation, it is important to control the impedance seen by the electrical signals that flow into and out of the TO package.
[0003] Conventional signal and ground connections to TO packages, which including distinct signal and ground connections, result in uncontrolled impedances that degrade data signal integrity at high frequencies (e.g., at or above 3 GHz).
BRIEF SUMMARY OF AN EXEMPLARY EMBODIMENT OF THE INVENTION
[0004] In general, exemplary embodiments of the invention are concerned with systems and devices configured to implement impedance matching schemes in a high speed data transmission environment. In one example, an optoelectronic assembly is provided that includes a TO package having a base through which one or more leads pass. The leads are electrically coupled to an optoelectronic device in the TO package, and are electrically isolated from the base. Some or all of the leads include a ground ring that is electrically isolated from the lead and electrically coupled with the base. A circuit interconnect is also included that is electrically coupled to the optoelectronic device and the TO package. The circuit interconnect includes a dielectric substrate having signal traces that are electrically coupled to the signal leads. A ground signal conductor disposed on the dielectric substrate is electrically coupled with the ground rings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Additional objects and features of the invention will be more readily apparent from the following detailed description and appended claims when taken in conjunction with the drawings, in which:
[0006] FIG. 1 is a diagram of an optoelectronic assembly in accordance an embodiment of the invention.
[0007] FIG. 2 depicts the ground signal conductor side of a circuit interconnect.
[0008] FIGS. 3A and 3B depict the back of a TO package in accordance with the first and second embodiments.
[0009] FIG. 4 is a diagram of a transmitter assembly in accordance with an embodiment of the invention. FIGS. 4A, 4B , 4 C, 4 D and 4 E are circuit diagrams of the transmitter assembly of FIG. 4 .
[0010] FIG. 5 is a diagram of a transmitter assembly in accordance with an alternate embodiment of the invention.
[0011] FIG. 6 is a diagram of a receiver assembly in accordance with an embodiment of the invention. FIG. 6A is a circuit diagram of the receiver assembly of FIG. 6 .
[0012] FIG. 7 is a diagram of a transceiver assembly in accordance with an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring to FIG. 1 , there is shown an embodiment of an optoelectronic assembly 100 in accordance with the present invention. The optoelectronic assembly may be a transmitter optoelectronic assembly or a receiver optoelectronic assembly. The optoelectronic assembly includes a transistor outline (TO) package 102 that houses an optoelectronic device. If the optoelectronic assembly is a transmitter optoelectronic assembly, the optoelectronic device is a light source such as a laser diode. If the optoelectronic assembly is a receiver optoelectronic assembly, the optoelectronic device is a detector such as a photo diode.
[0014] Signal contacts 112 , also called signal leads, extend through apertures in the base 124 of the TO package 102 and contact corresponding signal traces 114 on a circuit interconnect 104 . The signal traces 114 are mechanically and electrically connected to the signal contacts 112 by solder, conductive epoxy or any other appropriate conductive attachment mechanism. Signal contacts 112 and signal traces 114 convey power and data signals between an external circuit 118 and the device or devices in the TO package 102 .
[0015] The circuit interconnect 104 is preferably made of an elongated piece of flexible dielectric 120 . The dielectric 120 serves as an insulator between a ground signal conductor 116 on one side of the dielectric 120 and the data signal traces 114 on the other side of the dielectric. The ground signal conductor 116 conveys ground current between the external circuit 118 and the device or devices in the TO package 102 . While the embodiment shown in FIG. 1 has two signal contacts 112 and two corresponding signal traces 114 , in other embodiments the number signal contacts and signal traces may be greater or fewer, depending on the number of power and data connections needed by the device or devices inside the TO package 102 .
[0016] The external, back surface of the base 124 is sometimes called the “ground plate,” because the base 124 of the TO package is grounded by a connection between the ground plate and the ground conductor 116 on the circuit interconnect 104 . The ground connection to the base 124 provides a circuit ground voltage source and ground current connection for the electrical and optoelectronic components in the TO package 102 .
[0017] To avoid signal reflections and other signal degradations, the impedance of the signal path from the device in the TO package 102 to the external circuit 118 must be kept as consistent as possible. The impedance of the circuit interconnect 104 (i.e., the characteristic impedance of the transmission line formed by the circuit interconnect) is precisely determined by the thickness of the dielectric and the width of the data signal traces, and the circuit interconnect is configured so that for frequencies in the range of 3 to 10 GHz its impedance approximately matches the impedances of both the circuitry inside the TO package and the external circuit 118 . As used in this document, two impedances are defined to “approximately match” when the two impedances are either exactly the same or one of the impedances is larger than the other, but no more than 50% larger. In other words, the impedance of the circuit interconnect is within a factor of about 1.5 of the impedance of the circuitry inside the TO package and the external circuit 118 . Preferably the impedance of the circuit interconnect will be within 25% (i.e., within a factor of about 1.25) of the impedances of the circuitry inside the TO package and the external circuit 118 . The impedance of the circuit interconnect 104 of the present invention is typically between 20 and 30 ohms.
[0018] In other embodiments, the circuit interconnect 104 may be optimized for impedance matching (to the high frequency signal leads of the TO package 102 , and also to an external circuit) for a different range of operating frequencies than 3 to 10 GHz. Typically, the range of operating frequencies at the circuit interconnect 104 of the present invention approximately matches impedances at both ends of the circuit interconnect 104 will include a range of frequencies above 3 GHz.
[0019] In a preferred embodiment the circuit interconnect 104 has a thickness between 0.003 and 0.012 inches, and the dielectric substrate 120 of the circuit interconnect is preferably polyimide or polyester. Other insulating materials may be used besides polyimide or polyester. Moreover, the insulator 120 does not necessarily need to be flexible; however, the flexibility is useful for fitting the optoelectronic assembly 110 into a housing (not shown), such as the housing of an optoelectronic transmitter, receiver or transceiver. The flexible dielectric substrate 120 is coated on each side with a conductive material such as copper, a copper alloy, or other malleable, highly conductive metal or metal alloy. The data signal traces 114 are fabricated from the conductive material on one side of the circuit interconnect 104 , while the entire second side of the circuit interconnect 104 (excluding circular regions corresponding to the positions of the signal leads traversing the base of the TO package) serves as the ground signal conductor 116 . Other methods of creating the conductive signal traces may be used as is understood by one skilled in the art.
[0020] In an alternate embodiment, only a portion of the second side of the circuit interconnect 104 serves as the ground signal conductor 116 , leaving room for one or more additional signal traces (e.g., for power or low frequency data signals) on the second side of the interconnect 104 . In this alternate embodiment, the ground signal conductor 116 would be positioned relative to the traces on the first side of the circuit interconnect so as to provide connections with well controlled impedance.
[0021] The side of the circuit interconnect 104 that serves as the ground signal conductor 116 is depicted in FIG. 2 . The small circular regions 130 represent holes in the dielectric substrate 120 of the interconnect, through which the signal leads of the TO package extend. The annular circular regions 132 surrounding the smaller holes 130 represent non-conductive, unmetalized regions in which the conductive material has been removed from the second side of the circuit interconnect 104 so as to prevent electrical shorts between the signal leads and the ground signal conductor 116 .
[0022] Returning to FIG. 1 , the data signals are transmitted between the optoelectronic device in the TO package 102 and electrical circuitry 118 . The data signal contacts 112 extend through apertures in the base 124 of the TO package 102 and contact the data signal traces 114 . For each data signal contact 112 , a separate, respective ground ring 106 surrounds the data signal contact 112 and is attached to the base 124 of the TO package 102 . The base 124 is a circular (actually, cylindrical) metal plate, generally held at the circuit ground voltage during operation of the optoelectronic device. The base 124 is the foundation of the TO package 102 . In a preferred embodiment the base 124 is made of a metal known as “Alloy 42 ,” which is an alloy of iron and nickel. In other embodiments the base 124 may be made of other appropriate metals. The primary purpose of the ground rings is to form a low reflection connection between the data signal contacts 112 and the circuit interconnect 104 , so as to minimize signal reflections at the interface between the data signal contacts 112 and the circuit interconnect 104 . In some embodiments, ground rings 106 are used only with high frequency data signal contacts 112 (e.g., carrying data signals at frequencies at or above 2 or 3 GHz), but not with the power signal contact and any lower frequency data signal contacts, because ground rings 106 are not needed to form low reflection connections between the signal contacts 112 and the circuit interconnect 104 for low frequency connections.
[0023] FIG. 3A shows the ground rings 106 on the back surface of the base 124 . The ground rings 106 are preferably highly conductive, thin metal rings that are bonded to the back, planar surface of the base 124 , such as by solder, conductive epoxy or any other appropriate bonding or conductive attachment mechanism. As a result, the ground rings are mechanically and electrically connected to the back surface of the base 124 . The ground rings 106 rise slightly above the back planar surface of the base 124 , which facilitates the bonding of the ground signal conductor 116 of the circuit interconnect 104 to the ground rings. Alternately, the ground rings 106 may be implemented as raised annular regions of the base 124 , i.e., as integral parts of the base. The circuit ground connection provided by the ground signal conductor 116 , which is electrically and mechanically bonded to the ground rings 106 , and possibly other portions of the base as well, keeps the entire base 124 at the circuit ground voltage during normal operation. While the ground rings 106 are shown in FIG. 3A as being circular or annular in shape, in other embodiments other shapes could be used. For instance, the ground rings 106 could be oval shaped structures.
[0024] Although there are two ground rings 106 surrounding the two data signal contacts, only one ground ring is seen in FIG. 1 because of the angle of the perspective view shown in FIG. 1 . The ground signal conductor 116 directly contacts the ground rings 106 , and carries ground current from the ground rings 106 to a circuit ground terminal 122 ( FIG. 1 ). In a preferred embodiment, the ground signal conductor 116 also directly contacts the base 124 at the back surface of the TO package 102 so as to provide a high quality ground connection to the entire TO package and the devices therein. These contacts between the ground signal conductor 116 and the ground rings 106 and the back surface of the base 124 are preferably implemented by bonding these components together using solder, conductive epoxy or any other appropriate bonding or conductive attachment mechanism.
[0025] The ground signal and the data signals are maintained in a close relationship to each other, separated by the insulator 120 . This provides for a controlled impedance at high frequencies.
[0026] Referring again to FIG. 1 , the electrical circuitry 118 is electrically connected to the circuit interconnect 104 . The signal traces 114 contact the electrical circuitry 118 while the ground conductor 116 contacts the electrical circuitry's circuit ground node 122 . The electrical circuitry is typically mounted on or includes a circuit board (not shown) and the circuit interconnect is electrically connected to that circuit board. The electrical circuitry 118 amplifies and processes the electrical signals transmitted to a laser diode (in one embodiment) or from a photo diode (in another embodiment), or both (in yet another embodiment). Thus, the electrical circuitry 118 may include a laser driver circuit, a received signal recovery circuit, or both. Further, the electrical circuitry 118 may include digital signal processing circuits, such as serializing circuits and deserializing circuits, and circuits that perform data conversions, such as the 8b/10b conversion for converting a data stream into a “balanced” data stream that is balanced with respect to 1 and 0 bits, and that provides sufficient data transitions for accurate clock and data recovery.
[0027] FIG. 3A shows the base 124 at the back of the TO package 102 in one embodiment of the present invention. The signal contacts (leads) 112 carrying data signals and/or a power supply voltage extend through apertures in the base 124 of the TO package 102 . The data signal contacts 112 contact the data signal traces 114 ( FIG. 1 ) of the circuit interconnect. The signal contacts 112 do not contact the base 124 of the TO package 102 ; rather, they extend through a dielectric 140 , preferably a ring of glass, embedded in the base 124 . Each dielectric ring 140 is concentric with one of the signal contacts 112 . When the circuit interconnect 104 is bonded to the base of the TO package 102 , the unmetalized insulator region 132 ( FIG. 2 ) on the second side of the circuit interconnect overlaps the dielectric ring 140 in the base 124 . For each data signal contact 112 (or at least each high frequency data signal contact), there is a conductive ground ring 106 that surrounds the dielectric 140 , concentric with the contact 112 and the dielectric ring 140 .
[0028] In some embodiments, the ground rings 106 are the only parts of the TO package that directly contact the ground signal conductor 116 of the circuit interconnect. In one embodiment, however, the ground signal conductor 116 is mechanically and electrically bonded to a large portion of the external, back surface of the base 124 , in addition to the ground rings 106 . Alternatively, additional ground contacts may be provided by signal leads connected to the TO package.
[0029] FIG. 3B depicts an alternate embodiment, in which a ground lug 150 is used instead of the ground rings 106 to provide a high quality ground connection to the base 124 and to prevent signal reflections in the high frequency data signal paths. The ground lug 150 is a preferably a highly conductive, thin metal lug bonded to the back, planar surface of the base 124 , such as by solder, conductive epoxy or any other appropriate bonding or conductive attachment mechanism. The ground lug 150 rises above the back planar surface of the base 124 , which facilitates the bonding of the ground signal conductor 116 of the circuit interconnect 104 to the ground lug. Alternately, the ground lug 150 may be implemented as a raised regions of the base 124 , i.e., as an integral part of the base. The ground lug has two round (i.e., cylindrical) holes in it, aligned with the dielectric rings 140 surrounding the data signal contacts 112 .
[0030] The use of a ground lug, instead of ground rings, typically does not require any change in the design of the circuit interconnect 104 . As shown in FIG. 3B , the ground lug 150 is preferably positioned so as to surround the data signal contacts 112 . If the TO package includes more than two high frequency data signal contacts 112 , either the ground lug may be made larger or one or more additional ground lugs 150 may be positioned around those additional signal contacts 112 so as to provide a ground current path that is precisely positioned with respect to the data signal current flowing each of the data signal contacts 112 .
[0031] The low impedance connection or bond between the ground signal conductor and the ground lug 150 is preferably formed by placing solder on the top surface of the ground lug or on the back surface of the ground signal conductor 116 and then soldering the ground signal conductor 116 to the ground lug 150 . Alternately, the ground signal conductor 116 may be mechanically and electrically connected to the ground lug 150 using a conductive epoxy or any other appropriate conductive attachment mechanism.
[0032] In yet another alternate embodiment, the base 124 of a TO package 102 may include both ground rings and ground lugs for forming ground current connections to the ground signal conductor 116 of the circuit interconnect 104 .
[0033] Referring to FIG. 4 , there is shown a transmitter optoelectronic assembly 400 in accordance with an embodiment of the present invention. The transmitter optoelectronic assembly 400 includes:
a laser diode 402 , such as an edge emitter or other type of laser diode; a laser submount 404 , on which the laser diode is mounted; the laser submount 404 may be made of aluminum nitride or alumina ceramic; the laser submount 404 preferably incorporates one or more integrated or attached passive components, such as resistors, capacitors, and inductors, to provide improved impedance matching and signal conditioning; a laser pedestal 406 to which the submount 404 is attached; the laser pedestal 406 is a grounded, conductive structure having a partially concentric shape with respect to data signal contacts 412 , 414 that extend through the base 124 ; a monitor photo diode 408 for detecting the light emitted from a back facet of the laser diode 402 in order to monitor the intensity of the light emitted by the laser diode 402 ; a monitor photo diode sub-mount 410 on which the monitor photo diode 408 is mounted; and a Transistor Outline (TO) package 420 incorporating controlled impedance glass-metal feedthroughs.
[0040] The partially concentric shape of the pedestal 406 , which is held at the circuit ground potential, facilitates control of the impedance characteristics of the circuit that runs from the data signal contacts 412 , 414 , through bond wires 405 to the laser diode 402 and through the laser submount 404 and laser pedestal 406 of the TO package.
[0041] The laser diode 402 is activated when a positive voltage is applied across the p-n junction of the laser diode 402 . In the preferred embodiment, data signal contacts 412 , 414 form a differential data signal connection. The two contacts 412 , 414 are electrically connected to the laser submount 404 via bond wires 405 or any another appropriate connection mechanism. One terminal of the laser diode 402 is in direct contact with the laser submount 404 and is therefore electrically connected with one of the differential data signal contacts 414 via a corresponding one of the bond wires 405 . The other data signal contact 412 is electrically connected to the laser diode 402 via a bond wire 405 to the submount 404 and another bond wire connecting the second terminal of the laser diode 402 to the submount 404 . The differential signal provided by data signal contacts 412 , 414 supplies both a bias voltage and a time varying signal voltage across the p-n junction of the laser diode 402 .
[0042] Improved impedance matching between the circuit interconnect and the electrical circuitry in a TO package is achieved by incorporating resistors, capacitors and/or inductors into the submount 404 for the laser diode to provide a network (e.g., an RL network, or LC network, or RLC network) that compensates for the impedance presented by the bond wires 405 between the data signal contacts 412 , 414 extending through the TO package and the submount connection points. Typically, the bond wires are made of gold and have inductances of 1 to 5 nanoHenries. FIG. 4A is a circuit diagram of the circuit in which data signal contacts 412 and 414 are connected to the laser diode 402 through the laser submount 404 . The resistance, capacitance and/or inductance of the submount 404 are adjusted so that the impedance of the electrical circuitry inside the TO package approximately matches the impedance of the circuit interconnect. FIGS. 4B, 4C , 4 D and 4 E are circuit diagrams for alternative impedance compensation networks that may be constructed. In FIG. 4B the submount is represented as a single resistor 404 -R. In FIG. 4C the submount is represented as two resistors, 404 -R 1 and 404 -R 2 , on either side of the laser diode 402 . In FIG. 4D the submount is represented as a capacitor 404 -C connected to ground. Finally in FIG. 4E the submount is represented as a resistor 404 -R and a capacitor 404 -C. Typically component values are 10 to 30 ohms (preferably about 20 ohms) for resistor 404 -R and 0.6 to 1.0 picofarads (preferably about 0.75 picofarads) for capacitor 404 -C. The impedance matching provided by the network incorporated into the submount is preferably optimized for a predefined range of operating frequencies, such as 3 GHz to 10 GHz. The predefined range of operating frequencies is preferably the same as the range of operating frequencies at which the optoelectronic device is expected to be used. In the preferred embodiments, the predefined range of operating frequencies includes a range of frequencies above 3 GHz.
[0043] Referring again to FIG. 4 , as is understood by one skilled in the art, when the laser diode 402 is an edge emitter the laser diode 402 emits light in both the forward direction and the backward direction, from forward and back facets. The forward direction refers to the direction in which light is transmitted through a window of the TO package, while the backward direction refers to the opposite direction. The laser intensity in the backward direction is proportional to the laser intensity in the forward direction. Thus, it is useful to measure the intensity of the laser in the backward direction in order to track the laser intensity in the forward direction. Accordingly, a monitor photo diode 408 is positioned facing the back facet of the laser diode 402 . A power supply voltage contact 416 is connected to the monitor photo diode submount 410 by a bond wire. The monitor photo diode 408 is in contact with the monitor photo diode submount 410 and is connected to the monitor photo diode data signal contact 418 by a bond wire. Thus, the monitor photo diode 408 is reverse biased between the power supply and the data signal contact 418 . The transmitter assembly of FIG. 4 is operated in conjunction with a circuit interconnect having four data signal traces. The circuit interconnect, not shown, is preferably similar to the one shown in FIG. 2 , but having four data signal traces 114 . Each data signal trace contacts a respective one of the data signal contacts 412 , 414 , 416 , and 418 .
[0044] Other transmitter embodiments may include a Vertical Cavity Surface-Emitting Laser (VCSEL) transmitter assembly 500 as shown in FIG. 5 . The VCSEL 502 is mounted to a submount 504 , which is preferably a capacitor. The capacitor is mounted to the TO package 510 . The VCSEL is electrically connected to the submount 504 via direct contact. Contact 506 is connected to the submount by a bond wire 505 and contact 508 is connected to the VCSEL by another bond wire 505 . A differential signal is provided through contacts 506 and 508 , which results in a positive voltage across the VCSEL's p-n junction thereby activating the VCSEL 502 . The transmitter assembly of FIG. 5 is operated in conjunction with a circuit interconnect having two data signal traces, as well as a power connection trace, similar to the interconnects shown in FIGS. 1 and 2 . Each data signal trace contacts a respective data signal contact 506 , 508 .
[0045] Referring to FIG. 6 , there is shown an embodiment of a receiver optoelectronic assembly 600 in accordance with the present invention. The receiver optoelectronic assembly includes:
a photo diode 602 ; a photo diode submount 604 ; an integrated circuit preamplifier 606 attached to the photo diode 602 and the submount 604 ; a capacitor 608 for filtering background noise; and a Transistor Outline (TO) package 616 incorporating controlled impedance glass-metal feedthroughs.
[0051] The photo diode submount 604 is preferably a capacitor that serves to filter noise from the power supply (Vcc) 614 . The photo diode 602 is electrically connected to the submount 604 preferably through direct contact. The photo diode 602 is reverse biased between the charged capacitor 608 and a bond wire 605 to the integrated circuit preamplifier 606 . The integrated circuit preamplifier 606 produces a pair of differential data signals through bond wires 605 to contacts 610 and 612 . Finally, as is understood by those skilled in the art, the capacitor 608 is used by the integrated circuit preamplifier 606 to filter unwanted noise from the data signals. The receiver optoelectronic assembly of FIG. 6 is operated in conjunction with a circuit interconnect having three data signal traces (not shown, but similar to the circuit interconnects shown in FIGS. 1 and 2 ). Each data signal trace contacts a respective one of the data signal contacts 610 , 612 , and 614 . The data signals from the photo diode are typically transmitted through the circuit interconnect to a received signal amplifier that is mounted on the circuit board connected to the circuit interconnect.
[0052] FIG. 6A is a circuit diagram of the receiver assembly shown in FIG. 6 . The photo diode 602 is reverse biased so that V2 is less than V1. The output from the photo diode is amplified by the integrated circuit preamplifier 606 and then output through the data signal contacts 610 and 612 . The photo diode submount is represented as a capacitor 604 that filters noise from the power supply (Vcc) 614 . The capacitor 608 filters noise from the data signals.
[0053] FIG. 7 shows an embodiment of an optoelectronic transceiver 700 in accordance with the present invention. The optoelectronic transceiver 700 includes a transmitter TO package 702 and receiver TO package 704 . The transmitter TO package 702 houses a light source such as a laser diode, and the receiver TO package 704 houses a detector such as a photo diode. Data signals are transmitted from external electrical circuitry 710 to the transmitter TO package 702 via the transmitter circuit interconnect 706 . The data signals from the detector are transmitted through the receiver TO package 704 to the external electrical circuitry 710 via the receiver circuit interconnect 708 . Both the transmitter circuit interconnect 706 and the receiver circuit interconnect 708 ground their respective TO package through direct contact with the ground rings 712 (two of which are shown in FIG. 7 ) surrounding the data signal contacts 714 .
[0054] While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.
|
This disclosure concerns systems and devices configured to implement impedance matching schemes in a high speed data transmission environment. In one example, an optoelectronic assembly is provided that includes a TO package having a base through which one or more leads pass. The leads are electrically coupled to an optoelectronic device in the TO package, and are electrically isolated from the base. Some or all of the leads include a ground ring that is electrically isolated from the lead and electrically coupled with the base. A circuit interconnect is also included that is electrically coupled to the optoelectronic device and the TO package. The circuit interconnect includes a dielectric substrate having signal traces that are electrically coupled to the signal leads. A ground signal conductor disposed on the dielectric substrate is electrically coupled with the ground rings.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/325,775, filed Dec. 19, 2002 now U.S. Pat. No. 6,871,606.
BACKGROUND
The invention is directed to providing a method for providing generally uniform stitch lengths in a sewing or embroidery, as well as a device for implementing the method.
In sewing and embroidery machines, the article or material to be sewn is transported in each case after the execution of a sewing stitch by a material transport device. Such material transport devices are, for example, material feeders located underneath a throat plate or movable embroidery frame.
Material feeders can feature one or more bars lying horizontally, which are sawtooth shaped on the side facing the article to be sewn. Following the execution of each sewing stitch, i.e. after the sewing needle is no longer in contact with the article to be sewn, the material feeder performs one or more cyclical movements, whereby the article is transported one or more increments further in the direction of sewing. The material feeder is thereby raised so far that the bars protrude through slot shaped openings in the stitching plate and come into contact with the article to be sewn. The article to be sewn is pressed against the stitching plate and/or against the bars reaching through the throat plate by a presser foot. The material feeder then executes a pushing movement in the direction of sewing, whereby the article to be sewn is transported one increment in the direction of sewing. After this, the material feeder is lowered again, so that the bars no longer protrude above the throat plate and return to their original position. The individual partial movements can be merged into a continuous motion sequence. In most sewing machines, the direction of sewing can be reversed by reversing the described motion sequence, so that the new direction of sewing runs in the opposite direction of the original direction of sewing. There are also sewing machine models in which the material feeder, in addition to the direction of sewing, and in an analogous manner, can also execute transport movements that are perpendicular to the direction of sewing, so that the material or the article to be sewn can be moved in two dimensions or in a sewing plane predefined by the upper surface of the throat plate. Sewing machines of this type can be used for the embroidery of small patterns. Alternatively, an embroidery frame can also be used for the embroidery of patterns. Instead of material feeders, for example, an embroidery frame which can be driven by two stepper motors is used for moving the article within the sewing plane, whereby the material or the article is clamped into this embroidery frame.
Following the execution of a sewing stitch, the embroidery frame is moved via both stepper motors in such a way that the new stitching site is positioned underneath the sewing needle. For certain sewing procedures, and especially for the embroidery of patterns, it is of great importance that predetermined stitch lengths and directions within the sewing plane be observed. In conventional sewing and embroidery machines, the actual stitch lengths and directions can deviate, however, from the values set on the machine or calculated by the machine's control system. The actual material feeding in one or two directions during the individual transport steps or cycles does not correspond to the required specified values. Such deviations may be either system-contingent or random. Deviations of the actual stitch lengths or feeding increments from the respective target stitch lengths or target feeding increments of the material transport device may depend, for example, on the sewing machine model, or on the characteristics of the article or the material, or on the force effects on the article to be sewn when sewing or embroidering. Of particular importance is the sewing material-dependent slippage during the transport procedure or different transport characteristics of forwards and backwards transport of the material. Deviations of the actual values from the target values can also occur when using embroidery frames, for example, when the material buckles within the embroidery frame.
With deviations in the actual stitch lengths and/or the actual feeding increments from the target stitch lengths and/or target feeding increments, incorrect seam lengths or undesired misalignment of embroidery patterns can occur. It is not possible for conventional sewing machines to return the article to its original position by forwards and subsequent backwards transport with an equal number of each of a certain number of transport cycles. The same also applies to two-dimensional movement in the sewing plane. Incorrect seam lengths or cumulative misalignments of embroidery patterns can be the result.
A sewing machine with a device for measuring and regulating the size of the feeding increment is known from DE-C2-3525028. In the third embodiment, two CCD sensors situated opposite each other and vertically to the direction of sewing, with each being a line scan camera equipped with a light source. The line scan camera located to the front of the direction of sewing is switched on at the start of the sewing procedure and generates a digitalized real time line scan of a segment of the surface of the article. As soon as this segment of the surface is supposed to lie over the line scan camera situated to the rear in the direction of sewing according to the feeding speed, this line scan camera is switched on and scans the surface of the article until the pattern correlates with the pattern recorded beforehand by the forward line scan camera. A disadvantage of this device consists of its sensitivity to displacements which are perpendicular to the direction of sewing and to distortions of the article being sewn within the sewing plane. Even the smallest alterations in the position of the article to be sewn can lead to large differences in the calculation of correlation values. Furthermore, the brightness of the light source must be adjusted to the background brightness of the material. Also, the material to be sewn must at least be pushed forward the amount of the distance between both of the line sensors, until a value for the deviation of the actual feeding speed of the material from the target feeding speed can be determined. The measuring and regulation device can comprehend such deviations only in the direction of the feeding. In addition, the actual feeding speed must be slower than the target feeding speed. Both the calculation of the feeding speed and the position of the article to be sewn are afflicted with measurement errors.
SUMMARY
It is the object of the present invention to create a method and a device to quickly and accurately detect fabric movement to provide generally uniform stitch lengths for a sewing or embroidery machine.
This object is accomplished by a method and a device for controlling a sewing or embroidery machine using a sensor that detects an actual movement of the fabric in accordance with the invention.
With the method and device according to the invention, target values for feeding increments for a material to be sewn can be detected for each sewing step or each feeding cycle. If the sensor for detecting the feeding increments features a sufficiently high scanning rate, then actual values for the feeding movement and/or the pushing forward of the article to be sewn can also result during pushing forward, thus during the execution of the sewing stitches or feeding cycles. By regulating the size of the feeding increment, the actual increments for the article to be sewn can be adjusted in such a way to the predetermined values of the target increments, that the average over one or more feeding cycles of the accumulated value of the actual increments coincides with the accumulated value of the target increments. Depending on need, the regulation of the size of the feeding increment can take place either quickly and with sensitivity or slowly.
In the first case, established deviations of the actual feeding from the target feeding increments in the execution of a sewing step or feeding cycle can already be compensated for in the same or in the immediately following sewing step or feeding cycle. The compensation in the following sewing step causes a relatively large difference in two adjacent increments. If the sensor utilized for detecting the feed rate features a significantly higher scanning rate than the time required for the execution of the sewing step, then the regulation of the size of the feeding increment can even take place during the execution of this sewing step. The actual values coincide in this case with the target values in the context of the accuracy of the regulation for each sewing step. This variant of the regulation of the size of the feeding increment is particularly important for material transport systems in which the drive is independent of the main drive of the needle bar. In the second case, the compensation for the detected deviation is executed in a divided manner over several sewing steps or feeding cycles, whereby, on the average, only small differences between the individual stitch increments result.
The method can be used for regulating the size of the feeding increment in forward and/or backward movements of the article to be sewn in one or two dimensions of the sewing plane.
In a preferred embodiment of the invention, deviations in the actual feeding of the material in the direction of sewing and in a cross direction perpendicular to the sewing direction can be detected by the sensor. When sewing in the direction of sewing, deviations in the sewing direction and/or in the cross direction detected by the sensor can be compensated for by influencing the size of the feeding increments in the direction of sewing and/or cross direction. The same applies to sewing operations in the cross direction.
The method and device in accordance with the invention are suited to the regulation of cyclically working feeding devices linked with the main drive of the needle bar. The method and the device can also be utilized for regulating the transport of material in the direction of sewing and/or cross direction with independent drives which are not linked to the main drive. Such drives can be, for example, the stepper motors of an embroidery frame or electric motor roller actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail below based on the attached drawings of a preferred embodiment. In the drawings:
FIG. 1 is a foreshortened view of a sewing machine with the housing partially cut away and with an image sensor built into the throat plate;
FIG. 2 is a longitudinal section view through the throat plate in the area of the position sensor;
FIG. 3 is a cross sectional view through the lower arm and through a roller fastened to the presser foot which presses the article to be sewn onto a protective window;
FIG. 4 is a cross sectional view of the throat plate with the fixing device for the sensor located underneath;
FIG. 5 is a side view of a part of the sewing machine in the cross direction with a cross section of two pairs of rollers for the transport of the sewing material in the direction of sewing;
FIG. 6 is a perspective view of the sewing machine shown in FIG. 1 with a built-on embroidery frame;
FIG. 7 is a view of the throat plate with the article to be sewn lying on it during a sewing operation in the direction of sewing;
FIG. 8 is a schematic portrayal of a calculation by the controls 13 of the size of the feeding increment Δy T ;
FIG. 9 is a view of the throat plate with the article to be sewn lying on it during the sewing or embroidering operation in the direction of sewing and in the cross direction;
FIG. 10 is a schematic portrayal of the cyclical motion sequence of a material feeding device with a size of the feeding increment Δy T in the cross direction; and
FIG. 11 is a diagram showing the principle of regulation of the sizes of feeding increments through the increments measured by the position sensors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a preferred embodiment of a household sewing machine in accordance with the invention, referred to hereinafter as sewing machine 1 for short, with a machine housing, hereinafter the housing 3 , which includes a lower arm 5 , a machine arm 7 and an upper arm 9 with a machine head 11 . The housing 3 is partially cut away in FIG. 1 , so that a machine controller or controls 13 can be partially seen on the inside. A needle bar 15 , which can be operated by a drive for the lifting and moving of a sewing needle (not illustrated in FIG. 1 ) also called needle 17 , protrudes downwards out of the machine head 11 . Underneath the machine head 11 is an opening or a well 19 on the upper side of the lower arm 5 covered by a throat plate 21 . The upper side of the throat plate 21 and of the lower arm 5 are arranged flush with each other and define a sewing plane N that lies approximately perpendicular to the needle bar 15 . The throat plate 21 has a slot-shaped needle opening 23 located under the needle bar. On each side of this needle opening is an oblong, approximately rectangular material feeder opening 25 in the throat plate 21 . The three openings are not connected and together have the approximate shape of the capital letter “H”. The two material feeder openings 25 are arranged with their longitudinal dimension running permanently in a sewing direction y. The longitudinal dimension of the needle opening 23 extends in a cross direction x lying vertical to the sewing direction y. A material transport device 27 for the incremental transport of material or an article to be sewn 28 ( FIG. 7 ), located at least partially in the well 19 , is comprised of two bar-like material feeders 29 in the area of the material feeder openings 25 which are sawtoothed or roughened on their upper side. Also, in the sewing direction y, immediately behind the needle opening 23 , there is a round sensor opening 31 embedded in the throat plate 21 . Of course, the sensor opening 31 could also lie before or beside the needle opening 23 ; however, it should be located in the area surrounding the needle opening 23 , so that it lies in the immediate sphere of action of the material transport device 27 . This means that the material feeder operated by the material transport device 27 can be recognized by a sensor 32 located in or underneath the sensor opening 31 without significant errors. Of course, several sensors 32 can also be utilized independently of each other or in combination with each other for this purpose. The sensor opening 31 can be round or it can have any other form, such as rectangular or oval. It can also be comprised of several divided openings, such as slot openings located parallel to each other. The sensor(s) 32 are designed for detecting a measurement category in at least one spatial dimension. The measurement category is preferably an optical pattern or the optical structure of the article to be sewn 28 . A sensor 32 can be constructed in the form of a position sensor 33 , for example, or arranged as a CCD row parallel to the sewing direction (y), or as a CCD matrix ( 50 ), or as a micro-camera with a lens 34 ( FIG. 2 ) and with an image processing unit for detecting and processing a one or two dimensional image area. Of course, other location detecting sensors 32 can be used which use, for example, ultrasound, radar waves or other methods for detecting the position, location or speed of the article to be sewn 28 . The position sensor 33 is positioned in the well 19 in such a way that a protective window 36 ( FIG. 2 ) mounted in front of the lens 34 closes off the sensor opening 31 flush with the surface. As an option, the article to be sewn 28 can be pressed by a shoe or roller 38 ( FIG. 3 ) in the area of the protective window 36 from the side of the machine head 11 against the throat plate 21 and/or the protective window. The shoe or roller 38 , which can be pressed with the light pressure of a spring 40 on the article to be sewn 28 , can, for example, be fastened to a support bar of a presser foot. In this embodiment, it can be brought into contact with the article to be sewn 28 , together with the presser foot 42 , for the sewing process, and then be lifted up again. The shoe or roller 38 ensures that the lifting movements of the material feeder 29 do not cause any errors in the detection of the forward motion values by the sensor 32 . As an alternative to the position sensor 33 , other sensors 33 operating on the basis of other technologies and/or several sensors 32 can also be utilized in the sensor opening 31 , such as movement sensors or speed sensors. In the place of a sensor 32 , a suitable means of transfer or connection for transferring the measurement category/categories to be detected to the sensors 32 in the sensor opening 31 on the throat plate 21 can be used, such as a bundle of optic fibers, an optimized lens system and/or an arrangement of mirrors and/or prisms 44 ( FIG. 4 ). For transporting the article to be sewn 28 in the sewing direction y, a pair of rollers with at least a first roller 46 that is electrically driven ( FIG. 5 ) and a second roller 48 that can be pressed against the first one can also be used as an alternative to the material feeder 29 , whereby the article to be sewn 28 is fed through the rollers 46 , 48 . The surface of the rollers 46 , 48 is made of a material such as rubber or another material which features good holding characteristics with regard to textiles. The pair of rollers can be situated behind or in front of the needle opening 23 in the sewing direction y. Alternatively, there can be a pair of rollers located both in front of and behind the needle opening 23 . The advantage of such a roller drive lies in its independence from the main drive for the needle bar 15 and in the possibility of accommodating material feeding increments of any size in the direction of sewing y and opposite to the direction of sewing y.
In FIG. 6 , the sewing machine 1 from FIG. 1 is shown with a built on embroidery module 35 . The embroidery module 35 is comprised of an embroidery frame 37 for stretching and gripping the article to be sewn 28 and a positioning or movement device 39 driven by one of two (not portrayed) stepper motors for moving the embroidery frame 37 in or in opposition to the two directions x and y of the sewing plane N. The embroidery frame 37 is fastened to a frame holder 30 , which can be moved along a first arm 43 of the movement device 39 in the y direction. This first arm 43 can in turn be moved along a second arm 45 of the movement device 39 in the x direction. The article to be sewn 28 is clamped into the embroidery frame 37 in such a way that it lies on the sewing plane N.
FIG. 2 shows a longitudinal section through the throat plate 21 in the sewing direction y in the area of the position sensor 33 . The protective window 36 is made of a material such as a scratchproof sapphire glass or a hard, transparent plastic. By the flush fitting the window into the sensor opening 31 , the accumulation of dust or dirt particles is prevented. The lense 34 and a substrate 41 located underneath it, such as a conductor board used as a carrier of a two-dimensional CCD matrix 50 and a light source 52 , such as an LED, are contained in a sensor housing 47 . The position sensor 33 , in particular the substrate 41 with the CCD matrix 50 and the light source 52 , are connected with an electronic sensor 49 which can contain a processor with a clock rate of more than 10 MHz, for instance, and which can execute digital image processing algorithms.
Alternatively, the CCD matrix 50 and the electronic sensor 49 and, in another embodiment, the LED as well, can be integrated into a common semiconductor substrate. This is then held either on the substrate 41 or directly by the sensor housing 47 . In other embodiments, the LED can also be situated on the side of the lense 34 opposite the CCD matrix or outside of the position sensor 33 .
In FIG. 7 , a view of the throat plate 21 is portrayed in which the article to be sewn 28 lies on the throat plate during the sewing process in the sewing direction y. The stitching increment or the distance of the stitch sites 51 from the already executed sewing stitches in the article to be sewn 28 is, in the example portrayed in FIG. 7 , similar to a first actual increment Δy B of the material feeding through the material feeder 29 in the sewing direction y per feed cycle, since after each material feed cycle, a sewing stitch was executed. Basically, before the execution of sewing stitches, several material feeding cycles can be executed in which the actual material feed and/or the first actual increment in the sewing direction y each amounts to Δy B . It is also possible that the first actual increment Δy B of the material feed in sewing direction y can be changed during the sewing process by the user of the sewing machine 1 or by the controls 13 . In that embodiment of the sewing machine 1 which allows a material feed in both the direction of and the direction opposite the sewing direction y, the first target increments Δy A and the first actual increments Δy B can assume positive as well as negative values. In FIG. 8 , the entry or specification at the controls 13 of a specified value or a first actual increment Δy A for the material feed in the sewing direction y is symbolically portrayed. Such a specified value can be entered, for example, by a user of the sewing machine 1 by means of a dial or a by a menu on a touch screen.
Alternatively, or in addition, the controls 13 can also calculate such specified values for first target increments Δy A , especially in consideration of user input. The symbolically portrayed first feed increments Δy T in FIG. 8 likewise correspond to the pushing movement of the material transport device 27 , in particular the material feed 29 , operating on the article to be sewn 28 in sewing direction y. The first feed increment Δy T can take on a negative or positive value, depending on whether a movement backwards or forwards in sewing direction y is executed. In the ideal case, these values correspond to the first feed increment Δy T , and the first actual increment Δy B corresponds to the value of the first target increment Δy A . In reality, the first feed increment Δy T is, however, somewhat larger than the first target increment Δy A , because during each transport step, a certain slippage of the article to be sewn 28 must be reckoned with. The result of this, with an average sewing material 28 , is that the first actual increment Δy B corresponds approximately to the value of the first target increment Δy A . For this purpose, a value for the optimal relation to the first feed increment Δy T for the first target increment Δy A for the average sewing material 28 can be stored in a permanent memory of the controls 13 , for instance, whereby when this average sewing material 28 is pushed forward with this first feed increment Δy T , an actual material feed of a first actual increment Δy B is achieved which corresponds to the value of the first target increment Δy A .
In another embodiment of the sewing machine 1 , the material transport device 27 is constructed in such a way that the sewing material 28 can also be moved, in addition to the sewing direction y, in the cross direction x, which is oriented perpendicularly to the sewing direction y within the sewing plane N.
In FIG. 9 , a view of the throat plate 21 is shown in which the sewing material 28 is lying on the throat plate during the sewing operation, with feeding movements in the sewing direction y and in the cross direction x. In a manner analogous to the transport movement in the sewing direction y, the material feed 29 can also execute a transport movement in the cross direction x. In doing so, the material feeders 29 each execute a transport or feed cycle on the basis of a second target increment Δx A with a second feed increment Δx T in the cross direction x.
In FIG. 10 , the cyclical movement of a bar of the presser foot 29 for such a transport cycle is portrayed. For ease of explanation, the second feed increment Δx T is portrayed longer than they actually are, and the dimensions of the bars are portrayed smaller than they actually are in relation to the lifting movement. Possible positions of the bars during a transport cycle are drawn in as points.
The article to be sewn 28 is moved in each case by a second actual increment Δx B in the cross direction. Of course, Δx A , Δx T , and Δx B can take on both positive and negative values, which correspond to movements in and opposite to the cross direction x. As can be seen in FIG. 9 , the relative coordinates in units of the respective first actual increments Δy B in the sewing direction y and the respective second actual increments Δx B in the cross direction are indicated between the individual, already executed stitching sites 51 a – 51 e . The pertinent individual feeding cycles of the material feeder 29 in sewing direction y and in cross direction x can be executed consecutively one after the other. Alternatively, a part of the feeding cycles executed between two stitching sites 51 can also be executed as a combined simultaneous movement in sewing direction y and cross direction x.
If, as illustrated in FIG. 6 , an embroidery module 35 is attached to the sewing machine 1 , then the transport of the article to be sewn 28 no longer takes place by means of the material feeder 29 , but rather by the stepper motors through the movement device 39 . In this case, the first feed increment Δy T has the minimum value of the increment of the step motor operating in sewing direction y. Analogously, the second feed increment Δx T has the minimum value of the increment of the step motor operating in the cross direction x. If these increments are very small, under 0.1 mm for example, a multiple of these increments can also be defined as the first feed increment Δy T and/or as the second feed increment Δx T , in a permanent memory of the controls 13 or of the embroidery module 35 , for example. Alternatively, the first feed increments Δy T and/or the second feed increments Δx T can also be redefined for each new sewing stitch, as values for the stitch length in sewing direction y and in cross direction x, for example.
With both the transport of the article to be sewn 28 by material feeders 29 and with transport by the movement device 39 for an embroidery module 35 , the actual increments Δy B , Δx B may deviate from the respective target increments Δy A , Δx A . The reason for this can be, for example, the different transport characteristics which are dependent on the article to be sewn 28 , the sewing position within the article to be sewn 28 or the transport direction. Forces operating on the article to be sewn 28 during the sewing process and the results of wear on the sewing machine 1 are additional possible causes for transport characteristics which change.
As can be seen from the process diagram in FIG. 11 , the first feed increment Δy T and/or the second feed increment Δx T is regulated in dependence on the first actual increment Δy B of the actual material feed in sewing direction y and/or the second actual increment Δx B in cross direction x detected by the position sensor 33 . An area of the article to be sewn 28 lying over the protective window 36 ( FIG. 2 ), which has the measurements of 5 mm×5 mm, for example, is illuminated by the light source 52 and reproduced by the lense 34 on the CCD matrix 50 . In connection with the electronic sensor 49 , which is comprised of a digital image processing system, called IPS for short, or DSP (Digital Signal Processor), the position sensor 33 can detect and process 1500 images per second, for example. The position sensor 33 is in the position to recognize the smallest structures or differences in structures as well as their position in the detected display details by means of differences in intensity within the detected display details. On the basis of the change in position of characteristic irregularities in the surface structure of the article to be sewn 28 and/or on the basis of the change in position of color patterns of the article to be sewn 28 in consecutive and/or additional chronologically consecutive image exposures, the IPS of the position sensor 33 calculates relative displacements of the article to be sewn 28 in the sewing direction y and in the cross direction x and/or the corresponding feeding speeds. By considering several image exposures with at least one common structural characteristic, the resolution and accuracy of the position sensor 33 can be further improved. Preferably, the displacements or changes in position of the article to be sewn 28 are added up by the electronic sensor 49 , based on the x and y coordinates of a zero or starting value at the beginning of the sewing process, and made available as absolute x and y coordinates for the position values in relation to the starting value in the form of an output signal.
If the article to be sewn 28 is stationary following the execution of sewing stitches or feed cycles, the controls 13 reads each of the actual feed values of the article to be sewn 28 in the x and y direction calculated by the IPS in relation to the starting value and saves them in a memory of the controls 13 . Alternatively, if the sensor 32 possesses a sufficiently high clock rate, the feed value can also be transferred to the controls 13 during the material feed and be stored periodically, for example, in chronologically similar or changing intervals. As a result, a sewing step characterized by two consecutive needle stitches can be analyzed in any desired manner as individual target increments, for which then the actually executed increments are calculated by the sensor 32 .
By subtraction of immediately consecutively stored corresponding values, the controls 13 calculate the actual pertinent material feed, thus the first actual increment Δy B and/or the second actual increment Δx B .
Alternatively, the zero or starting value for each sewing step or feed cycle or a multiple of these can always be redefined again. In this case, the value transferred by the IPS to the controls 13 is directly the first actual increment Δy B and/or the second actual increment Δx B , and the subtraction does not apply.
The controls 13 now calculate the deviation of the respective first target increment Δy A from the calculated first actual increment Δy B and store this value as the first correction value D y . The first feeding increment Δy T is increased for the following sewing step or feeding cycle by the double of the first correction value D y , thus Δy T[2] :=Δy T[2] +2D y . With this, the calculated deviation is compensated for in only one sewing step. Finally, the value of the feeding increment Δy T is reduced again for the following sewing step by D y , thus Δy T[3] :=Δy T[2] −D y , and remains at this corrected value for further sewing steps until a deviation between the actual and target values is once again detected. In an analogous fashion, the regulation of the second feeding increment Δx T takes place.
With the regulation algorithm described, the controls 13 can correct recognized deviations with the first feeding increment Δy T and/or the second feeding increment Δx T very quickly within only one feeding or sewing step. Especially with the transport device 27 dependent on the main drive for the needle bar 15 , the individual target increments within a sewing step can be arbitrarily defined, so that a regulation of the feeding increments Δy T , Δx T can take place even within a single sewing step.
Alternatively, other known regulation algorithms can also be used for regulating the feeding increments Δy T , Δx T , in which an adjustment and a correction of errors takes place over the course of several feeding or sewing steps. By this, larger differences between the stitch lengths of two consecutive sewing stitches as well as undesired back coupling or oscillation of the sewing needle can be avoided. The calibration or regulation of the feeding increments Δy T , Δx T takes place by means of step motors. With the transport devices 27 with material feeders 29 , the stepper motors operate directly or indirectly on a (not illustrated) regulator for adjusting the respective feeding increments Δy T , Δx T . With transport devices 27 operated by stepper motors like those used in embroidery modules 35 , the feeding increments Δy T , Δx T of these stepper motors are directly adjusted.
The sensor 32 can also be used for the optical recognition of embroidery frames if an edge is positioned over the sensor 32 .
|
A method and device for creating uniform stitch lengths in an article being sewn by detecting actual feeding increments of the article using a sensor. With this information, the sewing or embroidery machine is controlled to provide generally uniform stitch lengths.
| 3
|
TECHNICAL FIELD
In general, the present invention relates to resources in a computing device and, more particularly, to managing resources in a computing device.
BACKGROUND
Operating systems employ resource management schemes to limit the interference between applications, implement policies that prioritize and otherwise control resource allocations, and generally manage the overall behavior of a system that is running many independent software applications.
Existing resource management schemes are largely first-come, first-served. Counter-based resource management schemes, such as those used in the Digital VAX/VMS, the BSD/UNIX, and the WINDOWS NT operating systems, attempt to maintain an absolute count of resource use by one or more processes. Counters may track, for example, kernel memory utilization, Central Processor Unit (CPU) utilization, or Input/Output (I/O) data transfers.
One of the problems with counter-based resource management schemes is determining what the limits are and the consequences of reaching or exceeding the limits. More often than not, the limit is simply raised when it is reached. In the context of the WINDOWS operating system, setting limits on the use of certain resources is generally achieved through mechanisms such as job objects, kernel quotas, CPU affinities, and various ad hoc resource-specific limits. Resource use can also be capped along functional lines, as, for example, when the memory manager caps the use of kernel virtual address space based on how it is to be used. Another example is when the use of kernel pool by the Transmission Control Protocol/Internet Protocol (TCP/IP) is dynamically capped based on the type of packet that is currently being transmitted, e.g., a packet representing voice data might have a higher cap on the use of kernel pool than a packet that does not in order assure a quality voice transmission.
In some cases, resource management schemes are based on setting relative priorities of the processes competing for the resources to aid in arbitrating resource contention, as is currently done, for example, in the scheduling of CPU resources. In addition, resource management schemes may be based on privileges, i.e., requiring processes to have privileges to carry out certain operations to effect the allocation of resources, as is currently done, for example, by requiring a process to have the privilege to lock physical pages in memory.
There are several problems with existing resource management schemes. As most resources are system-wide, managing resources on a first-come/first-served basis can lead to denial of service problems. This is because resources may be subject to unbounded consumption by other applications, other users, or network-visible services. Reliance on the existing mechanisms creates an unpredictable environment in which applications often cannot acquire the resources needed to run because errant, selfish, or malicious applications have already absconded with them. The problem is particularly acute in large terminal services machines.
Priority-based resource management schemes only worsen the competition. Since applications cannot independently establish their priority relative to other applications, it is generally not possible to set priorities to share the resource fairly. In most cases, it is not even possible to define priorities fairly. In the case of CPU resources, this often leads to applications artificially boosting their priorities to ensure access regardless of the demands present elsewhere. The end result is that applications will compete at the inflated priority level, nullifying any fairness policy the priority scheme was aiming to accomplish.
With no limits on resource competition, it is very difficult to provide pre-defined levels of service to specific applications. An administrator or service provider generally cannot specify either a minimum or maximum amount of resources for an application. This presents problems in server consolidation scenarios, and forces the administrators and service providers to support consolidation by, for example, dynamically adjusting priorities to manage CPU utilization by specific applications.
Some systems have attempted to overcome some of the problems inherent in resource management through the use of resource guarantees. Instead of just setting limits or priorities, applications may contract for implicitly allocated resources upfront. Guarantees eliminate instantaneous competition for resources by adding a layer of indirection between requesting a resource and actually using it. By explicitly reserving resources in a first-come/first served manner, a client obtains a contract regarding future use of the resource (e.g., guaranteed I/O latency), regardless of any other outstanding guarantees. Bandwidth is one example where resource guarantees are particularly important for the implementation of multimedia applications. However, guarantees themselves are resources and allocation of guarantees may fail.
As personal computers move into the living room and take on many new roles, resource management becomes more important, particularly when managing conflicts in resource usage. In addition, server computers need to manage resources more effectively in order to provide a more predictable operational environment.
SUMMARY
The foregoing problems with the prior state of the art are overcome by the principles of the present invention, which is directed toward methods, systems, computer program products, and data structures for managing resources in a computing device. The present invention is further directed toward methods, systems, computer program products, and data structures for managing resources in a computing device to facilitate the allocation of resources amongst competing processes or threads operating on the device.
According to one aspect of the invention, a budget encodes resource requirements and restrictions for one or more clients. Any number of processes, threads, or a combination thereof, executing on behalf of a client may be associated with a single budget. A particular process or thread may also be associated with multiple budgets, but is subject to only one budget at any instant in time. The processes and threads compete for resources based on, among other considerations, the requirements and restrictions encoded in the active budget.
In accordance with yet another aspect of the invention, the active budget for a particular process or thread may change numerous times over the course of its lifetime, depending, at least in part, on the client on whose behalf the process or thread is executing. In the case of a service process that is performing a service for one or more clients on a set of concurrently executing threads, the client on whose behalf the process or thread is currently executing may be determined using resource-client identity impersonation. Resource-client identity impersonation temporarily associates a process or thread with a client by assuming the client's resource-identity to locate and temporarily attach to the client's active budget. Typically, this is accomplished by examining the active budget for the current client thread.
According to another aspect of the invention, the budget encodes resource requirements and restrictions for the client (or clients) associated with the budget, at least in part, by maintaining one or more of three quantities for each resource supported for the client(s), the quantities indicating a limit, “L,” a reservation, “R,” and a commit, “C.”
According to one aspect of the invention, the budget limit, “L,” represents a maximum on the amount of a resource that the client(s) associated with the budget can obtain from the provider of the supported resource, i.e., the resource provider. Limits may be either hard or soft, a distinction that dictates the appropriate behavior when the threshold is reached. If the limit is hard, it is an absolute maximum and may be enforced by taking one or more actions, such as failing requests to allocate the resource or employing rate-control. However, if a limit is soft, then the limit only serves as an advisory to the relevant resource provider in deciding whether or not to fulfill a client's request to allocate the resource. Typically, the resource provider makes a determination whether to provide soft resource allocation based on resource utilization level and whether the allocation can be reclaimed when needed with minimal performance overhead.
According to one other aspect of the invention, the budget reservation, “R,” represents a pre-allocation of a resource that ensures that future requests to allocate the resource on behalf of a client up to the amount of the reservation, “R,” will likely succeed, also referred to herein as a guarantee. The budget reservation “R,” is constrained by the budget limit “L,” whether the limit is hard or soft. The budget reservation “R,” may further represent a sufficient amount of the resource to span multiple allocations, each allocation carving out a portion from the budget reservation.
According to one other aspect of the invention, the budget commit, “C,” represents the amount of a resource that a resource provider has thus far allocated to the client(s) with which the budget is associated. Like the reservation value, the budget commit, “C,” is constrained by the budget limit “L,” whether the limit is hard or soft. In addition, the budget commit, “C,” may exceed the reservation value “R.”
According to still another aspect of the invention, a budget hierarchy links together the resource requirements and restrictions encoded in separate budgets. Budgets in a budget hierarchy are organized in an n-ary tree format, with each budget object having at most one parent and an unbounded number of children. As such, a budget hierarchy may be considered to have a single root budget which has no parent. Clients associated with a child budget in a budget hierarchy are also subjected to the resource limit “L,” of a parent budget, including the root budget. A parent budget may function as the default active budget unless a child budget is not explicitly created. The limit imposed on the client is the more restrictive of the limits maintained in the child and parent budgets, referred to herein as the effective resource limit.
According to yet another aspect of the invention, budget hierarchies may be external or internal. External budget hierarchies may be explicitly constructed in advance of their use based on policy considerations. Internal budget hierarchies may be dynamically constructed by a client attempting to self-manage resource consumption by the threads and processes executing on its behalf. A client may be permitted to escape from the budget hierarchy of which its currently active budget is a part if it has sufficient privileges, for example, to subject an application to a policy other than that encoded in the current budget. An application that needs to limit the resources available to a new process can create a child budget in order to contain potentially malicious or dangerous behavior.
According to one other aspect of the invention, additional limits may be encoded in a budget or elsewhere to dynamically change the resource restrictions imposed on a client based on how the client is using the resource. A client's use of a resource may vary over time, depending on modes of operation and the like. The client defines the additional limits by the types of use, and communicates the current use of the resource by indicating an active flavor. The active flavor is one of a plurality of flavors that represent the various uses to which a resource may be put. In this manner, clients, within the constraints imposed by their associated budgets, may partition their use of resources based on the type of use. Typically, the active flavor can be communicated to the resource manager explicitly, for example, by passing it as a parameter to a resource allocation API, or implicitly, for example, by setting the active flavor into the user-mode and/or kernel-mode memory state for the client.
According to still another aspect of the invention, the resources that may be supported in a budget include discrete, rate-based, and guaranteed resources. A discrete resource is a resource that is allocated to a client for exclusive use by the process or thread executing on its behalf. Discrete resources include resources that are constrained by actual physical limitations on the operating system, or by artificial limitations imposed by the design of the operating system. Rate based resources include usage patterns of any discrete resource with respect to time, such as the rate of CPU consumption, I/O or network bandwidth, and the like. Guaranteed resources may be associated with either or both discrete resources and rate-based resources. A guaranteed resource serves as a voucher for the future availability of a resource up to a designated amount.
According to still another aspect of the invention, the clients for which resources may be managed may include applications or groups of applications. A client may optionally function as a budget manager having privileges to encode resource requirements and policy rules in a budget on behalf of other clients.
According to yet another aspect of the invention, a resource manager centralizes the administration of resources, including implementing the budgets, monitoring available resources, and recovering from resource allocation failures. The resource manager may further provide interfaces to specify budget constraints and communicate with resource providers. A resource manager may validate resource allocation requests forwarded from resource providers on behalf of clients in accordance with a dynamic policy state. The dynamic policy state represents the current state of resource management policy, including the identification of currently executing processes and threads, their relative importance, as might be indicated, for example, by a priority level, and their currently active budgets. The resource manager further arbitrates conflicts between a requesting client and a target client in accordance with an allowed action set specified for processes and threads executing on behalf of the target client in the dynamic policy state. The allowed action set ranges from passive actions for the target client to voluntarily cede resources for reallocation to a requesting client, pro-active actions to forcibly reclaim resources from a target client, and aggressive actions that result in terminating the target client from which resources are reclaimed. The resource manager may optionally enforce rate control of a resource on behalf of a resource provider.
According to one other aspect of the invention, resource providers allocate resources to requesting clients and reclaim resources from target clients separately from, but in accordance with, the resource manager's validation and arbitration determinations. As resources are allocated and reclaimed, the resource providers further interact with the clients' budgets directly or indirectly in cooperation with the resource manager, to record the consumption and release of supported resources.
According to still another aspect of the invention, resource notification services are provided to facilitate notifications regarding a resource to requesting and target clients from resource providers and the resource manager. Notifications include, among others, notifications related to resource arbitration and notifications that resource usage has reached or exceeded a threshold.
In accordance with yet other aspects of the present invention, a computer-accessible medium for managing resources in a computing device is provided, including a medium for storing data structures and computer-executable components for creating, maintaining, and querying budgets, reserving and managing resources, recording consumption of resources, and arbitrating resource conflicts. The data structures define the resources and resource providers, budgets, and other policy data in a manner that is generally consistent with the above-described systems and methods. Likewise, the computer-executable components, including the resource manager and resource manager interfaces to the budgets and resource providers, are capable of performing actions generally consistent with the above-described systems and methods.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a depiction of an exemplary resource management system and one suitable operating environment in which resources may be managed in accordance with the present invention;
FIG. 2 is a block diagram depicting in further detail an arrangement of certain components of the budgets illustrated in FIG. 1 for implementing an embodiment of the present invention;
FIGS. 3A-3B are pictorial diagrams of exemplary budget hierarchies formed in accordance with an embodiment of the present invention;
FIG. 4 is a block diagram depicting in further detail an arrangement of certain components of the budgets illustrated in FIG. 1 for implementing an embodiment of the present invention;
FIG. 5 is a block diagram depicting in further detail an arrangement of certain components of the resource notification services illustrated in FIG. 1 for implementing an embodiment of the present invention;
FIG. 6 is a block diagram depicting in further detail an arrangement of certain components of the resource arbitrator illustrated in FIG. 1 for implementing an embodiment of the present invention;
FIG. 7 is a block diagram depicting in further detail an arrangement of certain components of the policy module illustrated in FIG. 1 for implementing an embodiment of the present invention;
FIG. 8 is a block diagram depicting in further detail the interaction between the resource provider and certain components of the resource management system illustrated in FIG. 1 to allocate resources in accordance with an embodiment of the present invention;
FIG. 9 is a flow diagram illustrating the logic performed for managing resources in accordance with an embodiment of the present invention; and
FIG. 10 is a block diagram overview of example resource manager budget interfaces formed in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
To successfully run an application on a computing device, the device's operating system must provide the application with various resources. A computing system suitable for implementing an improved method for managing those resources to facilitate their efficient allocation and use in accordance with embodiments of the present invention is described in detail in the following discussion.
In general, the resources that may be managed in an embodiment of the present invention include any quantifiable resource for which it is meaningful to allocate all or part for the use of an application or the operating system under circumstances where the resources may be temporarily or permanently depleted, or otherwise unavailable. Some examples of resources that may be managed are described in detail below. The resources are typically allocated amongst competing processes or threads operating on the device. The competing processes or threads may be executing on behalf of one or more applications or the operating system.
The most familiar resources that may be managed in an embodiment of the present invention are based on real and virtualized hardware: physical memory pages, disk blocks, peripheral devices, virtual address space, pagefile space, CPU time, object namespaces, etc. Some of these resources are implicitly allocated. For example, scheduling the CPU allocates CPU time, requesting an I/O operation consumes bandwidth throughout the I/O system, and accessing an invalid address generates a page fault.
In most systems, there are only a few fundamental (or base) resources of note; typical examples include disk (storage), I/O, CPU, kernel virtual address space (KVA), user virtual address space (UVA), and physical page frames. Most other resources are typically composited from these fundamental base types. Although KVA and UVA are abstractions built on top of physical memory, they represent a fundamental resource in that the amount of KVA and UVA space is limited by the number of logical address pins and operating system design, and not the amount of underlying physical memory.
Examples of resources that may be managed in an embodiment of the present invention implemented in the MICROSOFT WINDOWS NT operating system include, but are not limited to, non-paged and paged pool, system page table entries (PTE) for virtual pages partitioned off the KVA, pagefile space, paging rate, and AWE memory. Each of these resources, whether base or composite, may be defined by some set of characteristics that arise from artifacts and/or design decisions or requirements present in the operating system. A list of such characteristics is given below:
Limited (Absolute) Resources: In many cases, the availability of particular resources may be constrained by artificial limits imposed by the operating system. For example, due to a fixed number of slots in some table, the data structures used by the operating system may be limited. On the other hand, anything that can be counted (the total number of page faults, I/O bytes transferred, context switches, CPU time, etc.) maybe considered a resource when combined with an artificial limit. Most of the resources that fall under the “counted” category are typically implicitly allocated by the application that needs the resource. In a typical environment, the operating system may also limit simultaneous resource consumption, for example, by restricting the number of active network connections it may concurrently support.
Rate-based: The rate at which a resource can be allocated can also be a resource. For example, CPU time scheduled, I/O, page faults, and context switches can all be limited by the rate at which they can occur. Such limits may be either artificial (imposed by the operating system) or a practical limitation (e.g., a maximum sustainable possible I/O rate). Limited resources may be differentiated from rate-based resources in that limited resources are accounted for and limited based upon absolute quantities (e.g., total CPU time consumed, total page faults incurred, or total non-paged pool allocated). Rate-based resources may also differ from other types of resources in that a rate-based resource is typically automatically replenished in the absence of resource use over some duration of time.
Guarantees: In the case of most allocated resources, the operating system must arbitrate for resource availability instantaneously. Depending upon the state of resource use by other clients, the operating system may be unable to satisfactorily address a resource request for an extended period of time. For example, a low priority thread may remain starved until the system boosts its priority or, alternatively, all higher priority threads cease to be in a ready/runnable state. To alleviate this difficulty, particularly for clients that have bounded latency requirements that are necessary to support quality of service (QoS) levels, the system may offer guarantees regarding resource availability. Examples include promising to provide 100 milliseconds (ms) of CPU time every second, or to transfer 2 megabytes of I/O data per second, or to service up to 80 hard page faults per second. Such guarantees are meaningful only because the system will later act to realize them; thus, there is necessarily some restriction on the number of such promises the system may concurrently make. In this regard, guarantees may themselves be considered to be a resource.
The resources that may be managed in an embodiment of the present invention include both renewable and non-renewable resources. Resources can be categorized as renewable or non-renewable based on how they are replenished. Renewable resources are consumed when allocated to an application, but are automatically replenished with the passage of time. Most implicit rate-based resources, such as CPU rate, I/O bandwidth, and page fault rate, are renewable. Non-renewable resources are replenished when the application returns the allocation. Memory blocks, devices, counted limits, and data structure limits are all examples of non-renewable resources. Most resources are non-renewable.
The resources that may be managed in an embodiment of the present invention also include reclaimable resources. A reclaimable resource is one the system can retrieve from an application without the application's cooperation. The most severe form of retrieval is to simply terminate the application so that all of its resources are relinquished to the system. However, individual resources can be retrieved in many cases, with the effect on the application varying from degraded performance, to reduced functionality, and possibly to abnormal exit. Examples of reclamation include un-mapping a memory resource, de-scheduling an application, invalidating handles, and ceasing to honor guarantees. Certain resources, of course, cannot be reclaimed in the sense described here; typically such resources are infinite in quantity, but any portion allocated to a client is “consumed” and cannot be returned to the system. Examples include monotonically increasing quantities such as total CPU time consumed and total page faults incurred.
FIG. 1 illustrates an exemplary resource management system 100 and one suitable operating environment in which resources, such as those described above, may be managed in accordance with the present invention. As shown, a resource manager 108 operates in conjunction with resource providers 112 and clients 102 to manage the allocation of resources to the clients 102 by the resource providers 112 in accordance with a dynamic policy state. The resource providers 112 control the actual allocation of resources, whereas the resource manager 108 centralizes the management of the resources. In this manner, the architecture of the resource management system 100 decouples the allocation of resources from the functions of managing the resources.
In a typical embodiment, the resource manager 108 is implemented in a kernel mode component, but could be implemented elsewhere without departing from the principles of the present invention. The resource providers 112 are typically implemented as either user or kernel mode components. Examples include memory managers, and CPU reserve and IO categorization mechanisms. In one embodiment, a user mode resource provider 112 interacts with a kernel mode resource manager 108 using a kernel mode resource provider as a proxy.
As noted earlier, the resource manager 108 operates in conjunction with resource providers 112 and clients 102 to manage the allocation of resources to the clients 102 by the resource providers 108 in accordance with a dynamic policy state. The dynamic policy state is embodied, at least in part, in one or more budgets 104 A, 104 B, 104 C formed in accordance with a policy module 114 . In one embodiment, the policy module 114 may comprise one or more policy managers 116 and a policy database 118 . In general, the policy module 114 operates to encode in the policy database 118 certain preferences such as the priority of specific clients 102 and other static (or relatively static) policy data. The budgets 104 A, 104 B, 104 C, on the other hand, generally encode the dynamic resource requirements and restrictions of a particular client or set of clients. The use of the policy module 114 in the management of resources will be described in further detail with reference to FIG. 7 .
The budgets 104 A, 104 B, 104 C may be active or inactive. An active budget is one that is currently associated with a client 102 . An inactive budget is one that has typically been created in advance for one or more clients to represent policy considerations, but for a number of reasons is not currently associated with a client 102 . In a typical embodiment, a budget is implemented in a budget object. Budget objects are associated with one or more processes or threads currently executing on behalf of a client 102 . Among other uses, the resource manager 108 uses the active budgets to determine how much of what resources the associated process or thread may use at a given point in time. In one embodiment, budgets may be dynamically created and/or activated and associated with any one or more of groups of related applications 102 A, unrelated applications 102 B, and budget managers 102 C. The groups of related applications 102 A, unrelated applications 102 B, and budget managers 102 C together comprise the clients 102 for whom resources are managed. The use of budgets to manage resources will be described in further detail with reference to FIGS. 2-4 .
In one embodiment, the functions of the resource manager 108 include, among others, enforcing budgets 104 A, 104 B, 104 C, including administering advance reservation requests for resources and bandwidth guarantees, monitoring available resources, and arbitrating resource contention. The functions of the resource manager 108 may further include adding and removing dynamic resources that may or may not be controlled by third-party resource providers.
In one embodiment, the functions of arbitrating resource contention among competing clients 102 may be embodied in a resource arbitrator module 122 . In a typical embodiment, arbitration is performed at the request of a resource provider 112 . In one embodiment, the resource arbitrator 122 determines whether resources should be reclaimed from an outstanding allocation to one client, i.e., a target client, to satisfy an outstanding request for the resource from another client, i.e., a requesting client. The resource arbitrator 122 makes such arbitration determinations in conjunction with the dynamic policy state, i.e., the current budget objects and other policy data, as will be described in further detail with reference to FIG. 6 .
In one embodiment, the resource manager 108 is further provided with a resource manager interface 106 to facilitate communication with the clients 102 , the resource providers 112 , and other components of the resource management system 100 . In particular, the resource manager interface 106 may be used to control interactions between the resource manager 108 and the budgets 104 A, 104 B, and 104 C, as well as between the resource manager 108 and the components of the policy module 114 . In one embodiment, the resource manager interface 106 may further control interactions between the resource manager 108 and resource notification services 124 . The resource manager 108 may optionally use resource notification services 124 to notify interested clients 102 about resource availability and management. Upon receiving a notification, clients 102 may, in turn, cooperate with the resource manager 108 to release resources that are in short supply to facilitate efficient resource management. In some cases, client cooperation with notifications may help to avoid having to arbitrate resource contention later on.
In one embodiment, the resource manager 108 may further include a resource rate controller 120 to enforce rate control of resources on behalf of a resource provider 112 , i.e. to control the consumption of a resource by one or more clients 102 per unit of time.
In a typical operating environment, the resource providers 112 may control interactions between the resource provider 112 , the clients 102 and the resource manager 108 via one or more resource provider interfaces 110 .
FIG. 2 is a block diagram depicting in further detail an arrangement of certain components of the budgets illustrated in FIG. 1 for implementing an embodiment of the present invention. A budget 104 may be implemented as a budget object 200 that is associated with one or more processes 202 and/or threads 204 executing on behalf of a client 102 . The budget 104 encapsulates the resource requirements of the clients 102 with which it is associated in a manner that assists the resource manager 108 and resource providers 112 in providing quality of service (QoS) levels, resource reservation, and client isolation (throttling of resource use by a client).
Internally, budgets track three quantities for each supported resource 206 : a limit (L) 208 , a reservation (R) 210 , and a commit value (C) 212 . In the discussion that follows, the threads, processes, etc. associated with the budget 104 are referred to as clients of the budget, where client generally refers to the client 102 on whose behalf the thread or process is executing. For ease of description, references to threads 204 include processes 202 or any logic executing on behalf of a client 102 unless otherwise indicated. At any instant an executing thread's resource usage is subject to a single budget 104 , i.e., the active budget object 200 . At the same instant, the active budget object 200 may be associated with multiple threads executing on behalf of the same or different clients 102 . The budget's parameters and the actual budget object 200 representing the budget 104 may vary over time, due to policy decisions implemented by the resource manager 108 or due to manipulation by the multiple threads 204 and/or processes 202 with which it is associated. Furthermore, budgets 104 may be hierarchically related in order to express relationships between different clients 102 on whose behalf threads 204 are executing such that the resource usage of one client may be tied to the resource usage of other clients associated with budgets in the same budget hierarchy.
The limit value (L) 208 represents a maximum amount of a resource that a budget may reserve for future use by the budget's clients. Though limits typically remain constant following budget creation, a system component with sufficient privilege may subsequently modify these limits. Limits may be of two types: hard or soft. A hard limit is an absolute limit on the amount of resources that may be assigned to a budget at the normal service level. If the limit is soft, then resource allocations in excess of the limit value L 208 are disbursed to the requesting client at a sufficiently degraded service level such that the system's ability to satisfy normal resource requests remains unimpaired. Such lower service level resource disbursements allow clients to make use of resources that might otherwise be underutilized
The reservation value (R) 210 represents a maximum amount of a budgeted resource that a client of the budget can reserve, and is always bounded by the limit L 208 , regardless of whether L is hard or soft. As such, the reservation value R 210 imposes a maximum on the amount of a resource that the clients of the budget will be able to subsequently allocate at the normal service level without requiring resource arbitration. Since reserved resources are effectively unavailable for reservation by other clients all reservations are typically conservative so as to minimize resource under-utilization and unnecessary resource contention.
The commit value (C) 212 records the actual amount of resource that a resource provider 112 has allocated to a client 102 of the budget. Because a limit L 208 that is soft marks the threshold at which resource allocations cease to be provided at the normal service level, the commit value C 212 may be written as the sum of two values: normal commit (Cn) and excess commit (Ce). All allocations up to the limit L are considered to be of the Cn type, which indicates that the resource provider allocated Cn resource to clients at the normal service level. Ce represents the fraction of commit that is granted to applications at a degraded service level, and is only granted to an application if both L is soft and Cn=L, i.e. when the resource provider has already allocated the full amount of the soft limit. Thus when L is a hard limit then Ce is necessarily zero.
The limit L 208 itself serves as a loose upper bound on the amount of a resource that may be reserved, R 210 . R 210 is constrained by the other reservations present in the client's budget hierarchy, as will be described below with reference to FIG. 3 , and reservations elsewhere in the system. Since resource allocations classified as excess commit Ce are reclaimable, clients 102 typically use excess resource allocations to perform optional or non-time critical processing (e.g., to provide additional MP3 video display effects, etc.).
The aim of soft limits is to ensure that resources in the system are not underutilized, particularly in the absence of contention. For resources that are idle, for example, it is generally safe for a resource provider 112 to classify the resource as excess and allow it to be allocated to needy clients. For resources that can be explicitly reserved in advance of being committed, i.e., finite resources as opposed to rate-based resources, a resource provider 112 may speculate as to which portions of a reserved but uncommitted resource are unlikely to be used in the near future. The resource provider 112 may then disburse such resources to a requesting client 102 , but must be sure that the resource can be reclaimed quickly, efficiently, and likely without the explicit cooperation of the client 102 . Otherwise, the resource provider 112 may subject clients 102 that have made advance reservations to unreasonable delay while the necessary resources are reclaimed. Thus, there are only a handful of resources for which the concept of soft limits is both meaningful and practical for the resource manager 108 to implement.
In an example implementation of a soft limit, suppose that at time a the value of C was Ca and at time b was Cb such that a<b, a single allocation of C′=Cb−Ca was made, and Ca<R<Cb. In this case a portion of Cn, (R−Ca), can always be guaranteed to be made without the need for resource arbitration. This requirement does not preclude the resource provider from reclaiming the resource quantity (R−Ca) from a Ce allocation granted to another client and using it to satisfy this request as long as the resource provider can perform such an action within a span of time that is approximately equivalent to the time required to allocate resource from the available (unused) resource pool. Note that if the resource cannot be allocated in a fragmented manner (as with e.g., physical pages), then arbitration may be required for the entire allocation C′ rather than just (Cb−R).
A typical use of soft limits is to avoid under-utilization of CPU. When a budget 104 has a limit L 208 of a certain percentage of CPU consumption, and there is no contention for CPU, then there is generally no reason that the clients of the restricting budget cannot consume all of the CPU (as otherwise, the CPU would go completely unused). The difficulty in simply disbursing the available CPU to the clients in question is that it must be easily revoked should any other clients (not bound to the restricting budget) become ready. If the CPU could not easily be reclaimed and disbursed to a legitimate client, the usefulness of the soft limit L 208 set in the restricting budget would be thwarted. While achieving zero reclamation cost is difficult to achieve, it can be greatly minimized in certain cases. In the case of CPU, for example, once the limit L 208 has been exceeded, the priority of the restricted threads can be dramatically lowered before allowing them to continue execution. Thus, in the absence of CPU contention, the restricted threads are scheduled on the CPU and their operation continues unhindered. Should any other unrestricted thread (not associated with the budget) become ready, or should contention for CPU otherwise occur, the lowered priority ensures that the restricted threads do not interfere with the legitimate activity of the unrestricted threads. When the resource is replenished, the restricted threads' priorities are restored to their former levels.
Typically, a resource provider will determine whether to provide excess resource allocations, i.e., whether to impose soft limits as opposed to hard limits, based upon the amount of time in which reclamation can be achieved. In this manner, the reclamation time may be used to bound the wait time that a legitimate normal resource allocation Cn may encounter, assuming the resource is held in Ce allocations in other budgets. Note in general as described above that the reclamation time can be bounded only for portions of a Cn allocation that are less than R; other portions of R can at worst be delayed by the time required to reclaim the resource from the Cn allocations given to other clients.
By allowing soft limits, a client 102 of a budget 104 may partially compensate for an artificial limitation set on its reservation requests due to unused reservations made by other clients in the system. It should be noted that soft limits may appear to negate the effectiveness of budgets 104 in constraining resource usage, as they permit committed usage to be unbounded. However, allocations beyond the soft limit are typically limited to resources that would otherwise be under-utilized. Not all resource providers 112 may support soft limits. For example, the use of soft limits to avoid under-utilization may not be desirable when the goal is to provide consistent performance (as opposed to optimal performance). Thus, not all supported resources 206 in a budget 104 may be subject to a soft limit L 208 .
Soft limits provide a means by which resource under-utilization may be combated, but do not offer a means by which interested parties may receive advance notice that the resource usage tracked by a particular budget has passed a certain threshold. To address this omission, resource budgets 104 support the notion of “sentinels,” or alarms, on resource usage by optionally including a budget sentinel value 214 . The only restriction on the value of budget sentinels 214 is that they are less than or equal to the current resource limit L 208 set in the budget 104 (if the resource limit L is contracted to a value less than the sentinel's value, then the sentinel is invalidated). The sentinel's value bears no ordering relation to the current normal commit (Cn) or reserve values R for the resource in question. When the current normal commit Cn value of a particular resource exceeds the sentinel value 214 , other clients 102 may be notified, for example, by using the notification services 124 described in detail with reference to FIG. 5 below. Upon receipt of such a notification, the client 102 may react as it sees fit (e.g., by adjusting resource usage, modifying resource limits, etc.). In a typical embodiment, to avoid severe performance degradation in cases of hysteresis (in which the current normal commit Cn value oscillates back and forth across the value of the budget sentinel 214 ), sentinel notifications are one-time events: once the notification has been issued, the sentinel remains inactive until an interested listener, e.g., a client 102 or system administrator, explicitly reactivates it.
A budget 104 may be part of a budget hierarchy, as will be described in detail with reference to FIGS. 3A-3B below. For simplicity in the following discussion the limit is assumed to hard such that Ce=0 and thus C=Cn. For a generalized discussion Cn may be substituted for C below. When part of a hierarchy, in addition to the L 208 , R 210 , C 212 , and budget sentinel 214 values described above, each budget 104 may include accumulated reservation 216 value, in which the accumulated amount of resource reservation R 210 of all hierarchically related budgets below the level of the current budget 104 is maintained, also referred to as the sub-tree reservation. The accumulated reservation 216 value facilitates the enforcement of budget restrictions for budgets that are part of a budget hierarchy as will be described in detail with reference to FIGS. 3A-3B below.
FIGS. 3A-3B are pictorial diagrams of exemplary budget hierarchies formed in accordance with an embodiment of the present invention. Among other uses, budget hierarchies provide a mechanism to express rules concerning the resource requirements and restrictions of the budgets belonging to the hierarchy. As illustrated in FIG. 3A , a exemplary budget hierarchy 300 links together in an n-ary tree formation the resource requirements and restrictions, i.e., the limits L 208 , reservations R 210 , and commitments C 212 , expressed in budgets 302 , 304 A-C and 306 A-E, that form the budget hierarchy 300 .
A budget hierarchy 300 typically comprises a root budget 302 and one or more child budgets 304 A, 304 B, and 304 C. The child budgets may, in turn, comprise additional child budgets 306 A, 306 B, 306 C, 306 D, 306 E, and 306 F. The resource manager 108 uses the root-level budget 302 to impose the final barrier to admitting or denying a resource reservation request initiated by the client 102 of one of the budgets in the budget hierarchy 300 . Any such reservation request must satisfy the budget constraints present at each level of the hierarchy 300 between the initiator's budget and the root. Thus, a request initiated by a client of budget 306 F must satisfy not only the constraints of budget 306 F, but also of budget 304 C, and root budget 302 .
In one embodiment, once a resource request is admitted by the resource manager 108 in accordance with the budgets in budget hierarchy 300 , requests are generally further reviewed by the appropriate resource provider 112 to ascertain whether it is practicable to admit the reservation request in light of outstanding reservations and allocations. Note that a request that is practicable to admit may be preemptively denied by the resource manager 108 under the constraints specified by the budgets in the budget hierarchy 300 .
In a typical embodiment, to improve the performance of traversing up the budget hierarchy 300 , the resource manager 108 may cache the total accumulated amount of reservation made in a sub-tree of the budget hierarchy 300 at the sub-tree's root budget. In this manner, a resource reservation request initiated by a client of a non-root budget (also referred to herein as a derived budget) need only be checked against the requestor's budget and all the budgets above it in the hierarchy. In the illustrated example, a request initiated by a client of child budget 306 F is checked against the requestor's budget, i.e., the child budget 306 F itself, and all of the budgets above it in the budget hierarchy 300 in the direct path to the root budget 302 , and not sub-tree budgets 304 A, 304 B, or budgets at the same level, child budgets 306 A-E.
Note that a derived budget need not necessarily have a limit (L) 208 that is less than the limit specified in any of its ancestors. This is because external policy may link a pre-defined budget 104 into a budget hierarchy 300 in response to the launch of an application of a client 102 . In cases in which the local limit, i.e., the child budget's limit, is greater than the limit in an ancestor, the correct result will still be achieved as the request will be blocked higher up the tree.
In a typical embodiment, a root budget 302 is not an absolute partition of the system's resources, unless the summation of the L values 208 across all root level budgets 302 exactly equals the total available resources in the system. Since limits L 208 can be adjusted post-budget creation and result in an over-subscription of resources, resource partitioning is instead typically accomplished by requesting a reservation of resource guarantees (e.g., CPU bandwidth guarantees).
As noted earlier, budget hierarchies 300 provide a mechanism to express rules concerning the resource requirements and restrictions of the budgets belonging to the hierarchy. An example 308 of a budget hierarchy and the rules that are expressed in the hierarchy is illustrated in FIG. 3B . In the example 308 , a system administrator wishes to constrain the aggregate use of CPU by the clients {A, B, C, D} 312 and clients {X, Y, Z} 318 to no more than 80 percent of the available CPU in the system. However, clients {A, B, C, D} may use up to 50 percent of the CPU, as shown in aggregate use rule 322 , while clients {X, Y, Z} are restricted to just 40 percent, as shown in aggregate use rule 324 . Expressing this type of rule using a single standalone budget proves difficult, particularly since the individual limits of 50 and 40 percent add up to more than the desired effective limit of 80 percent, as set forth in aggregate use rule 320 (L 2 +L 3 >=L 1 , e.g., 50+40=90>=80). However, a system administrator can achieve the desired result by creating the illustrated budget hierarchy 308 formed in accordance with an embodiment of the present invention.
As shown, the illustrated budget hierarchy example 308 is comprised of budgets B 2 314 (with limit L 2 of 50 percent) and B 3 316 (with limit L 3 of 40 percent), each of which is derived from a root budget B 1 310 (with limit L 1 of 80 percent). Clients {A, B, C, D} 312 are associated with budget B 2 314 and clients {X, Y, Z} 318 are associated with budget B 3 316 . The resource manager 108 enforces the limits in the example budget hierarchy 308 by restricting the respective amounts of committed resources to the limits L 2 and L 3 in budget B 2 314 and budget B 3 316 , as illustrated in aggregate use rules 322 (committed B 2 <=50, ΣB 2 ·C<=L 2 ) and 324 (committed B 3 <=50, ΣB 3 ·C<=L 3 ). The resource manager 108 further enforces the limits in the example budget hierarchy 308 by restricting the combined amount of committed resources to the effective limit L 1 expressed in budget B 1 310 , as illustrated in aggregate use rule 326 (ΣB 2 ·C+ΣB 3 ·C<=L 1 ).
As shown in the illustrated example budget hierarchy 308 , budget hierarchies 300 in general provide a means of apportioning resource limits L 208 to clients 102 in order to encapsulate their respective resource use, while imposing an effective limit equal to the most restrictive of the limits specified in a client's local budget, i.e., the child or derived budget, and the limits encoded in the budgets along the path to the corresponding root budget.
In general, the following invariants hold regarding any budget hierarchy 300 . A limit L 208 for any budget may be hard or soft. In addition, the limit L 208 is typically greater than or equal to the reservation R 210 and is also greater than or equal to the normal commit Cn 212 . If the value of the limit L 208 is soft, then the excess commit Ce may be greater than or equal to zero, and is generally bounded by the amount of idle resource available in the system. If the limit L 208 is a hard limit, then no excess commit value is usually permitted, i.e., the Ce is usually zero—a requirement that is typically enforced by the resource manager 108 . The amount of reservation R 210 for any budget 104 is restricted not only by the budget's limit value L 208 but also by the reservations and limits set elsewhere in the budget hierarchy 300 . As such, the limit L 208 typically serves only as a loose upper bound on the amount of reservation R 210 that may be made. Lastly, the normal commit value Cn can always reach the value of R, even if this requires the resource manager 108 , in cooperation with the resource provider 112 , to reclaim any excess committed resource Ce that may have been reserved or allocated to other clients 102 . Any portion of the normal commit value Cn that is less than R 210 also obtains a performance benefit in that a hierarchy traversal for limit considerations is avoided because the value of R in the budget has been previously validated against the limits in the hierarchy. Again, the maximum value that the normal commit value Cn may have is bounded by L 208 , but due to hierarchy restrictions and over subscription of resources it may never reach this value.
FIG. 4 is a block diagram depicting in further detail an arrangement of certain components of the budgets illustrated in FIG. 1 for implementing an embodiment of the present invention. As noted previously, the active budget 104 for a particular process 202 or thread 204 may change numerous times over the course of its lifetime, depending, at least in part, on the client 102 on whose behalf the process or thread is executing. In some cases it may be beneficial to temporarily associate with a particular budget for resource accounting purposes. For example, in the case of a service process that is performing a service for one or more clients on a set of concurrently executing threads, it may be desirable to enforce budget restrictions and record consumption based on the particular client on whose behalf the process or thread is currently executing. Examples include drivers and services, which often perform work (and consume resources) on behalf of a client.
In a typical embodiment of the resource management system 100 , such budget enforcement and consumption recording may be achieved through the use of client resource-identity impersonation 400 , a generalized overview of which is illustrated in FIG. 4 . Client resource-identity impersonation 400 temporarily associates a process or thread 202 , 204 with a client 102 by allowing the process or thread to assume the client's resource-identity 410 in order to locate and temporarily attach 412 to the client's active budget 104 . The resource manager 108 is then able to properly enforce the active budget's restrictions and record consumption for the resource 408 that the process or thread 202 , 204 is using on behalf of the client 102 . In a typical embodiment, the client's resource-identity 410 may be derived from the application ID 402 , or other identifying information that the system maintains for the client 102 , such as the current token.
In a typical embodiment, client resource-identity impersonation 400 is appropriate when a service, i.e., the process or thread 202 , 204 operating on behalf of the service, both allocates and relinquishes a resource while temporarily attached to the client's active budget 104 . If the service allocates a resource that persists beyond the impersonation period, such as objects (handles) or memory for local caches, this should not be charged to the client, since those resources are typically maintained by the service in order to facilitate other future requests for different clients. Thus, in a typical embodiment, upon receipt of a client request, the service first determines whether resource client impersonation is appropriate given the nature and lifetime of the resources required to accomplish the client's task. Even if the service ascertains that impersonation is the appropriate course of action, the service must have sufficient privilege to locate and attach itself to the client's budget 104 . If the service has insufficient privilege to accomplish resource client impersonation, or determines that such impersonation is inappropriate, the service may take alternate action to limit resource usage as described below.
Since a process or thread, 204 , 202 , operating on behalf of a service may offer services to any number of clients, but may allocate persistent resources in response to particular client requests (such as handles), the process (or thread) may desire to impose some type of limitation on this usage in a per-client manner. The service process or thread, 204 , 202 , can thus take one of two approaches to limiting its own resource consumption in a per-client manner: either limiting the rate at which a given client 102 can invoke the service, or partitioning its own budget to reflect its clientele.
In the first case, the service can control the rate at which a particular client forces the service to deplete its own resources by using the rate controller 120 function provided by the resource manager 108 to limit the rate at which the client may invoke the service. This can mitigate the effect that a particular client's requests may have on the service's ability to address the needs of all the clients in the system. To avoid the overhead of apportioning every client budget with a rate limit for every service, by default no such limits are typically present in any budget 104 . Rather, a service interested in imposing such a limitation may dynamically insert the limit 414 into the client's budget 104 , an operation which typically requires appropriate access rights. For example, a resource provider 112 may automatically attempt dynamic limit insertion based upon a failure code returned when attempting to charge for a particular resource. The resource manager 108 may then enforce the limit using the resource rate controller 120 when enforcing the client's active budget 104 . Since any client 102 associated with a budget 104 may cause additional per-service limits to be inserted in the budget, the resource manager 108 may periodically purge the least recently used budget entries during rate replenishment.
In the second case, the service assigns a flavor 404 to each client of interest and dynamically inserts 416 the desired resource limits 406 associated with this flavor into its own active budget 418 . This allows the service to ration its own resource usage in a per-client manner. Note in this case the burden of tracking which flavor corresponds to which client falls upon the service and not the resource manager 108 , whereas in the first case, once the limit is inserted into the client budget 104 , the resource manager 108 will automatically enforce adherence to it.
Note that the use of flavors illustrated in the second case may also be applied in a similar manner to clients 102 that want to manage their own use of resources based on type of use. In that case, the client maintains its own flavors 404 and corresponding flavor resource limits 406 , and dynamically inserts those limits into their active budget 104 depending on how they are currently using a particular resource.
Drivers may limit resources in a manner similar to services. In general however, correct impersonation becomes difficult as the driver may not necessarily execute code in response to a client request but rather in response to an external event. As such, the driver may not be in the appropriate context when it performs resource allocations. If a driver wishes to take the impersonation approach, it may maintain references to the appropriate budgets itself and manage their use appropriately. Again, such an approach leaves client budgets susceptible to driver resource leaks and/or errant resource use. Moreover, issues of fairness arise when considering persistent kernel state allocated by drivers but charged to client budgets. In a typical embodiment, drivers may avoid such problems by partitioning their own budgets using per-client flavors 404 , and flavor resource limits 406 , as described above, and allocate resources accordingly. However because drivers do not execute in the context of a single client, the active flavor can be specified explicitly to the resource allocation APIs as a parameter or by passing a reference to the actual budget, or implicitly associated with the current client (or current processor) for the duration of the drivers' execution.
FIG. 5 is a block diagram depicting in further detail an arrangement of certain components of the resource notification services 124 illustrated in FIG. 1 for implementing an embodiment of the present invention. Resource management works best with cooperation from the clients 102 for which the resources are being managed. Accordingly, a typical embodiment of a resource management system includes a notification services component 500 . In the illustrated embodiment, notification services 500 entails the delivery 508 to clients 102 of resource notifications 502 to enable the resource management system 100 to solicit the cooperation of those clients to achieve reduced resource consumption or temporary suspension, or to apprise clients 102 of changes in resource availability that may affect them, or otherwise be of interest to them. The purpose of notifications 502 is to give clients 102 an opportunity to cooperate with the resource manager 108 , but the system 100 must continue to function as best it can even if clients are errant.
Notification services 500 provide a reliable and lightweight event notification mechanism to interested clients 102 . Clients 102 may choose the desired delivery method, the delivery methods having various levels of delivery assurance. In a typical embodiment, the notifications 502 consist of a bitmask 504 representing a set of events that have occurred. In addition, auxiliary notification parameters 506 associated with a notification 502 may be optionally communicated between a client 102 and a notification provider, e.g., the resource manager 108 or a resource provider 112 , typically by using an out of band application programming interface (API).
In one embodiment, the notification services 500 utilizes a pull system to manage event delivery, giving clients 102 the freedom to decide when, if ever, to retrieve the full notification bitmask 504 . The first occurrence of an event in a client's interest set (some client-specified subset of the notification provider's supported bitmask) triggers the delivery technique specified by the client, whereas subsequent events, either of the same type or not, are batched into the stored bitmask. As such, repeat occurrences of a particular event are lost until the client opts to retrieve the bitmask 504 , at which point the batched bitmask is reset (i.e., cleared). Depending on the chosen delivery method, this approach gives clients 102 the freedom to process notifications 502 at their own volition. Example uses of the resource notification services 124 will be described with reference to resource arbitration in FIG. 6 below.
FIG. 6 is a block diagram depicting in further detail an arrangement of certain components of the resource management system 100 , as illustrated in FIG. 1 , for performing resource arbitration 600 in accordance with an embodiment of the present invention. In operation, a resource provider 112 receives a resource allocation request from a requesting client 102 D. If the resource provider 112 is unable to satisfy the resource allocation because insufficient resources are available, and not because the requesting client 102 D simply exceeded a budget resource limitation, the resource provider may request the resource manager 108 to perform resource arbitration using the facilities of a resource arbitrator 122 .
In a typical embodiment, the resource provider 112 provides the resource manager 108 with the information necessary to determine whether resources should be reclaimed from some outstanding allocation in order to satisfy the requesting client's request. The resource manager 108 in turn makes this determination in conjunction with the dynamic policy state embodied in the policy module 114 . As described with reference to FIG. 1 , the policy module 114 , comprises, among other components, a policy database 118 of client priorities and user preferences that is populated by a higher level entity, such as a policy manager 116 or a budget manager 102 C. The details of the policy module 114 will be further described with reference to FIG. 7 .
As an example, the policy database 118 may indicate that the user has assigned the highest preference to the requesting client 102 . The dynamic policy state may also indicate a potential reclamation target client 102 E, as well as a set of allowed actions that may be taken against the target in order to reclaim the resource. Depending on the current policy reflected in the dynamic policy state, the resource manager 108 may respond to the calling resource provider's 112 arbitration request by instructing the provider to satisfy the requesting client's allocation request by using any means necessary, including reclaiming resources that may have been allocated to one or more target clients 102 E in accordance with an action specified in the allowed action set for that target.
In attempting to reclaim resources for use by the requesting client 102 D, the resource provider 112 selects a potential target client 102 E from which resources can be reclaimed. If the resource manager 108 does not suggest a target for the reclamation (as indicated in the dynamic policy state), the resource provider 112 may choose a client of its resources as it deems appropriate. Once the resource provider 112 chooses a target, the resource manager may issue a resource notification 502 using the resource notification services 124 in an effort to solicit cooperation from one or more targets to release the resource in question. Alternatively, or in addition, the resource provider 112 may proceed to reclaim the resource by issuing its own resource notification 502 (again, using the resource notification services 124 ) and/or using one or more actions selected from a set of actions as indicated in the dynamic policy state. The set of actions may range anywhere from passive (contacting the target client 102 E and requesting that it voluntarily cede an amount of the resource, e.g., issuing the notification 502 ), to proactive (forcibly reclaiming the resource), to aggressive (terminating the target). In one embodiment, well-written clients can cooperate seamlessly with passive actions by obeying the various notifications issued by the resource manager 108 and various resource providers 112 concerning resource state changes. Example notifications 502 might include “release units of resource X” or possibly “freeze state for later resumption.”
When the client 102 does not cooperate with the notification 502 , such as by ignoring issued notifications, or, alternatively, when the target client 102 E is a legacy application that predates resource management, or has chosen not to participate in resource management, or is otherwise unresponsive, then the resource provider 112 may escalate its attempts to free resources using either the proactive or aggressive actions.
As noted earlier, a reclaimable resource is one than can be safely retrieved from an application without the application's cooperation. Resources can always be reclaimed transparently from an application, but the potential effect on the target client 102 E may vary from degraded performance, to reduced functionality, to abnormal termination. Reclamation is preferable to a more aggressive action (e.g., terminating the application) only insofar as the effect on the target's behavior is predictable and will not lead to an unexpected termination. For instance, reclamation methods can include ceasing to honor bandwidth guarantees, de-scheduling an application, invalidating handles, and un-mapping a memory resource. In this instance, reclamation is considered reasonable only in the first two cases, as it may have a non-deterministic effect in the latter two cases.
It should be noted that resources that cannot be reclaimed as earlier described, such as total CPU time consumed and total page faults incurred, are not generally subject to resource arbitration. This is because allocation failures of resources that cannot be reclaimed typically arise only due to artificial budgeted limits L 208 enforced by the resource manager 108 , in which case resource arbitration is unnecessary.
FIG. 7 is a block diagram depicting in further detail an arrangement of certain components of the policy module 114 illustrated in FIG. 1 for implementing an embodiment of the present invention. As shown, the policy module 114 comprises, among other components, a policy database 118 , and one or more policy managers 116 . The policy is expressed in at least one of a static portion 702 and a dynamic portion 704 , which together comprise the dynamic policy database state 706 that the resource manager 108 and resource providers 112 use in making their determinations to admit or deny requests to reserve and allocate resources. The static portion 702 generally represents the information that is recorded in the policy database 118 , and the dynamic portion 704 generally represents the information that is generated at the time that a process or thread is created, such as the limits L 208 , the reservations R 210 , and the committed resources C 212 maintained in the active budget objects 700 .
As shown in the illustrated embodiment in FIG. 7 , the dynamic policy database state 706 may comprise policy database entries that are identified by a unique <application ID, user ID> (<A, U>) tuple. As processes or threads 202 , 204 , are launched or created, they are mapped to an <A, U> tuple. Each <A, U> tuple may include an indication of the relative priority and the allowed action set for the mapped processes and threads. The data entries may also identify the budget or budgets 104 that may be actively associated with the processes and threads mapped to the <A, U> tuple.
In a typical embodiment, the allowed action set describes the set of actions that are considered acceptable in the course of arbitrating a resource conflict. For any <A, U> tuple that is not at the highest priority level, at least one such action must be specified. As described earlier, the allowed actions may range in severity from passive, to pro-active, to aggressive. Example actions include requesting that a client 102 cede resources (with timeout), transparently reclaiming reserved resources, reclaiming allocated resources, requesting that the client 102 save state and move to a quiescent state, or forcibly terminating the client to reclaim the resources in contention. If no actions are specified in the allowed action set, then any process or threads mapped to the corresponding <A, U> tuple are immune to all resource arbitration actions and are considered to be of infinite priority.
Among other uses, the dynamic policy database state 706 aids the resource manager 108 in the resolution of any conflicts that may arise as a result of an allocation failure and subsequent arbitration request from a resource provider 112 . In suggesting a potential course of action to a resource provider 112 , the dynamic policy database state 706 advantageously enables the resource manager 108 to significantly improve upon the first-come, first-served allocation policies found in contemporary versions of WINDOWS and other operating systems.
Another aspect of the policy module 114 is to store information in the policy database 118 that describes in advance the resource requirements and or limitations of a particular client 102 . In one embodiment, the operating system may query and utilize this stored information to ensure that a process or thread, 202 , 204 , executing on behalf of the client 102 begins its existence subject to the relevant resource requirements and restrictions contained in an appropriate budget 104 or budget hierarchy 300 . The requirements and restrictions are applied at process creation time to prevent the process or thread 202 , 204 , from executing outside the requirements and restrictions specified in the policy module 114 . The policy managers 116 may take advantage of this feature to, among other things, isolate potentially rogue applications (clients) or ensure that certain clients can startup only if the operating system can reserve a set of required resources in advance.
FIG. 8 is a block diagram depicting in further detail the interaction between the resource provider and certain components of the resource management system illustrated in FIG. 1 to allocate resources 800 in accordance with an embodiment of the present invention. As shown, a client resource request 802 is issued to the responsible resource provider 112 , which in turn determines whether it can satisfy the request and perform the requesting client resource allocation 808 , or whether to participate in the resource management system 100 by generating a request for validation 810 of the client resource request 802 via the resource manager 108 . Alternatively, or in addition, in those cases where the resource provider 112 cannot satisfy the client resource request 802 due to resource contention, the resource provider may further participate in the resource management system 100 by generating a request for arbitration 810 from the resource manager 108 , and subsequently performing target client resource reclamation 812 in accordance with the result of the arbitration request 810 .
In a typical embodiment, the requests for validation and arbitration 810 may be implemented in the form of a query 804 specifying the <A, U> tuple corresponding to the client that issued the resource request 802 . The query 804 is applied against the dynamic policy database state 706 , and a result list 806 is returned containing a list of the processes or threads whose corresponding <A, U> tuples are of priority less than the specified <A, U> tuple. In a typical embodiment, the resource provider 112 may optionally supply with the query 804 a list of processes (or threads) currently using the resource in question so that the result list 806 retrieved from the dynamic policy database state 706 may be appropriately trimmed to a reasonable number of entries.
FIG. 9 is a flow diagram illustrating the resource management workflow 900 of a method for managing resources in accordance with an embodiment of the present invention. The resource management workflow 900 will be described with reference to the foregoing descriptions of the various components of a resource management system 100 , including, among others, the resource manager 108 , the resource providers 112 , the budgets 104 and budget hierarchies 300 and their respective budgeted values, and the policy module 114 .
The workflow 900 includes a process 902 to transfer control from a resource provider 112 to the resource manager 108 prior to allocating a resource, followed by a process 904 in which the resource manager 108 receives from the resource provider 112 a request to validate a client's resource reservation or allocation request. The resource manager 108 commences validation at decision block 908 , at which time the resource manager 108 consults the active budget 906 associated with the allocation request, i.e., the active budget 104 associated with the process or thread 202 , 204 , that initiated the request. As described with reference to FIGS. 3A-3B , the resource manager 108 enforces the current budget limit L 208 , reservation R 210 , and commit C 212 values in the active budget 104 and any budget hierarchy 300 of which the active budget is a part. In so doing, the resource manager 108 may deny the request, should the request exceed the budgeted values. In that case, at process 910 , the resource manager 108 may enforce rate-control, if the resource provider 112 has requested rate control, or may return control to the resource provider 112 at process block 912 , which in turn returns control to the client at process 920 denying the client's resource reservation or allocation request.
Should the request fall within the budgeted values, the resource manager 108 may admit the request. At process block 914 , the resource manager 108 may further inform the resource provider 112 of the portion of a client's allocation request that can be satisfied from the client's pre-reserved pool. Control is returned to the resource provider 112 at process block 916 , after which the resource provider 112 may attempt to allocate the resource as needed by the requesting client. At decision block 918 , should the allocation succeed, then, at process 920 , control may be returned to the requesting client. Otherwise, should the allocation fail, then resource contention has occurred. At this point, at process block 922 , the resource provider 112 may optionally consult the resource manager 108 for resource arbitration, and reclaim resources where possible in accordance with such arbitration as previously described with reference to FIG. 6 . Once sufficient resources have been reclaimed, the resource management workflow 900 may resume at process block 916 to retry the allocation request in the same manner as previously described.
FIG. 10 is a block diagram overview of example resource manager budget interfaces 1000 that may be used to implement an embodiment of the invention. Table 1 below summarizes the interfaces and their intended audience. A brief discussion of each interface follows the table.
TABLE 1
Interface
Intended Audience
create budget (1002)
Policy managers (116), clients (102)
reserve resource (1004)
Policy managers (116), clients (102)
register admission callback
Resource providers (112)
(1006)
query budget (1008)
Policy managers (116), clients (102),
resource providers (112)
record consumption (1010)
Resource providers (112)
set sentinel (1012)
Policy managers (116), clients (102)
insert limit (1014)
Services, policy managers (116)
insert flavor (1016)
Clients (102), services, drivers, policy
managers (116)
set budget (1018)
Policy managers (116), clients (102)
In one embodiment, the create budget interface 1002 may be used by policy managers 116 and clients 102 to create and manipulate budgets 104 and budget hierarchies 300 . In a typical embodiment, the budgets 104 are created as budget objects 200 , as previously described with reference to FIG. 2 . The default behavior of the interface 1002 may automatically link the newly created budget object 200 to the caller's currently active budget to form part of a budget hierarchy 300 . In one embodiment, the caller may override the default behavior by optionally specifying a parameter that indicates the desire to “escape” the current hierarchy. By escaping the current hierarchy, a budget 104 effectively becomes its own root budget. Such a maneuver would release the budget from the constraints present elsewhere in the current budget hierarchy.
In most instances, clients 102 will not manage the creation of their own budgets 104 , as manually doing so would be difficult, error-prone, and burdensome. Rather, the task of budget creation is left to a human or software service acting as administrator with both the knowledge and authority to execute it correctly, using a policy manager 116 . In that case, the policy manager 116 may use the create budget interface 1002 to create the budget at the same time the process or thread 202 , 204 , with which the budget may be associated is created. The data used to generate a budget (e.g., what parameters should be used to populate the budget limit L 208 , which reservations to perform in advance, etc.) may be garnered from the policy database 118 or from automated administration software using heuristics to tune system behavior. In a typical embodiment, the policy database 118 may be populated in advance upon consideration of the availability of resources, the nature of the client, and user preferences.
Generally, no resource is committed or reserved in a budget 104 when it is initially created using the create budget interface 1002 . Therefore, budgets which require pre-population (to achieve machine partitioning and isolation) are typically first created by a policy manager 116 using the create budget interface 1002 , and then passed to a reserve resource interface 1004 to accomplish the necessary reservations, as will be next described.
A budget 104 may be dynamically associated with process groups, processes, or (possibly) threads at process creation time. For example, in one embodiment, once created using the create budget interface 1002 , a budget 104 may be passed as an argument to a routine that handles process (or thread) creation, such that the new process (or thread) is automatically associated with, and therefore subject to, the resource restrictions specified in the budget.
The create budget interface 1002 may be used to externally partition resource usage by specifying a parameter indicating one or more flavors at the time of budget creation. In the absence of such an indication, the default behavior of the create budget interface 1002 may be to create budgets having a single neutral flavor against which all resource usage is charged. Alternatively, or in addition, one or more flavors may be dynamically inserted into the budget following its creation as described with reference to the insert flavor interface 1016 below. This is in addition to the client's use of flavors to internally partition resource usage, for example to limit exhaustion of resources by a particular task or to reserve resources for use in recovering from errors.
In one embodiment, a reserve resource interface 1004 may be used by a client 102 to reserve one or more resources for future use. In this manner, a transactional means of acquiring resources is imposed on clients 102 in order to avoid deadlock conditions involving the ordering of resource acquisition. However, this is primarily an aid to the client 102 ; if the client so desires, the interface 1004 may be called multiple times to reserve resources independently, or over time. Since reserving a resource generally makes that amount of resource unavailable system-wide, reservations are typically conservative in nature. Soft limits may be used to ameliorate the potential for overuse of reservations and to avoid the under-utilization of resources.
In a typical embodiment, once the reservation has been successfully made, the reservation value R 210 is updated to reflect the reservation, and the client 102 may commit up to this amount of the resource, as represented in the budget's commit value C 212 , without the need for resource arbitration; it may commit up to the limit L 208 at the normal service level. When the limit L 208 of the budget is a soft limit, the client 102 may commit resource in excess of the limit L at a degraded service level, such that the system may efficiently reclaim it for other Cn allocations in the future.
In one embodiment, the reserve resource 1004 interface provides a means to validate the reservation request, i.e., to admit or deny the reservation request in the context of the currently active budget and applicable budget hierarchy 300 , if any. The actual reservation of the corresponding resource is typically handled separately by the resource provider 112 itself. In this manner two levels of control upon resource requests are enforced, one by the resource manager 108 in accordance with the currently active budget and budget hierarchy, if any, and one by the resource provider 112 . Thus, a reservation request that may be admissible in terms of the currently active budget and budget hierarchy may fail when presented to the appropriate resource provider 112 , and likewise, a reservation request that would have been deemed acceptable by a resource provider 112 may be preemptively denied by the resource manager 108 .
Once the reserve resource interface 1004 is used to validate a particular reservation request in the context of the applicable budget hierarchy 300 , the responsibility of determining whether the actual resource reservation can be satisfied, i.e., allocated, given all outstanding reservations, falls upon the resource provider 112 . Accordingly, a register admission callback 1006 interface may be provided so that the resource manager 108 can confirm whether the client's reservation request was or was not granted by the resource provider 112 . Reservation requests that have been granted render that portion of the resource unavailable for normal commit Cn use by other clients 102 . Therefore, when the request is granted, the resource manager 108 updates the appropriate budget or budgets in the budget hierarchy 300 to accurately reflect the current state of outstanding resource reservations.
In one embodiment, a query budget interface 1008 may be used by a client 102 to examine specific restrictions and requirements maintained in their budget 104 . For example, the ability to query a budget may be particularly useful for clients 102 that inherit a budget or have an externally assigned budget. By examining the current state of their budgets, the clients may make an informed decision on how to adjust their resource usage to stay within their budgets. For example, after querying their budget, a client 102 may wish to register with the resource manager 108 and resource providers 112 to receive notifications that a desired resource has become available, and the like. As another example, rather that waiting to receive a notification, the client 102 may decide instead to modify their budget as they deem necessary in an effort to more quickly obtain the resources that they need (assuming that they have sufficient authority to do so). As a further example, resource managers 108 may use notifications to request that cooperating clients reduce their resource consumption by reducing the sizes of their cached information or changing the set of algorithms being used to tradeoff space vs. time or time vs. space. Resource managers may further adjust the limits in budgets to keep the system from running too short on resources.
A record consumption interface 1010 may be provided to resource providers 112 to track the consumption of resources over time. In one embodiment, each resource provider 112 participating in the resource management system 100 is responsible for invoking the record consumption 1010 interface after the allocation of a supported resource to a client 102 , i.e., after the resource is committed. The resource manager 108 may then track the committed resource value (Cn) in order to facilitate any possible future resource manager decisions aimed at reclaiming resources. In contrast, tracking and managing which portion of the committed resource may be classified as excess commit Ce is typically left to the resource provider 112 as described below with reference to surplus amounts.
In a typical embodiment, the use of the record consumption interface 1010 to track the consumption of a resource does not require that the amount have been reserved in advance, e.g., by using the reserve resource interface 1004 . When a resource is available, it is, by default, implicitly “reserved” at the time it is allocated to the client 102 . Should enforcing the currently active budget prohibit the resource manager 108 from admitting the full amount of the recorded consumption as part of the normal commit Cn, the record consumption interface 1010 may report back the surplus amount to the resource provider 112 . In that case, resource providers 112 that support soft limits may optionally disburse the surplus amount to the client as excess commit Ce, assuming the client 102 has indicated that excess commit Ce resource is acceptable. Since excess commit Ce resources may be more readily reclaimed then normal commit Cn some clients may prefer to forego excess commit and wait until resources that can be allocated at normal commit are available. In the case of most implicitly consumed resources, the associated resource provider 112 typically has considerable flexibility in managing excess commit Ce allocations of resources.
In a typical embodiment, the resource provider 112 specifies in the record consumption interface 1010 the identity of the resource being charged. In this manner, the resource manager 108 is able to charge the consumption to the correct resource. Further, the resource manager 108 may also determine whether a dynamic limit needs to be inserted into the budget using the insert limit interface 1014 , as in the case of certain dynamically introduced resources as will be described in further detail below.
A set sentinel interface 1012 may be provided to policy managers 116 , clients 102 , and services to register for a one-time notification when the normal commit Cn value tracked for a particular budget 104 has exceeded the budget's sentinel value 214 . Should additional notifications be desired, the policy managers 116 and clients 102 may explicitly re-register using the set sentinel interface 1012 . In one embodiment, the registrant may specify the desired method of notification delivery, which will include at least all of the notification mechanisms supported by resource manager 108 , as generally described with reference to FIG. 5 . As an example, sentinel-based notification may be useful to change a resource billing model once the resource consumption exceeds the budget's sentinel value.
An insert limit interface 1014 may be provided to policy managers 116 to dynamically insert limits L 208 into budgets 104 . For example, when resources are consumed by a service operating on behalf of a client as described with reference to FIG. 4 , services may insert limits in the client's active budget to control the rate at which a client can force a service to deplete the latter's resources through the use of the insert limit interface 1014 . On subsequent invocations, the client 102 will be subjected to the dynamically inserted limit. In a typical embodiment, only trusted policy managers 116 and services may possess the requisite privilege to perform a dynamic limit insertion into a target budget, as maliciously inserting low limits into client budgets may constitute a denial of service attack.
An insert flavor interface 1016 may be provided to clients 102 , including services and drivers operating on behalf of clients, to dynamically insert flavors into budgets 104 as previously described with reference to FIG. 4 . In one embodiment, a client 102 may use the insert flavor interface 1016 to perform flavor insertion on its own currently active budget. Dynamic flavor insertion into budgets belonging to different clients may defeat the purpose of flavors, which are generally intended to provide clients a means of managing their own resource use within the constraints imposed by their own budget. To avoid this difficulty internal and external partitioning of resources using flavors must rely on distinct sets of flavors.
In the example introduced in FIG. 4 , a service may use the insert flavor interface 1016 to delineate a flavor (partitioning) of its budget based on the identification of a particular client 102 on whose behalf it is operating. Establishing a mapping between the client 102 and flavor is left entirely to the service. A similar scenario may be employed by drivers that would like to ration their resource usage based on the particular client on whose behalf resources are being consumed. Thus the burden of flavor management falls upon the service or driver that chooses to dynamically insert them using the insert flavor interface 1016 .
Alternatively, or in addition, in cases where there is no need for dynamic flavors, such as network drivers wishing to partition their allowed memory usage between a pre-defined static set of packet types, flavors need not be dynamically specified using the insert flavor interface 1016 . Rather, the desired flavors can be specified at budget creation time using the create budget interface 1002 , possibly yielding a performance benefit.
Flavors are also useful for implementing error recovery and improving software robustness and reliability. By reserving resources with a flavor used only for recovering from low-resource situations in a system, software can still function sufficiently to recover. For example a client needs enough resources available to respond to a resource manager 108 notification that it should reduce resource consumption by shrinking caches.
Lastly, a set budget interface 1016 may be provided to services and other components to, among other uses, temporarily attach a process or thread 202 , 204 executing on behalf of a client 102 to a particular budget 104 , such as described with reference to the client resource-identity impersonation scenario in FIG. 4 . For the duration of the attach operation, all of the service's resource usage may be charged to a specified budget. In cases in which a resource is reserved, allocated and released during the period of attachment, the set budget interface 1016 provides a way for services performing operations directly on behalf of a requesting client to charge resource consumption against the client's budget, and not their own.
The foregoing discussion has been intended to provide a brief, general description of a computing system suitable for implementing various features of the invention. Although described in the general context of a personal computer usable in a distributed computing environment, in which complementary tasks may be performed by remote computing devices linked together through a communication network, those skilled in the art will appreciate that the invention may be practiced with many other computer system configurations. For example, the invention may be practiced with a personal computer operating in a standalone environment, or with multiprocessor systems, minicomputers, mainframe computers, and the like. In addition, those skilled in the art will recognize that the invention may be practiced on other kinds of computing devices including laptop computers, tablet computers, personal digital assistants (PDAs), cell phones, game consoles, personal media devices, or any device upon which computer software or other digital content is installed.
For the sake of convenience, some of the description of the computing system suitable for implementing various features of the invention included references to the WINDOWS operating system. However, those skilled in the art will recognize that those references are only illustrative and do not serve to limit the general application of the invention. For example, the invention may be practiced in the context of other operating systems such as the LINUX or UNIX operating systems.
Certain aspects of the invention have been described in terms of programs executed or accessed by an operating system in conjunction with a personal computer. However, those skilled in the art will recognize that those aspects also may be implemented in combination with various other types of program modules or data structures. Generally, program modules and data structures include routines, subroutines, programs, subprograms, methods, interfaces, processes, procedures, functions, components, schema, etc., that perform particular tasks or implement particular abstract data types.
|
The present invention manages resources in a computing device to facilitate the allocation of resources amongst competing clients operating on the device. A hierarchy of budgets is constructed to encode restrictions on the aggregated use of a resource allocated by a resource provider to one or more clients. A resource manager validates and arbitrates requests to allocate resources to the one or more clients by resource providers in accordance with the budgets comprising the hierarchy. The resource manager notifies clients of availability and shortages of resources to promote compliance with the restrictions encoded in the budgets of the hierarchy.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 61/601,585 filed Feb. 22, 2012, the content of which is incorporated herein by reference in its entirety.
BACKGROUND
Electronic devices can generate a large amount of unwanted heat, which if not properly dissipated can adversely impact such devices. One way to dissipate the heat is by circulating air with a fan. Where air cannot be readily circulated and/or in cases where the air in not sufficiently clean, however, the heat from an electronic device can be dissipated by securing the electronic device to a heat removal device such as a heat pipe or thermosyphon. These heat removal devices typically include an evaporator, a condenser, and a heat dissipating feature such as a fin or other exterior surface of the heat removal device. For efficient heat dissipation, it is desirable to have the electronic device in contact with the evaporator, and the condenser in contact with the heat dissipating feature. However, the force required to secure the heat removal device to the electronic device sufficiently to achieve a desired level of thermal conductivity can sometimes deform or damage the heat removal device.
SUMMARY
Some embodiments of the present invention provide a backing plate for joining a heat removal device to a heat source. The backing plate includes a planar plate region having a first face and a second face opposite the first face, and at least one boss projecting from the first face, the boss having an opening therein for receiving a fastener.
In some embodiments, a backing plate for joining a heat removal device to a heat source with a fastener is provided, wherein the heat removal device has a first side and a second side. The backing plate includes a base having a first surface facing the first side of the heat removal device when secured thereto, and a second surface facing away from the heat removal device when secured thereto, and a boss extending along a longitudinal axis away from the base and toward the heat removal device when secured thereto, the boss shaped to releasably engage with the fastener from the second side of the heat removal device to clamp the heat removal device between the base of the backing plate and the fastener, and wherein the base has a footprint larger than a cross-sectional area of the boss taken in a plane orthogonal to the axis to distribute axial force from the boss across the first side of the heat removal device when secured thereto.
Some embodiments of the present invention provide a method of assembling a heat removal device onto a heat source. The method includes steps of providing a heat removal device having an evaporator side and a condenser side and at least one aperture defined therethrough, the aperture extending between the evaporator side and the condenser side of the heat removal device; disposing a backing plate against the condenser side of the heat removal device, the backing plate including at least one boss sized to fit within the at least one aperture, the boss adapted to mate with a fastener; disposing the evaporator side of the heat removal device against the heat source; inserting the at least one boss into the at least one aperture; passing the fastener through the heat source; and attaching the fastener to the boss to secure the backing plate and the heat removal device to the heat source.
In some embodiments, an electronic device is provided. The electronic device includes an electrical heat source; a heat removal device having a first side, a second side opposite the first side, and a vapor chamber; a backing plate on the first side of the heat removal device and having a boss extending at least partially through the vapor chamber; and a fastener extending at least partially through the vapor chamber from the second side of the heat removal device and secured to the boss, wherein the heat removal device is clamped between the fastener and the backing plate, which cooperate to exert a compressive load upon the heat removal device.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded view of an embodiment of a vapor chamber backing plate adjacent to a circuit board.
FIG. 2 shows a heat source having several heat removal devices attached thereto.
FIG. 3 shows the condenser side of a heat removal device with space for multiple backing plates, where a single backing plate without windows is installed.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
Aspects of the present invention relate to a backing plate that can secure a heat removal device to a heat source (e.g., a circuit board, one or more microprocessors, and the like) with a high level of force without damaging or unacceptably deforming the heat removal device. In some embodiments, the backing plate includes a generally planar body to distribute the force required to couple the heat removal device to the heat source over an area larger than the cross-sectional area of the fastening locations of the heat source and heat removal device, thereby preventing unacceptable deformation of the heat removal device.
The heat source can include, for example, an insulated-gate bipolar transistor (IGBT) or other type of circuit boards. In this regard, the heat sources can include diffuse sources of heat as well as point sources of heat (e.g., CPUs on a circuit board).
Heat removal devices such as a heat pipe (whether in the form of a plate-type heat spreader, an elongated closed pipe, or any other shape or form), a thermosyphon, or any other heat removal device having a vapor chamber, an evaporator adjacent the heat source, and a condenser typically opposite the evaporator, can be used in conjunction with the backing plate of the present invention. In many cases, the heat removal devices are sealed under vacuum and contain a small amount of working fluid such as water, ethanol, methanol, or ammonia, which evaporates at the evaporator surface and condenses at the condenser surface, transferring heat away from the heat source.
In some embodiments, a heat-dissipating device can be secured to the condenser of the heat removal device for dissipating heat to a body of cooling fluid (e.g., to the environment, a flowing or convective body of fluid, and the like), to another heat exchange device, and the like. By way of example only, the heat-dissipating device can be a set of fins of any type, such as those shown in FIG. 1 .
According to various embodiments, the disclosed backing plate structure, which can also be referred to as a bolster plate, can include bosses that extend into through holes in the heat removal device to receive fasteners from the evaporator side of the heat removal device. The bosses permit the heat removal device to be tightly secured to the heat source by bearing a relatively high level of force while preventing damage to the heat removal device.
FIG. 1 is an exploded view of an embodiment of a heat removal device 10 according to the present invention. The heat removal device 10 includes an evaporator 12 and a condenser 14 , either or both of which can be defined by structure of the heat removal device 10 at which working fluid within the heat removal device 10 evaporates and condenses, respectively, in operation of the device 10 . In various embodiments, the heat removal device 10 can also have a heat-dissipating device 16 such as a fin attached thereto. FIG. 2 also shows a heat source 30 (e.g., a circuit board in the illustrated embodiment) having three separate heat removal devices 10 attached thereto, where one of the heat removal devices ( FIG. 2 , left) has two separate backing plates 18 attached to the condenser 14 side. In the embodiment of FIG. 2 , a fastener 24 (e.g., a screw as shown, by way of example only) can be attached through an aperture in the heat source 30 to attach the backing plate 18 and the heat removal device 10 to the heat source 30 , such that the heat source 30 is clamped between the backing plate and the fastener 24 . In this manner, the fastener 24 and backing plate 18 can exert a compressive force upon each heat removal device 10 , and in some embodiments can also exert a compressive force upon the heat source 30 and the heat removal device 10 to improve heat conduction across the interface therebetween.
In some embodiments, any or all of the backing plates 18 can be coupled to shared or respective (dedicated) heat dissipation devices 16 such as sets of fins (omitted from FIG. 2 for clarity). FIG. 3 shows a heat removal device 10 having space for multiple backing plates 18 , where a backing plate 18 is installed (left) in one location while another location is unoccupied (right). By securing a heat dissipating device 16 to the backing plate 18 rather than directly to the condenser side of the heat removal device 10 , it is possible to remove the heat dissipating device 16 by removing the fasteners 24 thereof, and then removing the backing plate 18 with the heat dissipating device 16 attached thereto. This capability can also provide the ability to access, maintain, repair, remove, and replace one heat source (e.g., one circuit board sharing the same heat removal device 10 with one or more other circuit boards) or portion of a heat source (e.g., a microprocessor or electronic element on a heat source 30 having several) without disturbing others.
In certain embodiments, the heat removal device 10 can be formed of annealed copper. However, while annealed copper is well-suited to many applications due to its heat-conducting properties, annealed copper (and a number of other otherwise desirable materials) is relatively soft. As a result, the heat removal device 10 can bend or compress under high levels of force that are sometimes required to couple the heat removal device 10 to a heat source 30 , particularly in those cases where compressive force is desired to increase thermal conductivity between the heat source 30 and the heat removal device 10 . Thus, a backing plate 18 can be disposed adjacent the condenser 14 of the heat removal device 10 to spread the force required to couple the heat removal device 10 to the heat source 30 in a thermally-conductive manner (see FIGS. 1, 2, and 3 ). As described further below, the backing plate 18 can have a variety of sizes and shapes, and can cover any amount of the surface of the condenser 14 . Nevertheless, in certain embodiments where particularly high levels of force are applied, the components can be stressed and deformed even with the use of a backing plate 18 .
Therefore, in certain embodiments the backing plate 18 can further include one or more bosses 20 extending from one face of the backing plate (e.g., extending from a base of the backing plate 20 ) and which extend into respective apertures through the heat removal device 10 (i.e., through-holes 22 of the heat removal device) to receive fasteners 24 for fastening to the heat source 30 ( FIG. 1 ). In some embodiments, the bosses 20 have a length that is comparable to the depth of the through holes 22 , or a length that is less than the depth of the through holes 22 . The number of through holes 22 and bosses 20 that are used depends on factors such as the sizes and shapes of the heat source 30 , the backing plate 18 , and the heat removal device 10 , as well as the distribution of individual point sources of heat on the heat source 30 .
In some embodiments, the backing plate 18 includes one or more openings or windows 28 which, among other advantages, reduce the weight of the backing plate 18 ( FIGS. 1 and 2 ).
Also, in some embodiments, the backing plate 18 can be at least partially received within a recess 26 on the condenser side of the heat removal device 10 . For example, in those embodiments in which the backing plate 18 has a base that is substantially plate-shaped from which the bosses 20 extend as described herein, the base can be at least partially received within the recess. In some embodiments, the base of the backing plate is recessed within the condenser side of the heat removal device so that the surface of the backing plate 18 opposite the bosses 20 and adjacent exterior surfaces of the condenser side of the heat removal device 10 are co-planar or substantially co-planar. In this manner, a heat dissipating device 16 can be more readily attached to adjacent co-planar surfaces of the backing plate 18 and the heat removal device 10 , or can otherwise simultaneously be in contact with such surfaces.
In those embodiments of the present invention having a backing plate 18 with a window 28 (whether the backing plate 18 is recessed within the condenser 14 as described above or not), any part of the condenser 14 can extend into the window 28 . In such embodiments, a heat dissipating device 16 (e.g., a fin, as described above) can be in contact with the condenser 14 which extends upward through the window 28 ( FIG. 1 ). Alternatively, the window can be unoccupied by any portion of the condenser 14 , in which case a heat dissipating device 16 can be shaped to extend into the window 28 in those embodiments where direct contact between the heat dissipating device 16 and the condenser 14 is desired.
When the heat removal device 10 is fully assembled, the fasteners 24 run through the heat source 30 and attach to the bosses 20 , tightly joining together the heat source 30 , the heat removal device 10 , the backing plate 18 , and the heat dissipating mechanism 16 (e.g., fin) if used, in a thermally-conductive manner.
The backing plate 18 (i.e., the base of the backing plate 18 ) can have various shapes, such as rectangular, square, circular, triangular, any other regular or irregular polygons, or irregular shapes. Similarly, the window 28 can be various shapes, such as rectangular, square, circular, triangular, any other regular or irregular polygons, or irregular shapes. Further, the backing plate 18 can have more than one window 28 , and each window 28 can have the same or different shapes.
FIG. 1 shows a plurality of bosses 20 on a single backing plate 18 , although the backing plate 18 can have as few as one boss 20 . In some embodiments, a backing plate 18 with one boss 20 can be preferred because it is simple in construction and can reduce the cost of manufacturing. However, a backing plate 18 with two or more bosses 20 can alternatively be preferred because load can be distributed more evenly across a larger face of the backing plate 18 , and/or because the backing plate 18 can be held more firmly in place and can be less prone to twisting or rotating when there is more than one boss 20 . Each boss 20 can be cylindrically shaped, but can also have any number of other cross-sectional shapes including, but not limited to, circular, rectilinear (square or otherwise), elliptical, or any other regular or irregular polygonal shapes such as star shapes or other shapes having three or more sides where the faces of the shapes include convex and/or concave portions. As used herein and in the appended claims, the cross-sectional shapes are defined in a plane extending through the boss 20 and that is orthogonal to the longitudinal axis of the boss 20 .
A given backing plate 18 can include a combination of bosses 20 having various sizes and shapes. Also, in some embodiments, one or more of the through holes 22 in the heat removal device 10 can be sized to receive the fasteners 24 alone, without a boss 20 .
In some embodiments, each boss 20 can be tapered along at least a portion of its length such that it is wider at the point where it connects to the backing plate 18 . Also, each boss 20 can be adapted to receive a particular type of fastener 24 . For example, the bosses 20 can be internally threaded to receive fasteners 24 such as screws. In other embodiments, each boss 20 is adapted to mate with or otherwise be secured to a respective fastener in any other suitable manner, such as an externally-threaded boss received within a threaded aperture (e.g., blind hole) of a fastener 24 , bosses 20 that are brazed or soldered to fasteners 24 under compression during joining operations (e.g., by a temporary frame, brace, or other structure), and the like.
In embodiments with a plurality of bosses 20 , each boss 20 can have a similar size and shape, but in some embodiments one or more bosses 20 can have a different size or shape than the other bosses 20 to facilitate accurate alignment of the backing plate 18 onto the heat removal device 10 . In some embodiments, a plurality of bosses 20 (and their associated through holes 22 ) are arranged in a rectangular grid or a non-rectangular pattern to suit the layout of the heat source 30 (e.g., circuit board) and/or the heat removal device 10 . Bosses 20 can also be evenly spaced across the heat source 30 , or can be more unevenly spaced as desired (i.e., to be more closely spaced in desired areas). In the case where the heat source 30 is a circuit board, the bosses 20 and their associated fasteners 24 can be located so as to accommodate the placement of devices such as chips, while ensuring that regions of the circuit board which have higher heat production, such as where a CPU is located, are near one or more bosses 20 to ensure improved a thermally conductive connection with the heat removal device 10 .
In some embodiments, the backing plate 18 is formed of a material that is stronger than that of the heat removal device. By way of example only, the backing plate 18 can be formed of stainless steel. The bosses 20 can be formed of metals with good thermal conductivity, such as copper or aluminum, and can be made of the same or different material than the base of the backing plate 18 . For improved thermal conductivity, gold- or silver-plated metals can be used for the backing plate 18 and/or the bosses 20 . In some embodiments, the backing plate 18 measures 2-50 cm in a length dimension, and 2-50 cm in a width dimension. Also in some embodiments, the thickness of the base of the backing plate 18 can be from about 1 mm to about 10 mm. In various embodiments, the backing plate 18 is dimensioned so as to cover at least a portion of an insulated-gate bipolar transistor (IGBT) on a circuit board. While FIG. 1 shows a heat removal device 10 which includes one backing plate 18 , in some embodiments ( FIG. 2 ) the heat removal device 10 can include a plurality of backing plates 18 which are distributed across the condenser 14 side of the heat removal device 10 , where each of the backing plates 18 can be the same or a different shape, each may or may not have one or more windows 28 , and each may or may not be partially or fully received within a respective matching recess 26 of the heat removal device 10 .
As mentioned above, among other considerations, having multiple backing plates 18 on a single heat removal device 10 can permit individual backing plates 18 to be removed and replaced separately. This can be beneficial where one or more fins or other heat-dissipating mechanisms 16 are coupled to the backing plates 18 and can need to be replaced if they are damaged. In yet another embodiment ( FIG. 2 ), there can be multiple heat removal devices 10 , each with a separate backing plate 18 , on a given heat source 30 , in some cases enabling removal and replacement of a heat removal device 10 from the heat source 30 without disturbing other heat removal devices 10 secured to the heat source. Each of the heat removal devices 10 and associated backing plates 18 can have different sizes and shapes, and can have varying numbers of bosses 20 and windows 28 depending on factors such as the size, shape, and distribution of point sources of heat on the heat source 30 .
In various embodiments, the length of each boss 20 is set so as to be flush with the evaporator surface of the heat removal device 10 in the assembled state. In general, the length of a boss 20 can be comparable to the depth of the through hole 22 in which the boss 20 is intended to be received. The depth of the through hole 22 , in turn, can be generally the same as the thickness of the heat removal device 10 , minus the depth of the recess 26 , if present. In some embodiments, the bosses 20 are initially produced slightly longer than required. The backing plate 18 with such bosses 20 is then assembled into the heat removal device 10 , and the protruding ends of the bosses 20 are trimmed (e.g. by a flycut) so as to be flush with the evaporator surface of the heat removal device 10 . Each boss can have a cross sectional area which is large enough to distribute the compressive load exerted by the fasteners 24 . Accordingly, each boss 20 can measure 2 mm to 25 mm in length, and 1 mm to 25 mm in diameter. In some embodiments in which the heat removal device 10 can withstand limited compressive forces, each boss 20 can be dimensioned so as to be slightly recessed relative to the evaporator 12 or the condenser 14 .
By virtue of the relative size of the boss 20 and the backing plate base from which the boss extends, axial force from the boss 20 (experienced when the fastener 24 is tightened to clamp the heat removal device 10 between the backing plate 18 and the fastener 24 , and in some embodiments between the backing plate 18 and the heat source 30 ) is distributed across the backing plate base and therefore across a condenser surface of the heat removal device 10 . The backing plate base can have a footprint that is larger than the cross-sectional area of the boss 20 to enable this distribution. This force distribution reduces the likelihood of heat removal device deformation and damage, and can improve heat exchange between the heat source 30 and the heat removal device.
In some embodiments, the bosses 20 are formed separately from the backing plate 18 and are attached to the backing plate 18 in any suitable manner, such as by brazing, soldering, or welding. In some embodiments, the bosses 20 can be attached to the backing plate 18 by fasteners such as screws or rivets, which can facilitate later removal of the bosses 20 from the backing plate 18 , if desired.
In still other embodiments, the bosses 20 can be separate from and not be attached to the base of the backing plate 18 . In such embodiments, the bosses 20 can be inserted into the through holes 22 during assembly and, like the attached bosses 20 , would also serve the purpose of resisting compressive forces applied by the fasteners 24 . In the embodiments in which the bosses 20 are not attached to the base of the backing plate 18 , it is desirable to use fasteners 24 which attach at both ends, e.g. rivets, screws with nuts, or other similar types of fasteners 24 . Alternatively, the backing plate itself could be threaded to accept fasteners 24 such as screws while the bosses 20 could be threaded or unthreaded.
Alternatively, in certain embodiments, the bosses 20 can be integral with the base of the backing plate 18 . The combined backing plate base and bosses 20 can be formed by casting in some embodiments. In other embodiments, however, the combined backing plate base and bosses 20 can be formed by shaping a block of a metal, for example using one or more of milling, grinding, laser cutting, stamping, plasma cutting, and high pressure water jets cutting, to provide a single element having dimensional precision and stability. In still other embodiments, the combined backing plate base and bosses 20 can be molded using a thermally-conductive polymer.
Various types of fasteners 24 can be used, where the fasteners 24 generally have an elongated shaft with a head portion at one or both ends, and where at least a portion of the head extends laterally away from the shaft. The fasteners 24 can be secured in place in various ways, where the method of securing affects how readily the fasteners 24 can be removed. For example, the fasteners 24 can be screws, rivets, or pins with barbed shafts. One or both ends of the fastener (depending on the type of the fastener used) can also include a washer or other element under the head of the fastener for distributing force of the head of the fastener 24 over a broader area of the backing plate 18 or the heat source 30 , as applicable, in order to prevent stressing and possible damage to the respective structure. One or both of the respective surfaces of the backing plate 18 and the heat source 30 can be recessed or countersunk so that the head(s) of the fasteners 24 are flush or recessed relative to the nearby surface.
Varying levels of force can be applied to the fasteners 24 . In some embodiments, the fasteners 24 are tightened so as to bring together the heat source 30 , the heat removal device 10 , and the backing plate 18 (often having one or more heat-dissipating devices 16 attached thereto as described above) in thermally-conductive contact with one another. The use of bosses 20 permits an even higher level of force to be applied to the fasteners 24 without damaging (e.g. cracking, deforming, or compressing) the heat source 30 , the backing plate 18 , or the heat removal device 10 . In some embodiments, the fastener 24 can be tightened under 40 inch-pounds (in-lbs) of torque such that the total force exerted by the fastener 24 is 1052 pounds. In various embodiments, a single fastener 24 can be tightened under at least 50 in-lbs of torque, although other torque values are possible. In those embodiments with backing plates 18 having bosses, the amount of force applied to a single fastener 24 can be increased without causing damage to the heat source 30 , the heat removal device 10 , or the backing plate 18 .
As described above, in some embodiments, each backing plate 18 has one or more heat dissipation devices 16 such as a set of fins coupled thereto. In some embodiments, each heat-dissipating device 16 can be secured to the backing plate 18 , such as by brazing, soldering, or welding. In other embodiments, the heat-dissipating device 16 can be attached to the backing plate 18 by fasteners 24 such as screws, rivets, or barbed pins. In still other embodiments, the heat-dissipating device 16 can be attached (also by means such as brazing, soldering, or welding) to the heat removal device 10 instead of, or in addition to, the backing plate 18 . With various manners of attachment, however, the heat-dissipating device 16 can be permanently secured or can be removed from the backing plate 18 or heat removal device 10 .
In some embodiments, the backing plate 18 can be more permanently attached to the heat removal device 10 , for example by welding, soldering, or brazing together the parts described above. While this could make disassembly more difficult, it would have the advantage of making a connection with very high thermal conductivity.
As disclosed herein, various embodiments of the present invention also include methods of replacement of one or more backing plates 18 from a heat source 30 and heat removal device 10 . In various embodiments, the heat removal device 10 and the backing plate 18 , with optional bosses 18 and fins 16 (or other heat-dissipating elements) attached thereto, are attached to the heat source 30 in a manner that facilitates rapid assembly, disassembly, removal, and replacement, for example using screws as fasteners 24 . Replacement can also be facilitated by having several individual backing plates 18 , heat removal devices 10 , and/or heat dissipating mechanisms 16 in a system (e.g., see FIGS. 2 and 3 ), which can be individually removed and replaced as needed without having to completely remove a single large component.
In some embodiments, the present invention provides a method of assembling a heat removal device 10 onto a heat source 30 . The method can include steps of: providing a heat removal device 10 having an evaporator 12 side and a condenser 14 side and at least one through hole 22 therein, the through hole 22 extending between the evaporator 12 side and the condenser 14 side of the heat removal device 10 ; disposing a backing plate 18 against the condenser 14 side of the heat removal device 10 , the backing plate 18 including at least one boss 20 sized to fit within the at least one through hole 22 , the boss 20 being adapted to receive a fastener 24 ; disposing the evaporator 12 side of the heat removal device 10 against the heat source 30 ; inserting the at least one boss 20 into the at least one through hole 22 ; and passing the fastener 24 through the heat source 30 and into the boss 20 to secure the backing plate 18 and the heat removal device 10 to the heat source 30 . In some embodiments, the backing plate 18 can also include a heat-dissipating mechanism 16 such as a fin attached thereto.
|
A backing plate for joining a heat removal device to a heat source. The backing plate can include a planar plate region having a first face and a second face opposite the first face. The backing plate can also include at least one boss projecting from the first face and having an opening therein for receiving a fastener.
| 8
|
FIELD OF THE INVENTION
[0001] This invention relates to stereorigid metallocene catalysts supported on particulate polyamide supports and their use in the production of stereospecific polymers from ethylenically unsaturated compounds and, more particularly, to such catalysts incorporating spheroidal polyamide supports and their use.
BACKGROUND OF THE INVENTION
[0002] Stereospecific metallocenes can be characterized generally as coordination compounds incorporating cyclopentadienyl groups or derivatives thereof (which may be substituted or unsubstituted) coordinated with a transition metal. Various types of metallocenes are known in the art. They include bicyclic coordination compounds of the general formula:
(Cp) 2 MeQ n (1)
characterized by the isospecific metallocenes as described below and cyclopentadienyl fluorenyl compounds of the general formula:
Cp Cp′MeQ n (2)
characterized by the syndiospecific metallocenes as described below. In the aforementioned formulas the Me denotes a transition metal and Cp and Cp′ each denote a cyclopentadienyl group which can be either substituted or unsubstituted with Cp′ being different from Cp, Q is an alkyl or other hydrocarbyl or a halo group and n is a number within the range of 1-3. The cyclopentadienyl groups are in a stereorigid relationship normally provided by a bridged structure between the metallocene groups (not shown in Formulas (1) and (2) above) although stereorigidity can be provided through substituent groups which result in steric hindrance, as described, for example, in U.S. Pat. No. 5,243,002 to Razavi.
[0003] Isospecific and syndiospecific metallocene catalysts are useful in the stereospecific polymerization of monomers. Stereospecific structural relationships of syndiotacticity and isotacticity may be involved in the formation of stereoregular polymers from various monomers. Stereospecific propagation may be applied in the polymerization of ethylenically unsaturated monomers such as C 3+ alpha olefins such as propylene, 1-butene, 4-methyl-1-pentene, 1-dienes such as 1,3-butadiene, substituted vinyl compounds such as vinyl aromatics, e.g., styrene or vinyl toluene, vinyl chloride, vinyl ethers such as alkyl vinyl ethers, e.g., isobutyl vinyl ether, or even aryl vinyl ethers. Stereospecific polymer propagation is of most significance in the production of isotactic or syndiotactic polypropylene and polybutene.
[0004] The structure of isotactic polypropylene can be described as one having the methyl groups attached to the tertiary carbon atoms of successive monomeric units falling on the same side of a hypothetical plane through the main chain of the polymer, e.g., the methyl groups are all above or below the plane. Using the Fischer projection formula, the stereochemical sequence of isotactic polypropylene is described as follows:
In FIG. 3 each vertical segment indicates a methyl group on the same side of the polymer backbone. Another way of describing the structure is through the use of NMR. Bovey's NMR nomenclature for an isotactic pentad as shown above is . . . mmmm . . . with each “m” representing a “meso” dyad, or successive pairs of methyl groups on the same said of the plane of the polymer chain. As is known in the art, any deviation or inversion in the structure of the chain lowers the degree of isotacticity and crystallinity of the polymer.
[0005] In contrast to the isotactic structure, syndiotactic propylene polymers are those in which the methyl groups attached to the tertiary carbon atoms of successive monomeric units in the chain lie on alternate sides of the plane of the polymer. Syndiotactic polypropylene using the Fisher projection formula can be indicated by racemic dyads with the syndiotactic pentad rrrr shown as follows:
Here, the vertical segments again indicate methyl groups in the case of syndiotactic polypropylene, or other terminal groups, e.g. chloride, in the case of syndiotactic polyvinyl chloride, or phenyl groups in the case of syndiotactic polystyrene.
[0006] Syndiotactic polymers are semi-crystalline and, like the isotactic polymers, are largely insoluble in cold xylene. This crystallinity distinguishes both syndiotactic and isotactic polymers from an atactic polymer, which is non-crystalline and highly soluble in xylene. An atactic polymer exhibits no regular order of repeating unit configurations in the polymer chain and forms essentially a waxy product.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, there are provided supported stereospecific catalysts and processes for the stereotactic propagation of a polymer chain derived from ethylenically unsaturated monomers which contain three or more carbon atoms or which are substituted vinyl compounds, such as styrene and vinyl chloride. The preferred application of the present invention is in the stereospecific propagation of C 3 -C 4 alpha olefins, particularly the polymerization of propylene to produce syndiotactic polypropylene. Another application of the present invention involves isospecific metallocene catalysts and their use in the polymerization of propylene to produce isotactic polymers, including homopolymers and copolymers, specifically, isospecific ethylene propylene copolymers. In carrying out the present invention, there is provided a supported metallocene catalyst comprising a stereospecific metallocene catalyst component and a co-catalyst component comprising an alkylalumoxane. The metallocene catalyst component incorporates a metallocene ligand structure having two sterically dissimilar cyclopentadienyl ring structures coordinated with the central transition metal atom. At least one of the cyclopentadienyl ring structures is a substituted cyclopentadienyl group which provides an orientation with respect to the transition metal atom which is sterically different from the orientation of the other cyclopentadienyl group. Both of the cyclopentadienyl groups are in a relationship with one another by virtue of bridge or substituent groups, which provide a stereorigid relationship relative to the coordinating transition metal atom to prevent rotation of said ring structures. Both the metallocene catalyst component and the co-catalyst component are supported on a particulate polyamide support comprising spheroidal particles of a polyamide having an average diameter within the range of 5-60 microns, preferably 10-30 microns, and a porosity permitting distribution of a portion of the co-catalyst component within the pore volume of the polyamide particles while retaining a substantial portion, preferably the predominate portion, of the co-catalyst on the surface of the support particles. This supported catalyst is contacted in a polymerization reaction zone with an ethylenically unsaturated monomer which contains 3 or more carbon atoms or which is a substituted vinyl compound under polymerization conditions to produce stereospecific polymerization of the monomer.
[0008] The metallocene component can take the form of a single metallocene or can involve two or more metallocenes which are co-supported on the polyamide support. Such catalyst components incorporating two or more metallocenes can be employed to produce, for instance, syndiotactic or isotactic polymers having broad molecular weight distributions.
[0009] In a preferred embodiment of the invention, the supported metallocene catalyst incorporates a particulate polyamide support of a generally spheroidal configuration having an average diameter as described previously. The spheroidal polyamide incorporate an alkyl aluminum disposed predominantly on the outer particle surfaces. A stereospecific metallocene is supported on the polyamide support particles. In one application of the invention, the metallocene is an unbalanced metallocene having a ligand structure in which stereorigidity is imparted by means of a structural bridge extending between dissimilar cyclopentadienyl groups. The metallocene is preferentially supported on the outer surfaces of the polyamide particles to provide a predominance of the polymerization sites provided by the transitional metal atom on the exterior of the support particulate. The polyamide support is characterized by relatively low surface area. Preferably, the polyamide support has a surface area which is less than 50 square meters per gram (50 m 2 /g).
[0010] In a further aspect of the invention there is provided a process for the preparation of a supported metallocene catalyst. In carrying out this aspect of the invention, there is provided a particulate catalyst support material in the form of a generally spheroidal polyamide particles having an average diameter within the range of 5-60 microns, preferably 10-30 microns. The polyamide support material is contacted with an alumoxane co-catalyst in an aromatic hydrocarbon solution under conditions in which the alumoxane and the polyamide react with a preponderance of the alumoxane being retained on the polyamide support. The alumoxane containing polyamide support particles are recovered from the aromatic hydrocarbon solvent. A stereospecific metallocene incorporating a metallocene ligand structure having sterically dissimilar cyclopentadienyl ring structures coordinated with the central transition metal atom as described above is dispersed within an aromatic hydrocarbon solvent, or, alternatively, in an aliphatic hydrocarbon such as hexane where sufficient hexane solubility is present. The metallocene solvent dispersion and the product produced by the reaction of the polyamide support material and the alumoxane are mixed together for a period of time sufficient to allow the metallocene to become reactively supported on the polyamide support to form a supported metallocene catalyst. This supported catalyst is then recovered from the aromatic solvent.
[0011] In a specific embodiment of the invention, the metallocene is characterized by the formula:
R″(Cp a R n )(Cp b R′ m )MeQ p (5)
In formula (5), Cp a is a substituted cyclopentadienyl ring, Cp b is an unsubstituted or substituted cyclopentadienyl ring; each R is the same or different and is a hydrocarbyl radical having 1-20 carbon atoms; each R′ is the same or different and is a hydrocarbyl radical having 1-20 carbon atoms; R″ is a structural bridge between the cyclopentadienyl rings imparting stereorigidity to the catalyst and is selected from the group consisting of an alkylene radical having 1-4 carbon atoms or a substituted alkylene group such as a diphenyl methylene group, a silicon hydrocarbyl radical, a germanium hydrocarbyl radical, a phosphorus hydrocarbyl radical, a nitrogen hydrocarbyl radical, a boron hydrocarbyl radical, and an aluminum hydrocarbyl radical: Me is a group 4b, 5b, or 6b metal from the Periodic Table of Elements and each Q is a hydrocarbyl radical having 1-20 carbon atoms or is a halogen: p is from 0 to 3, m is from 0 to 3, n is from 1 to 4; and R′m is selected such that (Cp b R′ m ) is a sterically different ring than (Cp a R n ). Preferably, (Cp a R n ) is a substituted or unsubstituted fluorenyl group having bilateral symmetry, Me is a titanium, zirconium, hafnium, or vanadium atom and the bridge R″ is a methylene, ethylene, organosilyl, substituted methylene, propylidene, diphenyl methylene, or substituted ethylene radical. More preferably the metallocene ligand is configured so that (Cp a R n ) forms a fluorenyl group or substituted fluorenyl radical having bilateral symmetry and (Cp b R′ m ) forms an alkyl substituted or unsubstituted cyclopentadienyl radical having bilateral symmetry. More specifically the metallocene ligand R″(Cp a R n )(Cp b R′ m ) is an isopropylidene (cyclopentadienyl-1-fluorenyl) or diphenyl methylene (cyclopentadienyl-1-fluorenyl) ligand structure. Another embodiment of the invention involves polyamide-supported metallocenes which are isospecific. Such metallocenes include bridged bis-indenyl metallocenes and substituted cyclopentadienyl fluorenyl metallocenes which produce isotactic polypropylene.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a photograph of spheroidal polyamide support particles employed in the present invention.
[0013] FIG. 2 is a graph illustrating the particle size distribution of a syndiotactic polypropylene fluff produced employing a syndiospecific polyamide supported catalyst and with the fluff produced by the corresponding syndiospecific catalyst supported on a particulate silica support.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention involves processes for the preparation and use of supported stereospecific metallocenes which are effective in stereospecific polymer propagation, especially syndiotactic polymer propagation, with low fouling production, to provide polymer fluff having a narrow well-defined particle size with minimal fines, good bulk density and flowability. Metallocene catalysts are often supported on various high surface area inorganic supports. Typically such supports have surface areas in excess of 100 m 2 /g. Silica and magnesium chloride are common supports although other supports such as alumina and various clay minerals may be used. The present invention departs from the conventional procedure of employing inorganic supports such as silica, and provides for the incorporation of a stereospecific metallocene catalyst on an organic support of well-controlled and relatively narrow particle size. The use of the organic polyamide support offers the advantage of producing a polymer fluff which does not incorporate minute particles of an inorganic species as is the case with traditional support such as those provided by silica or alumina particles, for instance. The use of the polyamide support provides for minimal fouling during resin manufacture and a well-defined particle size distribution while exhibiting catalyst activity and polymer fluff characteristics similar to those obtained with silica supported metallocene catalysts.
[0015] As noted previously the polyamide support is a fine namely defined powder having an average particle size within the range of 5-60 microns with a preferred average particle size within the range of 10-30 microns. The surface area is less than 50 m 2 /g, and normally less than about 20 m 2 /g. The polyamide particles are in a general sense of a spheroidal nature as contrasted with the angular granules of silica or other inorganics of a highly irregular shape sometimes used as catalyst supports or carriers. Prior to contacting the polyamide support with the stereospecific metallocene, the support is treated with an alumoxane co-catalyst. Alumoxane co-catalysts are also referred to as aluminoxane or poly hydrocarbyl aluminum oxides. Such compounds include oligomeric or polymeric compounds having repeating units of the formula:
where R is an alkyl group generally having 1 to 5 carbon atoms. Alumoxanes are well known in the art and are generally prepared by reacting an organo aluminum compound with water, although other synthetic routes are known to those skilled in the art. Alumoxanes may be either linear polymers or they may be cyclic, as disclosed for example in U.S. Pat. No. 4,404,344. Thus, alumoxane is an oligomeric or polymeric aluminum oxy compound containing chains of alternating aluminum and oxygen atoms, whereby the aluminum carries a substituent, preferably an alkyl group. The exact structure of linear and cyclic alumoxanes is not known but is generally believed to be represented by the general formulae —(Al(R)—O—)-m for a cyclic alumoxane, and R 2 Al—O—(Al(R)—O)m-AlR 2 for a linear compound wherein R independently each occurrence is a C 1 -C 10 hydrocarbyl, preferably alkyl or halide and m is an integer ranging from 1 to about 50, preferably at least about 4. Alumoxanes also exist in the configuration of cage or cluster compounds. Alumoxanes are typically the reaction products of water and an aluminum alkyl, which in addition to an alkyl group may contain halide or alkoxide groups. Reacting several different aluminum alkyl compounds, such as, for example, trimethylaluminum and tri-isobutyl aluminum, with water yields so-called modified or mixed alumoxanes. Preferred alumoxanes are methylalumoxane and methylalumoxane modified with minor amounts of other higher alkyl groups such as isobutyl. Alumoxanes generally contain minor to substantial amounts of starting aluminum alkyl compounds. The preferred co-catalyst, prepared either from trimethylaluminum or triethylaluminum, is sometimes referred to as poly (methyl aluminum oxide) and poly (ethyl aluminum oxide), respectively. The alumoxane co-catalyst is a predominately located on the surface of the polyamide support particles. The orientation of the alumoxane on the surface of the support particles functions to activate the subsequently added metallocene.
[0016] In carrying out the polymerization reaction the normal practice is to employ a scavenging agent or polymerization co-catalyst which is added to the polymerization reactor along with the supported metallocene. These scavengers can be generally characterized as organo metallic compounds of metals of Groups IA, IIA, and IIIB of the Periodic Table of Elements. As a practical matter, organo aluminum compounds are normally used as co-catalysts in polymerization reactions. Specific examples include triethyl aluminum, tri-isobutyl aluminum, diethyl aluminum chloride, diethyl aluminum hydride and the like. Scavenging co-catalysts normally employed in the invention include triethyl aluminum (TEAL) and tri-isobutyl aluminum (TIBAL). Tri-isobutyl aluminum can also be employed as a dispersant in which the supported catalyst is aged for a suitable period of time of from one minute to several days prior to use in the polymerization reaction as described in U.S. Pat. No. 6,239,058 to Shamshoum et al., the entire disclosure of which is incorporated herein by reference.
[0017] Metallocene catalysts that produce isotactic polyolefins are disclosed in U.S. Pat. Nos. 4,794,096 and 4,975,403 to Ewen. These patents disclose chiral, stereorigid metallocene catalysts that polymerize olefins to form isotactic polymers and are especially useful in the polymerization of highly isotactic polypropylene. As disclosed, for example, in the aforementioned U.S. Pat. No. 4,794,096, stereorigidity in a metallocene ligand is imparted by means of a structural bridge extending between cyclopentadienyl groups. Specifically disclosed in this patent are stereoregular hafnium metallocenes which may be characterized by the following formula:
R″(C 5 (R′) 4 ) 2 HfQp (7)
In formula (7), (C 5 (R′) 4 ) is a cyclopentadienyl or substituted cyclopentadienyl group, R′ is independently hydrogen or a hydrocarbyl radical having 1-20 carbon atoms, and R″ is a structural bridge extending between the cyclopentadienyl rings. Q is a halogen or a hydrocarbon radical, such as an alkyl, aryl, alkenyl, alkylaryl, or arylalkyl, having 1-20 carbon atoms and p is 2.
[0018] Catalysts that produce syndiotactic polypropylene or other syndiotactic polyolefins and methods for the preparation of such catalysts are disclosed in U.S. Pat. No. 4,892,851 to Ewen. These catalysts are also bridged stereorigid metallocene catalysts, but, in this case, the catalysts have a structural bridge extending between dissimilar cyclopentadienyl groups and may be characterized by the formula:
R″(CpR n ) (CpR′ m )MeQ k (8)
In formula (8), Cp represents a cyclopentadienyl or substituted cyclopentadienyl ring, and R and R′ represent hydrocarbyl radicals having 1-20 carbon atoms. R″ is a structural bridge between the rings imparting stereorigidity to the catalyst. Me represents a transition metal, and Q a hydrocarbyl radical or halogen. R′ m is selected so that (CpR′ m ) is a sterically different substituted cyclopentadienyl ring that (CpR n ). In formula (8) n varies from 0-4 (0 designating no hydrocarbyl groups, i.e., an unsubstituted cyclopentadienyl ring), m varies from 1-4, and k is from 0-3. The sterically different cyclopentadienyl rings are configured in the ligand structure to produce a predominantly syndiotactic polymer rather than an isotactic polymer.
[0019] Specifically disclosed in U.S. Pat. No. 4,892,851 to Ewen, are bridged metallocene ligands having a dissimilar cyclopentadienyl group resulting from the reaction of 6, 6 dimethyl fulvene with a substituted cyclopentadiene, fluorene, to produce a ligand characterized by an isopropylidene bridge structure. Preferably, this ligand structure is characterized as having bilateral symmetry such as indicated by the isopropylidene (cyclopentadienyl fluorenyl) structure as shown below:
As indicated by Formula (9), the bilateral symmetry of the ligand structure is indicated by the balanced orientation about the broken line representing a plane of symmetry extending generally through the bridge structure and the transition metal atom.
[0020] While stereorigidity is normally established by a structural bridge as described above, an alternative approach is described in U.S. Pat. No. 5,243,002 to Razavi. This patent discloses the establishment of a stereorigid relationship imparted by a sterically-hindered relationship between substituted cyclopentadienyl rings which prevent rotation of the ring structures about their coordination axis. Alternatively, the cyclopentadienyl groups may be highly substituted such that a relatively low kinetic energy state is induced by the substituents in order to prevent rotation rings about their coordination axis at the temperature of the catalyst.
[0021] Catalyst systems useful in the formation of isotactic polyolefins include the racemic bis-indenyl compounds of the type disclosed in U.S. Pat. No. 4,794,096 to Ewen. The bis(indenyl) ligand structures may be unsubstituted or they may be substituted as described below. Other isospecific metallocenes useful in carrying out the invention are based upon cyclopentadienyl fluorenyl ligand configurations which are substituted to provide a lack of bilateral symmetry. Catalysts of this nature are disclosed in U.S. Pat. No. 5,416,228 to Ewen et al. Here, the ligand structure is configured so that one cyclopentadienyl group of a bridged ligand has a bulky group on one and only one of the distal positions of a cyclopentadienyl ring. Typical of such metallocenes is isopropylidene (3-tertiary butyl cyclopentadienyl fluorenyl) zirconium dichloride.
[0022] Other isospecific metallocenes based on cyclopentadienyl fluorenyl ligand structures are disclosed in EPO 0881,236A1 to Razavi. Here, the ligand structures are characterized by bridged cyclopentadienyl and fluorenyl groups in which the cyclopentadienyl group is substituted at both proximal and distal positions. The distal substituent is preferably a bulky group such as a tertiary butyl group, and the proximal substituent is a less bulky group such as a methyl group which may be either vicinal or non-vicinal to the distal substituent. The fluorenyl group may be substituted or unsubstituted with up to eight substituent groups but preferably are unsubstituted at the positions which are distal to the bridgehead carbon atom. Specifically disclosed in EPO 881,236A1 are isopropylidene(3-tertiary butyl, 5-methyl cyclopentadienyl fluorenyl) zirconium dichloride and isopropylidene(3-tertiary butyl, 2-methyl cyclopentadienyl fluorenyl) zirconium dichloride.
[0023] Yet other isospecific metallocenes based upon bis(fluorenyl) ligand structures are disclosed in U.S. Pat. No. 5,945,365 to Reddy. Here, the ligand structure is characterized by two bridged fluorenyl groups with 1 or 2 substituents at distal positions on each fluorenyl group with one group of substituents being located transversely from the other with respect to a plane of bilateral symmetry extending through the bridge group. Preferred ligand structures are bridged bisfluorenyl ligands substituted at the 4,4′ positions by methyl, methoxy, isopropyl or tertiary butyl groups. For a further description of isospecific metallocenes, reference is made to the aforementioned U.S. Pat. Nos. 4,794,096, 5,416,228 and 5,945,365 and EPO 881,236A1, the entire disclosures of which are incorporated herein by reference.
[0024] In experimental work respecting the present invention, syndiospecific and isospecific metallocene catalysts were supported on a polyamide support having an average particle size of 20 microns. The polyamide particles are available from ATOFINA Chemicals, Inc. under the designation Orgasol 3502(d). Orgasol 3502(d) and similar polyamide particles are produced by the polymerization of caprolactame either alone or with lauryllactame. The polyamide support particles are characterized by a density slightly in excess of 1 gram per cubic centimeter and a melting point of about 177° C. The polyamide particles are characterized as spheroidal, since while they are not perfect spheres, they conform generally to a spheroidal shape having surface imperfections on their outer surfaces. FIG. 1 is a photograph of Orgasol 3502(d) polyamide particles shown with a magnification of 20×.
[0025] The experimental work with the polyamide supports was carried out employing a syndiospecific metallocene, diphenyl methylene (cyclopentadienyl) (fluorenyl) zirconium dichloride. The isospecific catalyst employed in the experimental work was rac dimethyl silyl bis (2-methyl, 4-phenyl indenyl) zirconium dichloride. In preparing the polyamide supported metallocene catalysts, the polyamide support particles were dried under a nitrogen stream for 14 hours at 60° C. The polyamide support was then employed in a dispersion formed of 10 grams of the polyamide and 80 milliliters of toluene. After the polyamide dispersion was stirred to disperse the polyamide particles within the toluene carrier, methylalumoxane (MAO) was added in an amount to provide a weight ratio of MAO to polyamide of 0.7:1. The methylalumoxane 23.6 grams of MAO solution (30 wt. % in toluene) was added slowly to the polyamide dispersion. The two components were mixed at room temperature and the evolution of gas (presumably methane) occurred. Stirring of the mixture of the two components continued until gas evolution ceased. Thereafter the mixture was refluxed at 115° C. for about four hours and then allowed to cool. The supernate toluene was decanted and the residual solids were washed three times with 100 milliliters of toluene. Following decantation of the last toluene wash, the solid MAO polyamide particles were dispersed in 100 milliliters of hexane and left overnight. The hexane layer was then decanted and the solids were washed two times with 100 milliliter portions of hexane and then dried under a vacuum for two hours. The MAO-supported polyamide particles were then recovered as a fine white powder.
[0026] In order to support the metallocene on the polyamide particles, metallocene loading was accomplished by providing a dispersion of the stereospecific metallocene in toluene. In each case, a metallocene loading of a 2 wt. % on the MAO polyamide support was employed. By way of example of the metallocene loading procedure, about 5 grams of the MAO-reacted polyamide support were added to a round-bottomed flask along with 80 milliliters of toluene. On hundred milligrams of the metallocene was added in 20 milliliters of toluene. The contents were added in a 20 milliliter Wheaton vial and the contents stirred for about one hour. The solids were washed on a frit sequentially with three 50 milliliter portions of toluene followed by three 50 milliliter portions of hexane. The final catalyst was dried in vacuum to give a light purple powder weighing 4.53 grams. Mineral oil was then added to this solid to provide a total mineral oil dispersion of 47.878 grams containing about 9.5% solids.
[0027] In the comparative experimental work carried out using a silica supported catalyst, the syndiospecific metallocene, Ph2C(Cp)(Flu)ZrCl2 was supported on a silica support having a weight ratio of MAO to silica of 0.7/1. In preparation of methylaluminoxane on the silica support, the silica, Sunsphere H121, available from Asahi Glass Company, was dried in an oven at 150° C. for 24 hrs. The dried silica was placed in a 3-necked 1 liter round-bottomed flask equipped with a reflux condenser, magnetic stir bar and sealed using rubber septa in a glove box. The flask containing the silica was removed from the glove box and connected to a double manifold schlenk line (argon/vacuum). Toluene was added to the silica and the slurry was allowed to homogenize for 10 minutes. Clear and gel-free methylaluminoxane (140 milliliters of 30 wt % MAO in toluene) was added slowly. The slurry was heated to reflux and maintained for 4 hours at which time the solution was allowed to cool to ambient temperature and the solids allowed to settle. The toluene solution was decanted from the flask and the remaining wet solids were washed sequentially with three 450 milliliter portions of toluene. The wet MAO/silica was washed with three 450 milliliter portions of hexane and the solids were dried for 3 hours in vacuo to yield a dry white powder (111 grams) containing a small amount of residual solvent.
[0028] In the preparation of the silica supported metallocene catalyst, five grams of the MAO on the silica support and 50 milliliters of dry, deoxygenated toluene were added to a 100 milliliter round-bottomed flask. One hundred mg of diphenylmethylene (cyclopentadienyl) (fluorenyl) zirconium dichloride and 10 milliliters of toluene were added to a 20 milliliter Wheaton vial. The metallocene catalyst was added to the slurry containing the MAO on silica via cannula and the contents was stirred for 1 hr. The solids were then allowed to settle and the mother liquor was decanted using a cannula. The solids were washed on a frit sequentially with three 50 milliliter portions of toluene followed by three 50 milliliter portions of hexane. The final catalyst was dried in vacuo for 1 hr to give a blue solid weighing 4.8 grams. To the dried catalyst was added 46.3 grams of purified mineral oil (dry & deoxygenated) to make a final catalyst slurry containing 9.5% solids.
[0029] Polymerizations were performed in liquid propylene using a stirred, autoclave type reactor with either 2 liter or 4 liter capacity. For a 2 liter reactor, the reactor was charged with 360 grams of propylene and 5 mmoles of hydrogen. The catalyst (36 mgs) was flushed into the reactor with tributyl aluminum (TIBAL) for the syndiospecific catalyst and triethyl aluminum (TEAL) for the isospecific catalyst and 360 grams of propylene at room temperature. The reactor temperature was increased quickly to about 60-70° C. and the polymerization was allowed to proceed for one hour. Residual propylene and hydrogen were then flashed from the reactor and the polymer fluff was allowed to dry in air overnight. Catalyst activity values are reported as the grams of polymer produced per gram of catalyst used per hour.
[0030] Bulk density measurements were conducted by weighing the unpacked contents of a 100 milliliter graduated cylinder containing polymer powder and the results were reported as grams per cubic centimeter. Polymer melt flow was determined in accordance with ASTM D-1238 at 230° C. with a 2.16 Kg mass. Polymer powder was stabilized for the test with approximately 1 mg of 2,6-ditert-butyl-4-methylphenol (BHT) with the melt flow reported as gram/10 min.
[0031] Fluff particle size distribution was recorded on a mechanical sieve shaker. A plot of particle size versus cumulative amount (0-100%) was used to estimate the D10, D50 and D90. Fines are defined as the % by weight of particles less than about 106 μm in size. Catalyst and silica particle size distributions were measured using a Malvern Particle Size Analyzer.
TABLE 1 Activity MF BD Fouling % Fines Run No. (g/g/h) (dg/min) (g/cc) (mg/g) (<106 um) 1 11,000 1.6 0.26 — — 2 19,500 2.3 0.36 1.2 0 3 2,528 2.3 .30 3.37 .16 4 18,600 1.8 .40 1.0 0
[0032] The results of the polymerization runs for the above-described polyamide-supported catalyst and the silica-supported catalyst are set forth in Table 1. Run 1 was carried out with is the syndiospecific catalyst supported on the polyamide support. Run 2 indicates the results obtained for this same catalyst but with the catalyst first being aged in a tri-isobutyl aluminum solution. In the aging procedure 36 milligrams of catalyst was aged in the presence of 36 milligrams of TIBAL for a period of 12 hours.
[0033] Run number 3 indicates the results achieved for the above identified iso-specific metallocene without aging. Run number 4 indicates the results achieved with the syndiospecific catalyst supported on the above identified silica support, again without aging. In each case, the weight ratio of the MAO to the support was 0.7. The metallocene loadings for Runs 1 and 2 were 2%. For the iso-specific metallocene reported in Run 3 the metallocene loading was 3.0%. In Runs 1, 2 and 4 the co-catalyst employed was TIBAL. In Run 3 the co-catalyst employed was TEAL. The ratio of co-catalyst to catalyst weight ratio of a co-catalyst to catalyst was 3:1 for each of Runs 1, 2 and 4, and was 2:1 for Run 3. In the run carried out employing the polyamide supports the hydrogen usage was 97 mmoles for the syndiospecific catalyst but only 10 mmoles for the iso-specific catalyst.
[0034] As shown in Table 1, the activity for the syndiospecific polyamide supported catalyst was good and when aged in TIBAL actually exceeded the activity of the silica-supported catalyst. The melt flow and bulk density compared favorably with the silica-supported catalyst and the fouling was about the same as or less than the silica-supported catalyst. The activity for the isospecific metallocene supported on the polyamide support was substantially less than for the syndiospecific catalyst. Based upon this experimental data it is preferred to employ the polyamide support in conjunction with the syndiospecific catalyst, although as indicated, polymer production is achieved with the isospecific catalyst. Thus the polyamide support can be employed with the isospecific catalyst where it is desired to avoid an inorganic silica residue in the polymer fluff.
[0035] FIG. 2 shows graphs of the cumulative particle size distribution % plotted on the ordinate versus particle size in microns plotted on the abscissa for syndiotactic polypropylene fluff produced employing the unaged polyamide-supported catalyst indicated by curve 2 and the silica—supported syndiospecific catalyst indicated by curve 4 . As can be seen by an examination of FIG. 2 the particle size of distribution for the syndiotactic polymer produced by the polyamide supported syndiospecific catalyst is narrow and well-defined with a very few fines in the lower particle sizes. Thus the polyamide supported catalyst of the present invention is as effective as the corresponding silica supported catalyst, but offers the added advantage of providing predominantly organic catalyst residue in the polymer fluff.
[0036] Having described specific embodiments of the present invention, it will be understood that modifications thereof may be suggested to those skilled in the art, and it is intended to cover all such modifications as fall within the scope of the appended claims.
|
Supported stereospecific catalysts and processes for the stereotactic propagation of a polymer chain derived from ethylenically unsaturated monomers such as the polymerization of propylene to produce syndiotactic polypropylene or isotactic polypropylene. The supported catalyst comprises a stereospecific metallocene catalyst component and a co-catalyst component comprising an alkylalumoxane. Both the metallocene catalyst component and the co-catalyst component are supported on a particulate polyamide support comprising spheroidical particles of a polyamide having an average diameter with the range of 5-60 microns, and a porosity permitting distribution of a portion of the co-catalyst within the pore volume of the polyamide particles while retaining a substantial portion on the surface of the particles. The polyamide support is characterized by relatively low surface area, specifically a surface area less than 20 square meters per gram. The metallocene component can take the form of a single metallocene or two or more co-supported metallocenes.
| 8
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a yarn winding machine for continuously winding advancing yarns into packages.
[0002] In the production of melt spun yarns in a spinning process, the yarns are wound to packages at the end of the production process. To this end, winding machines are used, which continuously wind a yarn to packages without interrupting the process. To this end, winding machines of this type comprise a plurality of winding spindles, which are mounted on a movable spindle support, also referred to as a turret herein, and alternately moved by means of the turret to a winding position for winding the yarns, and then to a doffing position for removing the fully wound packages and putting on new tubes. The yarn change from a first winding spindle to a second winding spindle occurs automatically, so that the spinning process need not be interrupted.
[0003] To slip one or more tubes over the winding spindle held in the doffing position after removing a fully wound package, various systems for such winding machines are known in the art.
[0004] DE 24 27 016 discloses a winding machine with a rotatable turret that mounts two winding spindles in cantilever fashion. To this end, the winding machine comprises a device for slipping the tubes on an empty winding spindle while it is in the doffing position. The tube slip-on device comprises a gripper arm, which is pivotally supported on an axle. The gripper arm is adapted for axial displacement along the axle. To slip a tube on the winding spindle held in the doffing position, the gripper arm removes a tube from a tube magazine, and puts it on the empty winding spindle by performing pivotal and axial sliding movements. In this process, the position of the winding spindle in the doffing position remains unchanged. However, such a tube slip-on device is not suitable for winding machines, in which the turret performs a bypassing movement for enabling in the winding position a package buildup on the winding spindle being in this position. In particular, in the winding process of so-called spin textured yarns, wherein yarns with coarser deniers are produced, and thus entail a rapid package buildup, it is not realistically possible to stop the turret for doffing the full packages or putting on the tubes.
[0005] In such winding machines, in which the turret performs a bypassing movement for winding the packages, the fully wound packages and the tubes are each removed and replaced automatically by means of so-called doffers. For example, EP 0 757 658 A1 discloses such a winding machine, in which a traveling doffer is equipped with a mandrel that holds the tubes. The doffer moves to a certain winding spindle position of the winding machine and slides the tubes onto the empty winding spindle. However, in this case it is necessary that the turret perform no movement at the moment when the winding spindle receives the tubes. Yet, in the winding of yarns with coarse deniers, only very short doffing times are available. Any disturbance in such a time-critical tube slip-on process would thus lead to a discontinuation of this process, and a new process would have to be started in a changed position of the winding spindle.
[0006] It is therefore an object of the invention to further develop a winding machine of the described type such that it permits putting on tubes in a simple manner also in the case of very short shutdown times of the winding spindle.
SUMMARY OF THE INVENTION
[0007] The above and other objects and advantages of the invention are achieved by the provision of a winding apparatus of the described type and wherein a movement of the winding spindle in the doffing position has no critical effect on supplying the winding spindle with new tubes. To this end, a guide means for slipping on the tubes is adapted for moving for a short time or distance synchronously with the winding spindle that is moved by the spindle support or turret. This enlarges the time window in which it is possible to slip the tubes on the winding spindle. The guide means follows the winding spindle for a short period, so that it is not necessary to interrupt the rotational movement of the spindle support or turret that is needed for winding the yarns on a second winding spindle located at the winding position.
[0008] A simple positioning occurs in that the guide means is arranged on the side next to the spindle support, that it can be moved between a standby position and an operating position laterally toward the winding spindle, and that in the operating position, the guide means can be mechanically linked with the winding spindle. This enables an easy alignment of the guide means with the winding spindle. Even during the rotational movement of the spindle support, no significant errors occur in the alignment between the free end of the winding spindle and the guide means.
[0009] To enable an axial relative movement between the guide means and the winding spindle also when the guide means and winding spindle are mechanically linked, it is advantageous to provide the guide means with a slide shoe, which lies in the operating position against the winding spindle, and sees to the mechanical linkup. To avoid differences in the sequences of movement, the movement of the winding spindle and the movement of the guide means are advantageously performed during the phase of the mechanical linkup by the drive of the spindle support.
[0010] However, it is also possible to adapt the drive of the spindle mount to a drive of the guide means, so that a synchronous movement exists for a short time. For example, it is thus possible to perform the connection also by electronic means.
[0011] For putting the tubes on the winding spindle, it is advantageous to mount the guide means for horizontal movement. This permits the guide means to position the tubes not only in facing relationship with the free end of the winding spindle, but also to slide the tubes onto the winding spindle.
[0012] In a particularly simple realization, the guide means is formed by a trough-like tube carrier, which is supported at its one end on a pivot pin, and which has at its opposite end an opening for releasing tubes that are successively stored in the tube carrier. With that, it is possible and advantageous to position and slide on a plurality of tubes at the same time. It is not necessary to handle the tubes each individually.
[0013] Preferably the pivot pin with the tube carrier is mounted on a carriage, which moves in the lower portion of the machine frame parallel to the winding spindles in the doffing range. With that, it is possible to slide the tubes in the positioned tube carrier onto the winding spindle in a simple manner.
[0014] Preferably, the tube carrier has a width that corresponds to the total length of the tubes placed on the winding spindle. With that, it is possible to slip on in one step all tubes that are arranged on a winding spindle. It is thus possible to put on the winding spindle as many as eight, ten, twelve, or even more tubes at the same time.
[0015] An additional, especially advantageous further development of the invention makes it possible to position the tubes on the winding spindle. In particular in the cases in which the tubes are supported on the winding spindle in spaced relationship with one another, it would be necessary to reposition on the winding spindle by separate means the tubes that are put on as a column. As a result of dividing the tube carrier over its width into a plurality of separate compartments, it is possible to associate to each winding position one compartment in the tube carrier, so that the tubes kept in the compartment are allocated to a certain winding position. The spacings between the compartments are made to correspond to the spacings for positioning the tubes on the winding spindle. When sliding the tubes onto the winding spindle, it is thus possible to associate the tubes with the positions of the winding positions.
[0016] To be able to perform in the case of manual interruptions because of process breakdowns, several tube feeds one after the other within a short time, the further development of the invention will be advantageous, in which the tube carrier has a depth for receiving a plurality of tubes per winding position.
[0017] In this connection, it is easy to cause the tubes to move up to a delivery position on the tube carrier in that in the standby position, the tube carrier is positioned higher at its support end than at its opposite end, so that the tube carrier has an inclined orientation.
[0018] When a plurality of tubes are used per winding position, it is possible to retain the tubes respectively held at the feed end in the case of a partial filling of the tube carrier, in that the tube carrier comprises in the region of the feed end a blocking device, which permits securing the tubes at the feed end of the tube carrier.
[0019] For causing the tubes to move up automatically, the further development of the invention is especially suited, wherein the feed device comprises a tube magazine, which connects to the guide means.
[0020] To be able to perform the sequences of movements for positioning and putting on the tubes as quickly and as accurately as possible, the tube slip-on device comprises a vertical drive and a horizontal drive, which are controllable independently of each other for moving the guide means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the following, further advantages of the invention are described in greater detail by means of several embodiments which are described with reference to the attached Figures, in which:
[0022] FIGS. 1 . 1 and 1 . 2 are schematic front views of a first embodiment of a winding machine according to the invention;
[0023] FIGS. 2 . 1 - 2 . 4 are schematic side views of the embodiment of FIGS. 1 . 1 and 1 . 2 ; and
[0024] FIG. 3 is a schematic front view of a further embodiment of the winding machine according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] FIGS. 1 . 1 and 1 . 2 , and 2 . 1 - 2 . 4 schematically illustrate a first embodiment of the winding machine according to the invention. In this connection, FIGS. 1 . 1 and 1 . 2 as well as FIGS. 2 . 1 , 2 . 2 , 2 . 3 , and 2 . 4 show different operating situations of the winding machine. The following description will apply to all Figures, unless express reference is made to one of the Figures.
[0026] The winding machine comprises a movable spindle support 2 , which is rotatably supported in a machine frame 1 so as to define a horizontal central axis. The spindle support 2 is constructed as a turntable or turret and driven anticlockwise by a rotational drive unit 19 . The spindle support 2 mounts in cantilever fashion, 180° out of phase, two winding spindles 3 and 5 . The winding spindles 3 and 5 are rotatably supported on the spindle support 2 so that their rotational axes are parallel to the central axis. At their supported end, the winding spindles 3 and 5 connect to their respective spindle drive 21 and 22 . The opposite ends of the winding spindles 3 and 5 project freely.
[0027] Above the spindle support 2 , the machine frame 1 mounts a contact roll 7 by means of a rocker arm 9 . The contact roll 7 extends substantially over the entire length of the winding spindles 3 and 5 . Above the contact roll 7 , a yarn traversing device 10 is supported on the machine frame 1 . In the present embodiment, the yarn traversing device 10 is symbolically shown as a rotary blade type traversing system, in which two oppositely driven rotors with a plurality of blades reciprocate in a winding position a yarn for depositing it on a package. However, the yarn traversing device 10 may also be formed by different systems, such as, for example, a traversing system using a cross-spiraled shaft.
[0028] As shown in FIGS. 2 . 1 - 2 . 4 , the illustrated embodiment comprises three winding positions, in each of which a yarn 8 is wound to a package 6 . Associated to each winding position are a traversing unit of the yarn traversing device 10 and a tube 4 on the winding spindle 3 . The tubes 4 are supported in spaced relationship on the winding spindle 3 .
[0029] For winding, a yarn 8 is supplied to each winding position via a yarn guide (not shown). In the winding position, the yarn 8 advances through the yarn traversing device 10 , which reciprocates the yarn 8 within a traverse stroke. Subsequently, the yarn 8 is guided over the contact roll 7 with a partial looping and deposited on the surface of package 6 . In the winding position, the package 6 is driven by the winding spindle 3 and spindle drive 21 . In this process, the drive of the winding spindle 3 occurs such that the circumferential speed on the package 6 remains constant, while the yarn 8 is being wound. To enable a buildup of the package 6 , the rotational drive unit 19 rotates the spindle support 2 slowly in the anticlockwise direction about its central axis.
[0030] On the winding spindle 3 , three packages 6 are wound in parallel side-by-side relationship. As soon as the packages 6 are fully wound, the rotational drive unit 19 of the spindle support 2 is activated such that the winding spindles 3 and 5 are exchanged, and the yarn is transferred. With that, the winding spindle with the fully wound packages moves to a doffing position, and the winding spindle with the new tubes rotates into the winding position.
[0031] In the situations shown in FIGS. 1 . 1 and 1 . 2 and 2 . 1 - 2 . 4 , the winding spindle 3 is in the winding position, and the winding spindle 5 in the doffing position. The fully wound packages have already been removed from the winding spindle 5 . To this end, the winding machine comprises a removing device (not shown), which is used to slide the tubes with the fully wound packages axially off the winding spindle 5 . After the fully wound packages have been pulled off and removed from the winding spindle 5 , the latter will receive new tubes 4 .
[0032] To supply the new tubes 4 , a tube slip-on device 11 is arranged in the lower portion of the machine frame 1 . The tube slip-on device 11 comprises a guide means 12 for positioning and sliding the tubes 4 onto the winding spindle 5 . In the present embodiment, the guide means 12 is constructed as a trough-like tube carrier 16 . With its one end, the support end 18 , the tube carrier 16 is pivotally mounted on a pivot pin 13 . At its opposite end, the so-called feed end 17 , the tube carrier has an opening 23 which is made such that it permits inserting and removing a tube 4 both in the radial and the axial directions. A vertical drive 20 engages the tube carrier 16 , which permits pivoting the tube carrier 16 from a standby position below the winding spindle 5 to an operating position at the height of the winding spindle 5 . The vertical drive 20 may be, for example, a pneumatic cylinder.
[0033] The tube carrier 16 and the pivot pin 13 are arranged on a carriage 14 . The carriage 14 moves in a carriage guideway 15 in the lower portion of the machine frame 1 . For an axial displacement parallel to the winding spindle 5 , the carriage 14 is provided with a horizontal drive 24 . With this drive, it is possible to move the carriage 14 in the carriage guideway 15 between an outer and an inner position. FIG. 2 . 1 illustrates the carriage 14 in an inner position, and FIG. 2 . 2 in an outer position.
[0034] The tube carrier 16 has a width that extends substantially over the entire length of the winding spindle 5 , as can be noted from FIG. 2 . 1 . Inside the trough-like tube carrier 16 , a plurality of compartments 25 extend, one after the other, which are separated from one another by spacers 26 . At the feed end 17 , each compartment 25 holds a tube 4 for supplying it to the winding spindle 5 . Each compartment 25 is associated to one of the winding positions, with the spacers 26 corresponding in their size to the spacing of the tubes 4 positioned on the winding spindle 3 . The tubes 4 are axially secured in the compartments 25 , so that when being slid onto the winding spindle 5 by means of the tube carrier 16 , the tubes 4 are simultaneously being positioned on the winding spindle 5 .
[0035] As can be noted from FIG. 1 , the tube carrier 16 has a depth, which permits it to receive a plurality of side by side tubes per winding position. In this connection, the tube carrier 16 is moved in the standby position to an inclined orientation, in which the support end 18 of the tube carrier 16 is positioned higher than the feed end 17 . This ensures that after a tube slip-on procedure, tubes are automatically refilled at the feed end. Preferably, the tube carrier 16 has a partial cover, which has at the support end a second opening (not shown) for refilling tubes 4 .
[0036] In the following, the sequence of slipping the tubes 4 on the winding spindle 5 is described in greater detail with reference to the operating situations shown in FIGS. 1 . 1 and 1 . 2 and 2 . 1 - 2 . 4 . After the spindle support 2 has rotated the winding spindle 5 with fully wound packages to the doffing position, the tube carrier 16 is in its standby position, as shown in FIG. 1 . 1 . In this position, the tube carrier 16 holds at its feed end 17 a plurality of co-axially extending tubes 4 .
[0037] After having removed the fully wound packages from the winding spindle 5 by an auxiliary device on the winding machine, the horizontal drive 24 is activated, so that the carriage 14 moves from its inner position to an outer position. This movement can also be combined with a removing device on the winding device. FIG. 2 . 2 shows the situation of the moved out carriage 14 .
[0038] Now, the vertical drive 20 as shown in FIG. 1 . 1 is activated for moving the tube carrier 16 from the standby position to an operating position. In the operating position, the feed end 17 of the tube carrier 16 directly faces the free end of the winding spindle 5 . For positioning, the side of the tube carrier 16 that faces the winding spindle 5 mounts a slide shoe 27 , which is brought into contact with the circumference of the winding spindle 5 . Once the slide shoe 27 is in contact with the circumference of the winding spindle 5 , a desired positioning of the tube carrier 16 is achieved, so that the opening 23 of the tube carrier 16 with the tubes 4 held at the feed end 17 is aligned with the winding spindle 5 . This situation is shown in FIGS. 1 . 2 and 2 . 3 .
[0039] The further sequence of placing the tubes 4 on the winding spindle 5 can be noted from FIG. 1 . 2 . At the beginning of the tube slip-on process, the winding spindle 5 and the tube carrier 16 are held in the position A. The pivot pin 13 and the tube carrier 16 are designed such that a pivotal path 33 of the tube carrier 16 and a guide path 32 , along which the spindle support 2 moves the winding spindle 5 , overlap by a certain amount. This amount is selected such that it is somewhat smaller than the acceptable position deviation of the tube for slipping it onto the winding spindle. For example, were the tube inside diameter 73 mm and the spindle outside diameter 72 mm, an acceptable deviation in the diameter from the ideally geometric location of 0.5 mm would result. If greater, it would be no longer possible to slide on tubes. As an amount of the overlap one could select in this instance an overlap of 0.3 mm for being able to slide on the tube. Thus, the amount of the overlap results in two separate positions A and B, in which it would be still possible to put on the tube.
[0040] The positions A and B thus show the acceptable common pivotal path, through which the tube carrier 16 passes synchronously with the winding spindle 5 . The time in which the tube carrier 16 and the winding spindle 5 are synchronously moved, is defined by the buildup of the packages 6 that are being wound in the winding range on the winding spindle 3 . Taking into account the foregoing amount of the overlap when winding a yarn with a coarse denier, this resulted in a time of about 90 seconds, which corresponded to a angle of rotation of the spindle support of about 8°. The amount of the overlap may be both positive and negative.
[0041] For sliding on the tubes 4 during this phase, the carriage 14 axially displaces the tube carrier 16 with the pivot pin 13 . In so doing, the slide shoe 27 slides along the circumference of the winding spindle 5 , and the free end of the winding spindle 5 engages the opening 23 in the tube carrier 16 , and extends through the tubes 4 held in the individual compartments 25 . The horizontal drive 24 returns the carriage 14 to its inner position. In so doing, the tubes 4 reach their position provided on the winding spindle 5 . Once the carriage 14 has reached its inner position, the tubes 4 are positioned on the circumference of the winding spindle 5 . This situation is shown in FIG. 2 . 4 . It is now possible to pivot the tube carrier 16 by the vertical drive 20 from its operating position back to its standby position. In so doing, the tubes 4 positioned on the circumference of the winding spindle 5 are released from the tube carrier 16 via its opening 23 . As soon as the tube carrier 16 reaches its standby position, a tube 4 moves up in each compartment 25 to the feed end 17 . The tube slip-on device 11 is thus ready for supplying the next winding spindle with tubes.
[0042] In the embodiment shown in FIGS. 1 . 1 and 1 . 2 and 2 . 1 - 2 . 4 , the tubes are manually refilled in the tube carrier 16 . Basically, however, the tubes could also be supplied from a tube magazine directly to the tube carrier 16 . Such an embodiment is shown in FIG. 3 . The embodiment of FIG. 3 is largely identical with the foregoing embodiments, so that the foregoing description can herewith be incorporated by reference, and only differences are described.
[0043] The guide means 12 is likewise constructed as a trough-like tube carrier 16 . In this embodiment, however, the tube carrier 16 comprises at its support end 18 a refill opening 28 . Above the refill opening 28 of the tube carrier 16 , a tube magazine 29 is laterally provided on the machine frame 1 . The tube magazine 29 extends over the entire width of the tube carrier 16 and accommodates a supply of tubes 4 for each winding position. At the lower end of the tube magazine 29 a retaining device 30 is provided, which is movable between a holding position as shown in FIG. 3 and an opened position. In the opened position, the tubes 4 stored in the tube magazine are automatically removed from the tube magazine 29 and guided through the refill opening 28 into the trough-like tube carrier 16 . In the trough-like tube carrier 16 , the tubes automatically roll to the feed end 17 . For securing the tubes 4 at the feed end 17 , the tube carrier 16 comprises a blocking device 31 , which prevents the tubes held at the feed end 17 from rolling back. The tube carrier 16 is pivotally mounted with its support end on the pivot pin 13 , which is arranged on the carriage 14 .
[0044] For the further construction and the further function of the tube slip-on device shown in FIG. 3 , the foregoing description is herewith incorporated by reference.
[0045] The construction of the tube slip-on device shown in the illustrated embodiments is exemplary. For example, the guide means of the tube slip-on device could also be formed by a gripper or a mandrel. With that, the invention extends to similar constructions of the winding machine and the tube slip-on device, in which the tube slip-on device for supplying tubes to a winding spindle comprises a guide means, which moves synchronously together with a winding spindle driven by a spindle support for at least a short time for supplying the tubes. However, it is also possible to combine the tube slip-on device with a package removing device. With that, it would be possible to replace external doffer systems. Furthermore, the tubes could be floatingly stored in their receptacle, i.e., the receptacle is not rigidly connected to the guide means, but is able to move independently thereof to a slight extent. With that, it would be possible to adjust possible alignment errors.
|
A yarn winding apparatus for continuously winding yarns to packages. The winding apparatus has a plurality of winding spindles, which are mounted in cantilever fashion for rotation on a movable turret, and which are alternately guided between a winding position for winding the yarns and a doffing position for removing the packages and assembling fresh tubes. To put on the tubes on the winding spindle, a tube slip-on device is provided, which comprises a movable means for guiding the tubes. To make it possible to put on tubes on the winding spindles held in the doffing position even during the progressive movement of the turret, the guide means for slipping on the tubes is movable for a short time or distance synchronously with the winding spindle that is moved by rotation of the turret.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a board connector for electrically connecting together circuit boards which are incorporated in, for example, a mobile telephone.
2. Description of the Prior Art
A plurality of circuit boards (PCBs, hereinafter referred to merely as “boards”) are incorporated in a mobile telephone. A conventional board connector for electrically connecting the boards to each other has the following configuration. One-end sides of plural socket contacts which are fixed in parallel to a socket are fixed to one of the boards by soldering, and the socket is mounted on the board. By contrast, one-end sides of plural socket contacts which are fixed in parallel to another socket are fixed to the other board by soldering, and the other socket is mounted on the other board. A plug in which one-end sides of plug contacts configured by plural thin conductors are fixed in parallel is fitted to the socket, and one-end sides of the plug contacts are contacted with and held by the socket contacts. Another plug to which the other-end sides of the plug contacts are fixed in parallel is fitted to the other socket, and the other-end sides of the plug contacts are contacted with and held by the other socket contacts. As a result, the boards are electrically connected to each other.
In the case where plural thin conductors are used as plug contacts in a board connector for electrically connecting together boards, an insulation plate which holds the plug contacts at regular intervals is disposed so as prevent the plug contacts from contacting with each other (Japanese Patent No. 2,959,094)
SUMMARY OF THE INVENTION
Problems to be solved by the invention are that, in a board connector, a narrow pitch of contacts of a plug and socket easily causes a trouble such as a contact failure between the contacts of the plug and socket due to dust or the like, and that multiplication of the number of pins by which the number of contacts is increased disables easy insertion and extraction of a plug.
In order to solve the problems, the board connector of the invention comprises: a plug in which one-end sides of plug contacts configured by plural thin conductors are fixed in parallel to a plug body made of an insulating material; a socket in which a plug fitting recess is disposed in a socket body made of an insulating material, socket contacts configured by plural thin conductors are fixed in parallel to the socket body, and movable contact pieces that are disposed in one-end sides of the socket contacts, and that are elastically displaceable are projected in the plug fitting recess; and a cover member which is attached to the plug to cover the plug and the socket that are in a fitting state. Contact portions of the plug and socket in the fitting state are covered by the cover member to cause dust and the like to hardly enter therein, thereby suppressing occurrence of a contact failure between the contacts of the plug and socket because of a narrowed pitch.
In the invention, preferably, the cover member is swingably attached to the plug via a fulcrum shaft.
Preferably, in one of the plug and the cover member, a protrusion which causes an end portion to continuously butt against another one of the plug and the cover member from one end to another end is disposed. According to the configuration, when the plug is inserted, the force of inserting the plug can be evenly transmitted from the cover member to the whole plug. Even when the number of contacts is increased as a result of multiplication of the number of pins, therefore, insertion of the plug can be easily performed.
Preferably, the board connector further comprises engaging means for, when the plug and the socket are fitted to each other, fixing the cover member to the socket.
Preferably, joining portions which, when the plug and the socket are fitted to each other, are joined to each other in a front side with respect to the fulcrum shaft are disposed in the socket and the cover member, and the plug is pulled up by swinging the cover member with setting the joining portion with the socket as a fulcrum. According to the configuration, the plug can be pulled up by a small force with using the cover member as a lever. Even when the number of contacts is increased as a result of multiplication of the number of pins, therefore, extraction of the plug can be easily performed.
Preferably, in addition to the plug, the socket, and the cover member constituting the board connector, the board connector further comprises another plug, another socket, and another cover member constituting another board connector having a same structure as the board connector, other-end sides of the plug contacts are fixed in parallel to a plug body of the other plug, the socket is mounted on a board, the other socket is mounted on another board, and the boards are electrically connected to each other by the board connector and the other board connector.
Preferably, the board connector further comprises an insulating member made of an insulating material, plural thin contact grooves through which plug contacts between the plug and the other plug are to be passed are alternately disposed in one and other faces of the insulating member, and the insulating member is pressingly held in a movable manner by the plug contacts passed through the contact grooves disposed in the one face of the insulating member, and the plug contacts passed through the contact grooves disposed in the other face of the insulating member. According to the configuration, a predetermined gap is ensured between the plug contacts by the insulating member which is not fixed to the plug contacts, so that the plug contacts are prevented from contacting with each other. Therefore, the attachment position and number of the insulating member can be easily changed, and can readily cope with the connecting configuration such as the connecting distance between the boards and the connecting direction thereof.
As described above, according to invention, it is possible to provide a connector in which, even when the pitch of contacts of a plug and socket is narrowed and the number of pins is increased, a contact failure between the contacts of the plug and socket due to dust or the like can be suppressed, and insertion and extraction of the plug can be easily performed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a board connector of an embodiment of the invention;
FIG. 2 is a side view of the board connector;
FIG. 3 is a section view of the board connector taken along the line A—A in FIG. 1 ;
FIG. 4 is a section view of the board connector taken along the line B—B in FIG. 1 ;
FIG. 5(A) is a side view of a plug contact in which a linear portion has a high-level intermediate portion, and FIG. 5(B) is a side view of a plug contact in which a linear portion has a low-level intermediate portion;
FIG. 6(A) is an external view of an inner face side of a cover member, and FIG. 6(B) is an external view of an outer face side of the cover member;
FIG. 7 is a section view of the board connector showing a plug insertion starting state in fitting of a plug and a socket;
FIG. 8 is a section view of the board connector showing a plug insertion intermediate state in fitting of the plug and the socket;
FIG. 9 is a section view of the board connector showing a fitting state of the plug and the socket (plug insertion completed state);
FIG. 10 is a side view of the board connector showing the fitting state of the plug and the socket; and
FIG. 11 is a section view of the board connector showing a state where the plug is pulled up in a plug fitting recess of the socket with using the cover member as a lever in extraction of the plug.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, a board connector of an embodiment of the invention will be described with reference to the accompanying drawings. As shown in FIGS. 1 to 4 , the board connector 1 is used for electrically connecting a board (PCB) 2 A and another board (PCB) 2 B which are juxtaposed, and configured by: a board connector 6 A which is configured by adding a cover member 5 A to a pair of a plug 3 A and a socket 4 A; another board connector 6 B which is configured by adding another cover member 5 B to a pair of a plug 3 B and a socket 4 B; and an insulating member 7 .
In the plug 3 A, plural thin contact grooves 31 are disposed in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction in a plug body 30 which is made of an insulating material (synthetic resin), and which has an approximately rectangular parallelepiped shape that is laterally elongated. One-end sides 11 A of plug contacts 10 which are configured by plural thin plate-like conductors, and which are easily bent or bendable are fitted into the contact grooves 31 from the side of the lower end (insertion side end) of the plug body 30 . The one-end sides 11 A are bent into a substantially U-like shape along the longitudinal direction of the plug contacts. In the plug contacts 10 , outer-side pieces elongating from lower-end bent portions of the one-end sides 11 A are pressingly inserted into and fixed to the respective contact grooves 31 so as to be substantially flush with the rear side face of the plug body 30 , and inner-side pieces elongating from lower-end bent portions of the one-end sides 11 A are fitted into the contact grooves 31 in an elastically deformable manner in the front side of the plug body 30 , so that the one-end sides 11 A of the plug contacts 10 are fixed in an insulated state in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction. On the rear side face of the plug 3 A, therefore, the outer-side pieces elongating from the lower-end bent portions of the one-end sides 11 A are exposed in a substantially flush manner, and, from an upper portion of the front side face of the plug 3 A, the plug contacts 10 are drawn out. In order to attach the cover member 5 A to the plug 3 A, a horizontal laterally-directed fulcrum shaft 32 which is perpendicularly projected from upper portions of the right and left side faces of the plug body 30 is integrally disposed.
In the socket 4 A, a plug fitting recess 41 into which the plug 3 A is inserted from the upper face side and fitted is disposed in a front portion of a socket body 40 which is made of an insulating material (synthetic resin), and which has an approximately rectangular parallelepiped shape that is laterally elongated. Plural thin contact grooves 42 in which the lower ends are opened in the bottom face of the socket body 40 , and which communicate with the plug fitting recess 41 with breaking a partition wall with respect to the plug fitting recess 41 are disposed in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction in a rear portion of the socket body 40 . Plural legged socket contacts 20 which are configured by plural thin plate-like conductors, and which are bent into a substantially inverted U-like shape along the longitudinal direction are fitted into the contact grooves 42 from the bottom face side of the socket body 40 . In the socket contacts 20 , rear side pieces elongating from upper-end bent portions are pressingly inserted into and fixed to the respective contact grooves 42 so as to elongate along the rear wall faces of the contact grooves 42 , and front side pieces elongating from the upper-bent portions, i.e., movable contact pieces 21 which are disposed in one-end sides of the socket contacts 20 , and which are elastically displaceable are fitted into the contact grooves 42 in an elastically deformable manner. Tip end portions (free-end portions) of the movable contact pieces 21 are projected in the plug fitting recess 41 . In a state where leg portions which are horizontally rearward extended from lower ends of the rear side pieces with respect to the upper-end bent portions of the socket contacts 20 , i.e., soldering portions 22 which are disposed in the other-end sides of the socket contacts 20 are projected in the rear outer side of the socket body 40 so as to be substantially flush with the bottom face of the socket body 40 , the socket contacts 20 are fixed in an insulated state in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction. Thin groove holes 43 are disposed in a front portion of the socket body 40 and in right and left outer sides of the plug fitting recess 41 . One piece of a reinforcing terminal 44 which is an L-like metal part is pressingly inserted into and fixed to each of the groove holes 43 from the side of the bottom face of the socket body 40 , and the other piece of the reinforcing terminal 44 , i.e., a soldering portion (leg portion) is projected to each of the right and left outer sides of the socket body 40 so as to be substantially flush with the bottom face of the socket body 40 . Therefore, a plug insertion port (the open end of the plug fitting recess 41 ) is opened in a front portion of the upper face of the socket 4 A, and the soldering portions 22 of the socket contacts 20 and the soldering portions of the reinforcing terminals 44 are exposed on the bottom face of the socket 4 A so as to be substantially flush with each other. The soldering portions 22 of the socket contacts 20 are projected to the rear outer side of the socket 4 A, and the soldering portions of the reinforcing terminals 44 are projected to the right and left outer sides of the socket 4 A. In order to fix the cover member 5 A when the plug 3 A and the socket 4 A are fitted to each other, engagement claws 45 are integrally disposed in right and left or two places of the rear side face of the socket body 40 .
The socket 4 A is surface-mounted on the board 2 A, whereby the soldering portions 22 of the socket contacts 20 and the soldering portions of the reinforcing terminals 44 are fixed by soldering to the board 2 A, and the socket contacts 20 are electrically connected to the board 2 A. In the socket 4 A, positioning protrusions 47 are integrally disposed in two places of the bottom face of the socket body 40 in order to fit the socket to positioning holes 60 disposed in the board 2 A and position the socket with respect to the board 2 A.
The cover member 5 A is a molded piece made of an insulating material (synthetic resin), and covers the plug 3 A and the socket 4 A in the fitting state from the upper and rear sides. As shown in FIG. 6 also, in the cover member 5 A, the following components are integrally disposed: a rectangular plate-like cover top plate portion 50 which covers the plug 3 A and the socket 4 A in the fitting state from the upper side; a rectangular plate-like cover rear side plate portion 51 which is perpendicularly continuous to the rear edge of the cover top plate portion 50 , which covers the plug 3 A and the socket 4 A in the fitting state from the rear side, and which covers the soldering portions 22 of the socket contacts 20 from the upper side; and cover right and left side plate portions 52 which are perpendicularly bent so as to extend along the right and left side edges of the cover top plate portion 50 and those of the cover rear side plate portion 51 , which are projected from a front portion of the upper side face of the socket 4 A into which the plug 3 A is fitted, and which laterally integrally cover rear portions of the right and left side faces of the socket 4 A from upper portions of the right and left side faces of the plug 3 A. In the cover member 5 A, front portions of the right and left side plate portions 52 are pivotally supported via mounting holes 53 by the fulcrum shaft 32 which is disposed on the plug 3 A. The cover member 5 A is swingably attached to the plug 3 A via the fulcrum shaft 32 . The plug 3 A is set by the cover member 5 A to a state where the upper, rear, and right and left sides are covered, and the front side in the direction of drawing out the plug contacts 10 , and the lower side in the direction of inserting the contacts into the socket 4 A are opened. In the cover member 5 A, a protrusion 54 in which the tip end continuously butts against the upper end face of the plug 3 A in a range from the left end to the right end at a swing position where the cover top plate portion 50 is perpendicular to the plug 3 A is integrally disposed on the inner face of the cover top plate portion 50 , and engagement claws 55 which, when the plug 3 A and the socket 4 A are fitted to each other, are engaged in the plug extraction direction with the engagement claws 45 disposed on the socket body 40 to fix the cover member 5 A to the socket 4 A are integrally disposed in right and left or two places of the inner face of the cover rear side plate portion 51 . Furthermore, joining portions 46 , 56 which, when the plug 3 A and the socket 4 A are fitted to each other, are joined to each other in a front side with respect to the fulcrum shaft 32 are disposed in the socket 4 A and the cover member 5 A. When the plug 3 A and the socket 4 A are fitted to each other, front-end portions of the lower end faces of the cover right and left side plate portions 52 are joined to right and left end portions of the upper end face of the front sidewall of the socket body 40 . The right and left end portions of the upper end face of the front sidewall of the socket body 40 are set as the joining portions 46 on the side of the socket 4 A, and the front end portions of the lower end faces of the cover right and left side plate portions 52 are set as the joining portions 56 on the side of the cover member 5 A.
In the cover member 5 A, U-like cutaways 57 which are upward opened are formed in right and left or two places of an upper portion of the cover rear side plate portion 51 , right and left side portions of the cutaways 57 are elongated from a rear portion of the cover top plate portion 50 , and movable plate portions 58 which are surrounded by the cutaways 57 , which are configured by parts of the cover rear side plate portion 51 and a part of the cover top plate portion 50 , and which are perpendicularly bent are integrally disposed. In the movable plate portions 58 , operation levers 59 which are projected from and flushly with parts of the cover top plate portion 50 more rearward than parts of the cover rear side plate portion 51 are integrally disposed, and the engagement claws 55 on the side of the cover member 5 A are integrally disposed on the inner faces of lower end portions of parts of the cover rear side plate portion 51 which are free-end portions of the movable plate portions 58 . In order to facilitate elastic deformation, parts of the cover rear side plate portion 51 in the movable plate portions 58 are thinned.
As described above, the board connector 6 A is configured as a board connector with a dust-proof cover in which the cover member 5 A is added to the pair of the plug 3 A and the socket 4 A.
Next, the other pair of plug 3 B and socket 4 B of the other board connector 6 B, and the cover member 5 B to be added to the plug and the socket have the same structure as the pair of plug 3 A and socket 4 A of the board connector 6 A and the cover member 5 A to be added to the plug and the socket, and the other board connector 6 B is configured as the same board connector with a dust-proof cover as the board connector 6 A. Therefore, the identical components are denoted by the same reference numerals, and there detailed description is omitted. As shown in FIG. 3 , however, the other plug 3 B of the other board connector 6 B is configured so that other one-end sides 11 B which are bent into a substantially U-like shape along the longitudinal direction of the plug contacts 10 are fixed to the plug body 30 in an insulated state in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction. Furthermore, the other socket 4 B of the other board connector 6 B is surface-mounted on the other board 2 B, whereby the soldering portions 22 of the socket contacts 20 and the soldering portions of the reinforcing terminals 44 are fixed by soldering to the board 2 B, and the socket contacts 20 are electrically connected to the board 2 B.
Next, a plug insertion method in which, in order to fit the plug 3 A and socket 4 A of the board connector 6 A to each other, the plug 3 A is inserted into the plug fitting recess 41 of the socket 4 A will be described with reference to FIGS. 7 to 10 .
As shown in FIG. 7 , first, the cover member 5 A which is swingably attached via the fulcrum shaft 32 to the plug 3 A is swung about the fulcrum shaft 32 , and held to a swing position where the cover top plate portion 50 is perpendicular to the plug 3 A and the tip end of the protrusion 54 butts against the upper end face of the plug 3 A. By butting (surface contact) between the tip end of the protrusion 54 and the upper end face of the plug 3 A, the plug 3 A is held to a posture perpendicular to the cover top plate portion 50 . In this state, the cover member 5 A is positioned directly above the socket 4 A mounted on the board 2 A, and the cover member 5 A is lowered to approach the board 2 A, whereby the rear lower end side of the cover member 5 A is fitted from the upper side into the tall rear outer side of the socket 4 A. As result of this fitting, the cover member 5 A and the plug 3 A are positioned with respect to the socket 4 A, and the plug 3 A is positioned directly above the plug fitting recess 41 of the socket 4 A. In this state, the cover member 5 A is further lowered to approach the board 2 A, whereby, while the rear portion of the cover member 5 A is further fitted into the rear outer side of the socket 4 A, the lower end portion of the plug 3 A is fitted into the plug insertion port opened in the low-height front upper face side of the socket 4 A (start of plug insertion). In this state, the cover member 5 A is further lowered to approach the board 2 A, whereby, while the rear portion of the cover member 5 A is further fitted into the rear outer side of the socket 4 A as shown in FIG. 8 , the plug 3 A is inserted into the plug fitting recess 41 of the socket 4 A until the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 hit the tip end portions of the movable contact pieces 21 of the socket contacts 20 which are projected in the plug fitting recess 41 of the socket 4 A. In the subsequent insertion, the movable contact pieces 21 of the socket contacts 20 produce an insertion resistance against the plug 3 A. When the cover member 5 A is pressed down to cause the protrusion 54 of the cover top plate portion 50 to press down the plug 3 A, therefore, the rear portion of the cover member 5 A presses the movable contact pieces 21 of the socket contacts 20 to cause the contacts to be elastically deformed, while the rear portion of the cover member 5 A is further fitted into the rear outer side of the socket 4 A, and the tip end portions of the movable contact pieces 21 are pressed back from the plug fitting recess 41 into the contact grooves 42 . When the plug 3 A passes beyond the tip end portions of the movable contact pieces 21 to be further inserted into the plug fitting recess 41 of the socket 4 A, the tip end portions of the movable contact pieces 21 of the socket contacts 20 are pressed against and contacted with the outer-side pieces elongating from the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 which are exposed on the rear side face of the plug 3 A so as to be substantially flush with each other. In this state, the cover member 5 A is further pressed down, and the plug 3 A is pressed down by the protrusion 54 of the cover top plate portion 50 . As a result, as shown in FIGS. 9 and 10 , while the rear portion of the cover member 5 A is further fitted into the rear outer side of the socket 4 A, the plug 3 A is completely inserted into the plug fitting recess 41 of the socket 4 A until the lower end of the plug 3 A bumps against the bottom face of the plug fitting recess 41 of the socket 4 A, whereby the plug 3 A and the socket 4 A are fitted together (completion of the plug insertion).
During fitting of the plug 3 A and the socket 4 A (when the plug 3 A and the socket 4 A are to be fitted to each other), the plug 3 A is hidden by the cover member 5 A. Since the positioning of the plug 3 A with respect to the socket 4 A can be performed by the cover member 5 A, however, it is not difficult to insert the plug 3 A.
As the number of contacts of the plug contacts 10 and socket contacts 20 is more increased because of multiplication of the number of pins of the board connector 6 A, the insertion resistance on the plug 3 A in fitting of the plug 3 A and the socket 4 A becomes higher. The protrusion 54 disposed on the cover top plate portion 50 of the cover member 5 A continuously butts against the upper end face of the plug 3 A in the range from the left end to the right end to press the plug 3 A in the insertion direction, and hence the force of inserting the plug can be evenly transmitted by the cover member 5 A to the whole plug 3 A. Even when the number of contacts is increased as a result of multiplication of the number of pins, therefore, insertion of the plug 3 A can be easily performed. In the embodiment, the protrusion 54 is disposed on the side of the cover member 5 A. Alternatively, the protrusion may be disposed on the side of the plug 3 A.
As shown in FIGS. 1 to 3 , 9 , and 10 , from the timing just before the fitting of the plug 3 A and the socket 4 A, the engagement claws 55 disposed on the movable plate portions 58 of the cover member 5 A ride on the engagement claws 45 disposed on the socket 4 A while producing elastic deformation of the movable plate portions 58 , the engagement claws 55 disposed on the movable plate portions 58 of the cover member 5 A pass beyond the engagement claws 45 disposed on the socket 4 A to enter below the claws when the plug 3 A and the socket 4 A are fitted together, and at the same time the engagement claws 55 disposed on the movable plate portions 58 of the cover member 5 A are engaged with the engagement claws 45 disposed on the socket 4 A in the plug extraction direction by an elastic return of the movable plate portions 58 . Therefore, the cover member 5 A is fixed (locked) to the socket 4 A, the plug 3 A is fixed (locked) to the socket 4 A by the fixed cover member 5 A, and the fitting states of the plug 3 A and the socket 4 A, and the cover member 5 A and the socket 4 A are held. As a result, in the plug fitting recess 41 of the socket 4 A, the contact between the outer-side pieces elongating from the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 , and the tip end portions of the movable contact pieces 21 of the socket contacts 20 is held, and the one-end sides 11 A of the plug contacts 10 are electrically connected to the board 2 A.
When the plug 3 A and the socket 4 A are fitted together, the plug 3 A and the socket 4 A in the fitting state are covered from the upper and rear sides by the cover member 5 A fixed to the socket 4 A, and contact portions of the plug 3 A and socket 4 A in the fitting state, i.e., the plug fitting recess 41 of the socket 4 A is covered to cause dust and the like to hardly enter the plug fitting recess 41 . Therefore, occurrence of a contact failure between the contacts 10 , 20 of the plug 3 A and socket 4 A because of a narrowed pitch of the contacts 10 , 20 can be suppressed. Furthermore, the soldering portions 22 of the socket contacts 20 are covered from the upper side by the cover member 5 A, so that dust and the like hardly fall and deposit on the surfaces of the soldering portions 22 and gaps therebetween. Therefore, an insulation failure in the soldering portions 22 of the socket contacts 20 because of a narrowed pitch of the contacts 10 , 20 of the plug 3 A and socket 4 A can be suppressed.
When the plug 3 A and the socket 4 A are fitted together, the joining portions 46 on the side of the socket 4 A, and joining portions 56 on the side of the cover member 5 A which are disposed in the front side with respect to the fulcrum shaft 32 are joined to each other. Namely, the right and left end portions of the upper end face of the front sidewall of the socket body 40 are joined to the front-end portions of the lower end faces of the cover right and left side plate portions 52 .
A plug insertion method in which, in order to fit the plug 3 B and socket 4 B of the other board connector 6 B to each other, the plug 3 B is inserted into the plug fitting recess 41 of the socket 4 B, and a fitting state of the plug 3 B and the socket 4 B are identical with the plug insertion method of the board connector 6 A and the fitting state of the plug 3 A and the socket 4 A shown in FIGS. 7 to 10 . Therefore, their detailed description and corresponding drawings are omitted.
As shown in FIGS. 1 to 3 , in the board connector 6 A, the plug 3 A is inserted and fitted into the plug fitting recess 41 of the socket 4 A, and, in the plug fitting recess 41 of the socket 4 A, and the outer-side pieces elongating from the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 , and the tip end portions of the movable contact pieces 21 of the socket contacts 20 are contacted and held to each other, thereby electrically connecting the one-end sides 11 A of the plug contacts 10 to the board 2 A. By contrast, in the other board connector 6 B, the other plug 3 B is inserted and fitted into the plug fitting recess 41 of the other socket 4 B, and, in the plug fitting recess 41 of the socket 4 B, and the outer-side pieces elongating from the lower-end bent portions of the other-end sides 11 B of the plug contacts 10 , and the tip end portions of the movable contact pieces 21 of the socket contacts 20 are contacted and held to each other, thereby electrically connecting the other-end sides 11 B of the plug contacts 10 to the board 2 B. Therefore, the board 2 A and the other board 2 B can be electrically connected together via the plug contacts 10 , the socket contacts 20 of the socket 4 A, and the socket contacts 20 of the other socket 4 B.
Next, a plug extraction method in which, in order to separate from each other the plug 3 A and socket 4 A of the board connector 6 A in the fitting state shown in FIGS. 1 to 3 , 9 , and 10 , the plug 3 A is extracted from the plug fitting recess 41 of the socket 4 A will be described with reference to FIG. 11 .
First, in the board connector 6 A in the fitting state shown in FIGS. 1 to 3 , 9 , and 10 , an operation of lifting up a rear portion of the cover member 5 A is performed by engaging the fingers with the operation levers 59 disposed on the movable plate portions 58 of the cover member 5 A. When the rear portion of the cover member 5 A is lifted up in this way, the engagement claws 55 disposed on the movable plate portions 58 of the cover member 5 A separate from the rear side face of the socket body 40 while producing elastic deformation of the movable plate portions 58 , and the engagement with the engagement claws 45 disposed on the socket 4 A is canceled. In this state, as shown in FIG. 11 , the cover member 5 A is swung with setting as a lever fulcrum the joining portions 46 , 56 joined to each other in the front side with respect to the fulcrum shaft 32 by which the cover member 5 A is swingably attached to the plug 3 A. In accordance with the swinging operation of the cover member 5 A, the plug 3 A is pulled up in the plug fitting recess 41 of the socket 4 A via the fulcrum shaft 32 (with setting the fulcrum shaft 32 as a point of action). Namely, the plug 3 A can be pulled up in the plug fitting recess 41 of the socket 4 A with using the cover member 5 A as a lever. By the operation of pulling up the plug 3 A, the plug 3 A is pulled up in the plug fitting recess 41 of the socket 4 A by the degree at which the lower end portion of the plug 3 A is lifted up to the vicinity of the tip end portions of the movable contact pieces 21 of the socket contacts 20 . Then, the cover member 5 A is lifted up substantially directly above the socket 4 A, whereby the plug 3 A is extracted away from the plug fitting recess 41 of the socket 4 A.
In the process of pulling up the plug 3 A in the plug fitting recess 41 of the socket 4 A, in an initial stage of the extraction in which the tip end portions of the movable contact pieces 21 of the socket contacts 20 are in contact with the outer-side pieces elongating from the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 , the contact pressure functions as a large pulling resistance on the plug 3 A. When the lower end portion of the plug 3 A is lifted up to the vicinity of the tip end portions of the movable contact pieces 21 of the socket contacts 20 , the tip end portions of the movable contact pieces 21 of the socket contacts 20 are contacted with the lower-end bent portions of the one-end sides 11 A of the plug contacts 10 . At this timing, the contact pressure (the pulling resistance on the plug 3 A) is reduced. As the contact pressure is further reduced when the lower end portion of the plug 3 A passes beyond the tip end portions of the movable contact pieces 21 of the socket contacts 20 and the one-end sides 11 A of the plug contacts 10 separate from the tip end portions of the movable contact pieces 21 of the socket contacts 20 , the pulling resistance on the plug 3 A is further substantially eliminated. When, as described above, the plug 3 A is pulled up with using the cover member 5 A as a lever in the plug fitting recess 41 of the socket 4 A by the degree at which the lower end portion of the plug 3 A is lifted up to the vicinity of the tip end portions of the movable contact pieces 21 of the socket contacts 20 , the pulling and extraction of the plug 3 A in the plug fitting recess 41 of the socket 4 A can be easily performed with applying a small force.
As the number of contacts of the plug contacts 10 and socket contacts 20 is increased as a result of multiplication of the number of pins of the board connector 6 A, the pulling resistance on the plug 3 A is larger in extraction of the plug 3 A fitted to the socket 4 A. Since the plug 3 A can be pulled up by a small force with using the cover member 5 A as a lever in the plug fitting recess 41 of the socket 4 A, however, extraction of the plug 3 A can be easily performed even when the number of contacts is increased as a result of multiplication of the number of pins.
A plug extraction method in which, in order to separate the plug 3 B and socket 4 B of the other board connector 6 B in the fitting state shown in FIGS. 1 to 3 from each other, the plug 3 B is extracted from the plug fitting recess 41 of the socket 4 B is identical with the plug extraction method of the board connector 6 A shown in FIG. 11 . Therefore, its detailed description and corresponding drawings are omitted.
The socket contacts 20 which are configured by plural thin plate-like conductors are formed in parallel into a state where end portions of the soldering portions 22 are continuous to a carrier (not shown) with forming predetermined intervals at predetermined pitches therebetween, by punching and bending a thin conductive metal plate. In this state, the socket contacts 20 are fitted into the contact grooves 42 of the socket body 40 , and fixed to the socket body 40 in parallel in an insulated state with forming predetermined intervals (regular intervals) in the right and left or lateral direction, and then the carrier is separated from the socket contacts 20 , thereby configuring the sockets 4 A, 4 B. The plug contacts 10 which are configured by plural thin plate-like conductors, and which are easily bent or bendable are formed in parallel into a state where end portions of the one-end sides 11 A are continuous to a carrier (not shown), and end portions of the other-end sides 11 B are continuous to another carrier (not shown), by punching and bending a thin conductive metal plate with disposing predetermined intervals at predetermined pitches between the carrier and the other carrier. In this state, the one-end sides 11 A of the plug contacts 10 are fitted into the contact grooves 31 of the plug body 30 , the one-end sides 11 A of the plug contacts 10 are fixed to the plug body 30 in an insulated state in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction, and then the carrier is separated from the one-end sides 11 A of the plug contacts 10 , thereby configuring the plug 3 A. By contrast, the other-end sides 11 B of the plug contacts 10 are fitted into the contact grooves 31 of the plug body 30 , the other-end sides 11 B of the plug contacts 10 are fixed to the plug body 30 in an insulated state in parallel at predetermined intervals (regular intervals) in the right and left or lateral direction, and then the carrier is separated from the other-end sides 11 B of the plug contacts 10 , thereby configuring the other plug 3 B.
As shown in FIGS. 1 to 3 , and 5 , in the plug contacts 10 through which the plug 3 A is linked with the other plug 3 B, intermediate portions 12 , 13 (between the one-end sides 11 A and the other-end sides 11 B) between the plug 3 A and the other plug 3 B are formed into a linear shape so as to elongate in parallel to the boards 2 A, 2 B, except their both end portions. The both end portions are formed into an inclined state which is upward inclined toward the respective end portions. The lengths of the linear portions of the intermediate portions 12 , 13 are set on the basis of the distance between the board 2 A and other board 2 B which are placed in parallel to each other, i.e., the connecting distance. One-end side inclined upper ends of the intermediate portions 12 , 13 , and upper end portions of the inner-side pieces elongating from the lower-end bent portions of the one-end sides 11 A are continuously integrally linked with each other, and other-end side inclined upper ends of the intermediate portions 12 , 13 , and upper end portions of the inner-side pieces elongating from the lower-end bent portions of the other-end sides 11 B are continuously integrally linked with each other. The plug contacts 10 are formed so as to be symmetrical about a point where the length of the linear portion of the intermediate portion 12 or 13 is bisected.
As shown in FIGS. 2 , 3 , and 7 to 10 , the inclined portions of the both end portions of the intermediate portions 12 , 13 of the plug contacts 10 are drawn out obliquely downward from the front side faces of the plugs 3 A, 3 B. As shown in FIG. 11 , therefore, the front portions of the cover members 5 A, 5 B which are lowered by the swing of the cover members 5 A, 5 B in pulling of the plugs 3 A, 3 B in the plug fitting recesses 41 of the sockets 4 A, 4 B with setting the cover members 5 A, 5 B as a fulcrum do not interfere with the plug contacts 10 drawn out from the front side faces of the plugs 3 A, 3 B, and hence it is possible to prevent the plug contacts 10 from being bent and damaged.
As shown in FIGS. 1 to 5 , the plug contacts 10 are formed into two kinds in which only the level positions of the linear portions are differentiated by changing the lengths of the inclined portions of the both end portions in the intermediate portions 12 , 13 . The plug contacts 10 having the intermediate portion 12 in which the level of the linear portion is high, those having the intermediate portion 13 in which the level of the linear portion is low are alternately arranged. Therefore, the linear portions of the intermediate portions 12 , 13 of the plug contacts 10 are positionally shifted from each other in the thickness direction (the vertical direction) of the contacts, so that predetermined gaps 14 in a side view are ensured in the linear portions of the intermediate portions 12 , 13 of the plug contacts 10 . The both ends of the gaps 14 are closed by the inclined portions of the both end portions of the intermediate portions 13 in which the level of the linear portion is low.
As shown in FIGS. 1 to 4 , an insulating member 7 is disposed in the intermediate portions 12 , 13 of the plug contacts 10 between the plug 3 A and the other plug 3 B. A predetermined gap is ensured between the adjacent plug contacts 10 by the insulating member 7 , so that the plug contacts are prevented from contacting with each other. The insulating member 7 is made of an insulating material (synthetic resin), and has an approximately rectangular parallelepiped shape that is laterally elongated. Plural thin contact grooves 70 through which the intermediate portions 12 , 13 of the plug contacts 10 are to be passed at a predetermined pitch with forming predetermined intervals are alternately distributively disposed in the upper and lower faces of the insulating member 7 . The linear portions of the intermediate portions 12 of the plug contacts 10 having the intermediate portion 12 in which the level of the linear portion is high are fitted from the upper face side into and passed in the anteroposterior direction through the contact grooves 70 disposed in the upper face of the insulating member 7 , and those of the intermediate portions 13 of the plug contacts 10 having the intermediate portion 13 in which the level of the linear portion is low are fitted from the lower face side into and passed in the anteroposterior direction through the contact grooves 70 disposed in the lower face of the insulating member 7 . A plate-like core part 71 that is the insulating member 7 the thickness of which is reduced by the contact grooves 70 is interposed in the thickness direction (the vertical direction) of the core part between the linear portions of the intermediate portions 12 of the plug contacts 10 having the intermediate portion 12 in which the level of the linear portion is high, and those of the intermediate portions 13 of the plug contacts 10 having the intermediate portion 13 in which the level of the linear portion is low, and the insulating member 7 is interposed between the intermediate portions 12 , 13 of the plug contacts 10 so as to be movable in the contact length direction, whereby a predetermined gap is ensured between the adjacent plug contacts 10 by partition walls 72 which are the insulating member 7 between the contact grooves 70 , so that the plug contacts are prevented from contacting with each other.
The adjacent plug contacts 10 are prevented: from contacting with each other by the insulating member 7 which is simply interposed between the intermediate portions 12 , 13 of the plug contacts 10 so as to be movable in the contact length direction, and which is not fixed. Therefore, the attachment position and number of the insulating member 7 can be easily changed, and can readily cope with the connecting configuration such as the connecting distance between the boards 2 A, 2 B and the connecting direction thereof. The predetermined gaps 14 in a side view are ensured from the beginning between the linear portions of the intermediate portions 12 of the plug contacts 10 which are passed through the contact grooves 70 disposed in the upper face of the insulating member 7 , and those of the intermediate portions 13 of the plug contacts 10 which are passed through the contact grooves 70 disposed in the lower face of the insulating member 7 . Therefore, interposing of the insulating member 7 can be easily performed. When the attachment position or number of the insulating member 7 is changed, furthermore, a deforming force is not applied to the plug contacts 10 , and hence plastic deformation can be prevented from occurring.
In the embodiment, the board connector 1 used for electrically connecting the board 2 A and other board 2 B which are placed in parallel has been described. Alternatively, the plug contacts 10 may be bent in the linear portions of the intermediate portions 12 , 13 , thereby enabling also stepped or angled boards to be connected to each other. The sockets 4 A, 4 B of the surface-mount type have been described. Alternatively, sockets of the pin-mount type may be used.
|
The present invention relates to a board connector for electrically connecting together circuit boards which are incorporated in, for example, a mobile telephone. A dust-proof measure is carried out by swingably attaching a cover member to a plug via a fulcrum shaft, and covering contact portions of the plug and socket in a fitting state with the cover member. In one of the plug and the cover member, a protrusion which causes an end portion to continuously butt against another one of the plug and the cover member from one end to another end is disposed, whereby, when the plug is inserted, the force of inserting the plug is evenly transmitted from the cover member to the whole plug. Joining portions which, when the plug and the socket are fitted to each other, are joined to each other in a front side with respect to the fulcrum shaft are disposed in the socket and the cover member. The plug is pulled up with using the cover member as a lever by swinging the cover member with setting the joining portions as a lever fulcrum.
| 7
|
PRIORITY CLAIM
[0001] This application claims priority from Indian patent application No. 2440/Del/2004, filed Dec. 6, 2004, which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to a supply-voltage identifier circuit.
BACKGROUND
[0003] Conventional integrated circuits operate on dual voltages, the lower voltage being in the core side in the range 1.8 v, 1.2 v or 1.0 v. External voltages are available in ranges of 5 v, 3.3 v, 2.5 v, 1.8 v, 1.2 v. An existing method for supplying different ranges of external supply voltages for a single IC is to turn on a step down regulator (switching or linear) to supply the low voltage core logic of the IC if the external voltage is higher than required by the core. A switch can be turned on to supply the core if the external supply is in the same range as the required core supply. If the external supply is less than the required internal core supply, a boost-switching regulator can be turned on. All these options can be exercised by options set on the application board for a dedicated external supply.
[0004] Patent number FR2838840, which is incorporated by reference, suggests using a comparator for comparing the supply with a reference and take decision accordingly. The comparator is kept on all the time, but the operator IC generates lots of noise and may cause erroneous switching of the comparator and may cause lots of noise on the internal supply line, especially, when two ranges of the supply are so that the lower limit of the higher supply range is relatively close to the higher limit of the lower supply range.
[0005] Furthermore, during the power up phase, when the decision-making circuit is not fully activated, then an erroneous supply-management decision, however momentary, may expose low-voltage components to a high voltage.
SUMMARY
[0006] A need has arisen for a circuit that identifies the external supply range automatically and registers a value only once at the power up corresponding to the identified external supply voltage rather than catering to variable supply voltage as in the case of battery voltage dropping from one range to the other.
[0007] An embodiment of the present invention provides accurate supply-voltage-range identification.
[0008] Another embodiment of the present invention registers the status of the external supply voltage and makes the decision immune to any switching noise generated from the logic circuit during normal operation of the integrated circuit.
[0009] Another embodiment of the present invention avoids erroneous supply management decisions during a power-up phase.
[0010] Another embodiment of the present invention minimizes power consumption.
[0011] An embodiment of the present invention provides a supply voltage identifier comprising:
supply voltage sensing means incorporating enable/disable input and receiving supply voltage, a reference generator incorporating enable/disable input for generating reference voltage, a comparison means having first input connected to the output of said sensing means, a second input connected to said reference generator and a third input for enabling/disabling its operation, a registering means connected to the output of said comparison means at its first input for storing the comparison output, a selecting means having a first input connected to the supply voltage, a second input connected to the output of a voltage regulating means, a third input for enabling/disabling and a selection input connected to the output of said registering means, a control means having a first output coupled to the enable/disable input of each of said supply voltage sensing means, reference generator, comparison means, a second output connected to said third input of said selecting means and a third output coupled to the store input of said registering means; the arrangement being such that said selecting means is disabled by said control means on receipt of a control signal at the input of said control means, said supply voltage sensing means, reference generator, comparison means are enabled for a predefined period, after which the output of each comparison means is stored in each corresponding registering means, and finally the selection means are enabled, and said supply voltage sensing means, reference generator, comparison means are disabled.
[0019] In one embodiment, the said supply voltage sensing means is a voltage divider circuit.
[0020] In one embodiment, the said comparison means is an offset compensated comparator.
[0021] In one embodiment, the said registering means comprising latches.
[0022] In one embodiment, the said control means comprises an oscillator connected at the clock input of a finite state machine.
[0023] In one embodiment, the said control means comprises an additional control input for disabling itself after disabling said supply voltage sensing means, comparison means, and reference generator.
[0024] An embodiment of the present invention also provides a method for supply-voltage identification comprising steps of:
disabling the output of the supply voltage identifier, sensing the supply voltage, comparing the sensed supply voltage with one or more reference voltages, after supply voltage and reference voltages settle, storing the results of the comparisons, enabling the selection of either the input supply voltage or a regulated voltage output based on the stored results, and disabling sensing and comparison of the supply voltage and the oscillator.
[0031] Another embodiment of the invention is a supply voltage identifier comprising:
one or more sets of:
supply voltage sensing means incorporating enable/disable input and receiving supply voltage, a reference generator incorporating enable/disable input for generating reference voltage, a comparison means having first input connected to the output of said sensing means, a second input connected to said reference generator and a third input for enabling/disabling its operation, a registering means connected to the output of said comparison means at its first input for storing the comparison output, a selecting means having a first input connected to the supply voltage, a second input connected to the output of a voltage regulating means, a third input for enabling/disabling and a selection input connected to the output of said registering means,
a control means having a first output coupled to the enable/disable input of each of said supply voltage sensing means, reference generator, comparison means, a second output connected to said third input of said selecting means and a third output coupled to the store input of said registering means; the arrangement being such that said selecting means is disabled by said control means on receipt of a control signal at the input of said control means, said supply voltage sensing means, reference generator, comparison means are enabled for a predefined period, after which the output of each comparison means is stored in each corresponding registering means, and finally the selection means are enabled, and said supply voltage sensing means, reference generator, comparison means are disabled.
[0040] Thus, an embodiment of the present invention provides a supply-voltage identifier, which measures the external supply voltage at power on or at chip enable, only once and registers the value for a proper supply-management decision for the remaining time of the operation and switches itself off so that it is immune to switching noise of the IC in normal operation, and to reduce power consumption. It also avoids any erroneous decision, even momentary, during power up, by keeping the decisions in an inactive state until power-on events settle, and then making the decision for supplying the required voltage to the core of the integrated circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a block diagram of the supply-voltage management to supply an internal core of an IC according to an embodiment of the invention.
[0042] FIG. 1A is a block diagram of a supply identifier in accordance with another embodiment of the instant invention.
[0043] FIG. 2 is a detailed circuit diagram of a supply identifier in accordance with an embodiment of the invention.
[0044] FIG. 3 illustrates the control signals of a supply identifier according to an embodiment of the instant invention.
[0045] FIG. 4 illustrates multiple-range supply identification in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0046] The supply identifier ( 100 ), as shown in FIG. 1 according to an embodiment of the invention, is used to determine at power up or at chip enable CE ( 101 ), whether external voltage Vext ( 102 ) is greater than a predetermined threshold, in which case the regulator ( 103 ) is turned on to supply internal voltage Vint ( 104 ). If Vext is less than the predetermined threshold, which means that the external voltage is in the same range as the internal voltage, then switch ( 105 ), is turned on to connect Vext to Vint. This concept can be extended to multiple regulators, step down or step up, as well as to switches that cater to multiple ranges of the external supply voltage, i.e., greater than Vint, equal to Vint as well as less than Vint.
[0047] FIG. 1A shows a block diagram representation of the supply identifier 100 of FIG. 1 according to an embodiment of the invention, wherein sensing means ( 106 ) are used to generate a fraction of the external supply voltage. The comparison means ( 108 ) are used to compare the fraction of the external supply voltage generated by the sensing means ( 106 ) and the reference voltage generated from the reference generator ( 107 ). The control means ( 109 ) is used to generate the enable and disable signals for the sensing means 106 , reference generator 107 , and comparison means 108 , wherein the sensing means, reference generator and comparison means are disabled after the supply voltage is compared and stored in registering means ( 110 ). The stored output is used to provide the final output through the selection means ( 111 ), which is disabled at the commencement of the supply-voltage identification, and is enabled after the comparison output is generated. In accordance with the comparison output, the selection means ( 111 ) selects the regulated output ( 112 ) or the supply voltage for generating the final output voltage at O/P.
[0048] FIG. 2 shows the detailed circuit of the supply identifier 100 of FIGS. 1 and 2 according to an embodiment of the invention. The identifier 100 makes a decision at the beginning of the operation, registers the decision, and turns itself off for supplying the identified external supply voltage to the core of the integrated circuit. The supply identifier 100 includes a switched capacitor comparator ( 200 ), for offset-cancelled precise comparison between reference voltage ( 201 ), and a fraction of the external voltage (Vext)=k*Vext 202 , wherein k*Vext is derived through a resistor-divider network ( 203 ).
[0049] At power up, the Power On Reset (POR 204 ) generates a power-on-reset signal with a threshold lower than the minimum allowed supply, provided CE ( 205 )=1 (or tied to the Vext). The POR can be kept independent of the CE control, but power consumption would occur when CE=0. POR output is combined with chip enable CE in the combinational circuit ( 206 ) for generating a reset signal nrst ( 207 ). nrst resets the decision registers for Switch enable (SwtEn 208 ), and regulator enable (RegEn 209 ), to their respective inactive states for avoiding any erroneous decision until the external supply Vref ( 201 ) and the comparator ( 200 ) settle to their respective operational levels. Further, the reset signal nrst also resets the finite state machine (FSM 210 ). There is a crude oscillator ( 211 ), which generates the clock for the FSM. The FSM in turn generates the control signals for the comparator ( 200 ) and the registers ( 208 , 209 ). The control signals include φ 1 212 and φ 2 213 , for the switched-capacitor comparator 200 . The FSM also generates ( 214 ) for the registers ( 208 ) and ( 209 ), and finally a stop signal ( 215 ) for the circuit to switch itself off after the decision has been made. The CE and stop signal are combined in logic ( 216 ) to generate a power down (PD 217 ) signal for disabling the supply-voltage identifier 100 .
[0050] When CE=0 even after the power up, the circuit is switched off by PD generated through logic ( 216 ); the FSM ( 210 ) and the registers 208 & 209 are reset by nrst generated by the logic ( 206 ). The reset states of SwtEn and RegEn make sure that neither the regulator ( 103 ) nor the switch ( 105 ) ( FIG. 1 ) is activated, and Vint ( 104 ) is cut off, i.e., is floating. The PD signal 217 ensures minimum power consumption. When CE goes high, the circuit becomes active, turns on the reference ( 201 ), comparator ( 200 ), oscillator ( 211 ) and the resistor divider network ( 203 ).
[0051] When CE is tied to the external supply voltage Vext, i.e., CE=Vext, then POR ( 204 ) provides the reset state to FSM and to the registers. There is no power down (PD) signal generated at the beginning, hence the oscillator ( 211 ), Vref ( 201 ) generator, resistor divider ( 203 ), and comparator ( 200 ) turn on immediately.
[0052] After a fixed delay (ensured by FSM 210 ), the decision on the value of the external supply is taken through the comparator 208 , by comparing the fraction of the Vext, i.e., k*Vext ( 202 ), with Vref ( 201 ), where k=R 2 /(R 1 +R 2 ). The switched-capacitor comparator operates on two non-overlapping phase signals, φ 1 212 , and φ 2 213 in a conventional manner. The output of the comparator during phase (φ 2 ) is stored in register SwtEn ( 208 ), and RegEn ( 209 ) at the rising edge of the strobe. Either the regulator ( 103 ), or the switch ( 105 ) of FIG. 1 turns on to properly supply the internal core voltage Vint ( 104 ).
[0053] After the decision is made, the PD signal switches off the oscillator ( 211 ), the Vref generator ( 201 ), the comparator ( 200 ) and the resistor divider ( 203 ). It does not generate a reset, hence the decision registered in the SwtEn ( 208 ) and in the RegEn ( 209 ) registers remains for the rest of the period of operation until CE=0 or power off. During the normal operation period of the IC no further comparison is made. Thus, the supply identifier 100 is made immune to noise, which is invariably generated once the internal core logic starts working in any IC. Here the decision is stored before the core logic of the IC even gets the supply. If the supply identifier 100 is kept on, this noise may cause the malfunctioning of the comparator, when the IC is operational and can induce a wrong value for the Vint power supply.
[0054] Almost the entire supply-identifier circuit ( 100 ) is powered down apart from the low-power consuming POR ( 204 ) circuit after deciding the range of the external supply voltage. Hence, during normal mode of the operation of the IC, the supply identifier 100 consumes very little power.
[0055] Further, the circuit described according to this embodiment works in the entire supply range for the core of the integrated circuit. It takes advantage of the higher voltage transistors usually provided in common CMOS processes with dual gate oxide, along with the lower voltage compliant transistors used in the core section of the IC.
[0056] FIG. 3 shows the control signal generation and their relative timing relations with respect to their logic values (“high” represented by 300 and “low” represented by 301 ) generated by the finite state machine (FSM, 210 of FIG. 2 ) and associated circuitry. FIG. 3 ( a ) describes the case when chip enable, CE ( 205 ) is not connected to the external supply, and it is asserted later than settling time of the external voltage Vext. Here, supply-rise (Vext) cannot cause a power on reset pulse, as POR ( 204 ) is disabled by CE. The reset signal (nrst 303 ), remains low as long as CE is low, for providing a reset to FSM( 210 ) and the registers ( 208 , 209 ). During this time PD is also high ( 308 ) ensuring little or no power consumption. Once CE goes high, nrst and PD are deactivated and the oscillator 211 starts generating the clock (CK). The threshold voltage Vref rises to a designed value (it is not same as the “high” level). A Power on Reset (Vpor) signal may not be generated and may be of no consequence as CE=0 ensures proper reset. The offset-storing phase of the comparator, φ 1 , remains high until Tstrt ( 304 ) time. The power on reset value of φ 1 is high for this time. The time shall be such that before the external supply voltage value is attained for the core supply, the reference and the comparator attain their operational level. The power on reset value of the SwtEn ( 208 ) and the RegEn ( 209 ) are in an inactive phase until the operational level is attained by the external supply voltage and by the external reference so that the core of the integrated circuit does not get any supply (Vint, 104 ). Thus, there is no chance of a wrong decision at the power up, even momentarily, else it may expose the internal low-voltage transistors to a higher supply. When φ 1 goes low, the comparison phase (φ 2 ) goes high only after a non-overlapping time (Tno 305 ). The strobe signal is set high only after the comparator delay (Tcd 306 ) this is the signal, which acts as the clock to the SwtEn & RegEn registers. After a short period (Tcl 307 ), the stop signal is set high by the FSM, which in turn generates the power down signal ( 309 ) to stop the clock (CK). In one embodiment, Tcl is less than the time when the core logic starts generating switching noise or the strobe signal is regenerated. Hence the state of the signals generated by the FSM and value registered in the decision registers do not change for the rest of the IC operation.
[0057] If chip enable (CE) is tied to Vext, then the timing diagram shows a slight difference from FIG. 3 ( a ), as shown in FIG. 3 b according to an embodiment of the invention. The reset signal, nrst ( 310 ), is generated only during the Vpor ( 302 ) pulse. The initial pulse of PD ( 308 ) is not generated, but the later part ( 311 ) is generated similar to that in FIG. 3 ( a ). In FIGS. 3 a and 3 b, the delays shown as Tstrt, Tno are multiples of the time period of CK.
[0058] In an embodiment, in FIG. 4 , it is shown how the concept of FIG. 2 can be extended to multiple external supply range selection. Here, a multi-tapped resistor chain, ( 400 ), provides the different fractions of Vext as, k 1 .Vext . . . km.Vext. These values are compared with single reference voltage (Vref) in multiple comparators and register sections ( 401 , 402 ) which in turn provide decisions as D 1 , nD 1 , . . . , Dm, nDm. The control signals and the reference voltage are similar to those of FIG. 2 and FIG. 3 . The combination logic ( 403 ) makes the final decision to turn on the suitable regulator (step up or step down), and the switch as well if indicated by reg 1 En, reg 2 En . . . regmEn signals. A limitation of the multiple-range identification is that the supply identifier circuits may have to work with a wide range of Vext. It is, needless to say, as the control signals are the same as before, the circuit also turns itself off after the decision is made, and is hence immune to logic switching noise and consumes minimal power in normal operation of the IC.
[0059] The supply-identifier circuits of FIGS. 1, 1 a, 2 , and 4 may be incorporated in an integrated circuit, which may be incorporated in a system such as a computer system.
[0060] From the foregoing it will be appreciated that, although 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.
|
A supply identifier takes precise decision on the range of the external supply to manage a proper internal supply to the core of the IC by controlling a regulator or a switch connected to external supply. This supply identifier defers the decision until everything that influences the decision settles after power-up, then makes a decision only once depending on the external supply range and switches itself off, keeping the decision stored, to avoid noise-induced wrong behavior and to reduce power consumption.
| 8
|
TECHNICAL FIELD
[0001] This invention relates to sensing strain in hydrocarbon wells. The invention is particularly concerned with sensing strain experienced by the casing of a hydrocarbon well.
BACKGROUND OF THE INVENTION
[0002] During the extraction of hydrocarbons, the medium surrounding the well, for example earth and rocks, can experience compaction. This, in turn, applies strain to the casing of the hydrocarbon well. It is desirable to be able to monitor the strain being experienced by the casing.
[0003] Previous sensing arrangements have incorporated a number of strain gauges fitted to the casing. However, the casing is typically several kilometers long, necessitating a large number of strain gauges and a complex arrangement to extract strain data from each sensor.
SUMMARY OF THE INVENTION
[0004] The invention provides apparatus for sensing strain applied to a region of a hydrocarbon well, comprising an optical fibre in communication with the region, the optical fibre being responsive to strain applied to the region and to a light signal transmitted through it, in order to produce a sensing light signal incorporating scattered light, wherein a characteristic of the scattered light is indicative of the strain being applied to the region.
[0005] Preferably, the characteristic of the scattered light being monitored is so-called Brillouin scattering.
[0006] The provision of a single optical fibre in order to sense strain being applied along a relatively large area simplifies the sensing of strain.
[0007] The invention will now be described, by way of example, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a schematic cross sectional drawing of a hydrocarbon well;
[0009] [0009]FIG. 2 illustrates a region of the casing of the hydrocarbon well of FIG. 1, incorporating a sensor constructed according to the invention;
[0010] [0010]FIG. 3 illustrates a typical sensing light signal from the apparatus of FIG. 2;
[0011] [0011]FIG. 4 shows schematically the light sensing and transmitting apparatus of the present invention; and
[0012] [0012]FIG. 5 illustrates a typical trace from the analyser of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0013] [0013]FIG. 1 shows a cross section view of a typical arrangement of a well, from which hydrocarbon fluids or gases may be extracted via production tubing 1 . During the extraction process the medium 2 around the casing, adjacent the bore 3 , can suffer compaction. This results in substantial stresses being applied to the casing 4 , via the cement 5 which is injected between the bore and the casing at installation. It is beneficial to monitor the strain in the casing resulting from the compaction stresses.
[0014] Referring now to FIG. 2, in accordance with the invention there is provided an optical fibre 6 in communication with the casing. FIG. 2 shows a section of the length of the casing 4 with the fibre 6 strapped to the casing 4 by straps 7 in a simple vertical geometry. During installation, the casing 4 is lowered into the bore 3 with the optical fibre 6 attached. The assembly is then bonded to the casing/rock formation by a cementation program i.e. the normal process of injecting cement or concrete into the space between the medium 2 surrounding the bore 3 and the casing 4 . Strain imparted to the optical fibre (via the cement or concrete) can be sensed by making use of an optical effect known as Brillouin back-scatter.
[0015] When a high intensity light pulse of a very narrow line width is coupled into an optical fibre, a number of different back-reflected signals are generated at each point along the fibre. FIG. 3 depicts a typical scattered light spectrum in an optical fibre. The spectrum is composed of Raleigh back-scattered light of a frequency identical to that of the original source but with a much reduced amplitude. Added to this is the so-called Raman back scattered light which has up and down-shifted frequency components called stokes and anti-stokes, respectively; and finally, Brillouin scattering signals also with up- and down-shifted frequency components. It can clearly be seen that the frequency shift in the case of the Brillouin scatter is much smaller than that for Raman. Brillouin is in the order of GHz, while the Raman is in the THz range. The other main difference is that the Brillouin scatter is at least two orders of magnitude stronger in intensity compared to Raman.
[0016] Rayleigh scattering is related to inhomogeneities due to the material structure of the optical fibre. Small refractive index fluctuations scatter light in all directions without changing the frequency of the scattered light. Raman scattering occurs when light is absorbed by molecules and re-emitted at different frequencies. Brillouin scattered light occurs as a result of the interaction between a highly coherent incident light source and an acoustic wave generated within the guiding material, i.e. the fibre. The scattered light experiences a Doppler frequency shift, because the pressure variations of the acoustic wave are periodic and travelling in the material. This frequency shift is known as Brillouin frequency shift and is dependent on the material and its acoustic wave velocity. Typical Brillouin shifts are of the order of +/−13 GHz for incident light at 1.33 um and of +/−11 GHz for incident light at 1.55 um. The key characteristic of the Brillouin scattering is that its frequency shift is strain dependent, with a coefficient of 433 MHz % of strain @ 155 um of incident light.
[0017] The basic architecture of the interrogation system employed to transmit light through the fibre, and to detect scattered signals, is shown in FIG. 4. A Distributed FeedBack (DFB) laser 8 is used as a light source and reference source. The centre frequency of this source is at ν o . The light is split into two signals, one acting as the reference signal in a coherent detector 9 , the other fed into light modulators and a frequency shifter 10 . The light modulators are indicated by the references A 01 and A 02 . These modulators are acousto-optic modulators; they modulate the incoming continuous source light into standard pulse light. The frequency shifter 10 then adds a variable frequency shift to the light pulse. The light pulse, at frequency ν o +ν s , is injected into the optical fibre. The back-reflected light returning to the same fibre end will be the sum of the Rayleigh and Brillouin scattered light. This returned signal is then mixed with the local reference light signal and fed into the coherent detector 9 and thus to an analyser 11 . The component marked “G” in the Figure denotes an optical fibre amplifier (to obtain gain). In practice the dynamic range of strain measurement is limited, typically, to about 3% due to the maximum frequency shift that can be detected by the instrument i.e. bounded between 9.9 GHz to 11.9 GHz.
[0018] [0018]FIG. 5 shows a typical trace on the screen of the analyser 11 . The horizontal axis denotes the fibre length in kilometers. The vertical axis shows signal strength. The third axis (conning out and going into the page) is the frequency axis. When the fibre experiences strain along its long axis, the Brillouin backscatter signal at that point will shift in frequency. From this frequency shift, the applied strain and thus stress is determined. The illustration of FIG. 5 is of a forty meters long section of a fibre strain sensor. The first twenty meters of the fibre (measured from the left) are resting without strain. The last twenty meters of the fibre sample are with induced strain. Note the shift of the Brillouin signature to lower frequencies.
[0019] Optical fibre sensors are attractive because of their small size, light weight, EMI immunity and galvanic isolation, high sensitivity, and capacity for distributed sensing.
[0020] Other fibre optic techniques, such as employing Bragg gratings written into the fibre, may also result in a fibre that is sensitive to both temperature and strain. However a technique that leaves the fibre pristine is preferred, such as the afore-described Brillouin back scatter technique, because techniques such as Bragg gratings result in a reduced maximum strain capability of the fibre resulting from writing the grating on to it. Even a pristine fibre has the limitation of a maximum strain of about 6%. The higher strain capability of the pristine fibre is important when long fibre lengths are required for wells. A further advantage of applying the Brillouin technique is that it is less sensitive to temperature, although the variation in temperature after the casing has been installed is relatively small. If temperature monitoring is also required, the Raman back-scatter, shown in FIG. 3, can be monitored instead.
[0021] In the past, several bench-top prototype systems of distributed strain measuring, using Brillouin scattering, have been developed. These systems used counter propagating light signals, using Brillouin amplification between a high intensity pump light pulse and a CW probe light pulse. However, one drawback of this technique is the need for a pair of highly stable, frequency-stabilized, light sources at each end of the fibre. By contrast, the system shown in FIG. 4 involves only one end of the optical fibre and employs the methods of coherent detection and light frequency conversion to accurately detect the Brillouin frequency shift along each point in the fibre.
[0022] Thus the advantage of the invention is that distributed monitoring of the strain of the casing is achieved without the need for a multiplicity of separate sensors, and the interface to the system is reduced to a single fibre optic connection.
[0023] On a practical point, it is known that optical fibres are inherently fragile and it is normal practice to form a cable from the fibre by protecting it in a sheath. The design of this sheath is crucial because it has to protect the fibre from the harsh environment downhole hole and yet at the same time transmit the strain experienced by the casing to the fibre. Thus, the sheath has to protect the fibre from becoming opaque in the presence of fluids involved in the fluid extraction business and naturally occurring fluids such as hydrogen gas. Typically, the fibre is housed in a metal tube and is pre-stressed before being bonded to the tube by means of a strain transmitting bonding agent. This enables the fibre to be sensitive to both tension and compression forces as a result of compaction in the well.
[0024] The installation of the single fibre cable, with a single interface, is therefore relatively simple, resulting in substantial installation cost reduction. Furthermore the reliability of the monitoring system is greatly improved, due to the fibre being a single passive device, and the interface connections being reduced to one.
[0025] On a further practical point, interfacing with the analyser is fairly straightforward. It can be remotely controlled typically via a GPIB, RS232 or parallel port. Offline interpretation can be done on any computer with the emulation software that is provided with the analyser. The analyser has a working temperature range of typically +10° C. to +40° C. Therefore if the natural environmental conditions are expected to exceed these limits, the analyser will have to be located in a controlled environment location. It should also be noted that the analyser is typically rated for non-hazardous area operation only. One analyser can interrogate multiple fibres (wells), but can only interrogate one fibre at a time and the switching between different fibres can vary in complexity. Multiple fibres could be brought back to an optical switch for single location interrogation. If the wells are too far spaced apart, it may be necessary to move the analyser to each well location as required.
|
An apparatus for sensing strain applied to a region of a hydrocarbon well comprises an optical fiber in communication with the region. The optical fiber is responsive to strain applied to the region and to a light signal transmitted through it, in order to produce a sensing light signal incorporating scattered light. A characteristic of the scattered light is indicative of the strain being applied to the region.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to testing computer software. More particularly, this invention relates to testing software, which runs concurrently as multiple processes or threads, or on distributed processors.
2. Description of the Related Art
The main problem in testing a concurrent computer program, which executes as a plurality of threads or operates on a plurality of distributed platforms, is nondeterminism: two executions of such a program may yield different results. Most of the work in the field of concurrent testing has been focused on detecting race conditions. However, race conditions have a low probability of manifesting themselves, and even when they do, it is not always an indication of a fault. In any case, identifying race conditions is insufficient. It is possible that a program without races contains concurrent bugs, e.g., bugs due to incorrect usage of message-based synchronization.
Another approach to testing software is disclosed in the documents O. Edelstein, E. Farchi, Y. Nir, G. Ratsaby, and S. Ur., Multithreaded Java Program Test Generation, IBM Systems Journal, 41(1):111-125, 2002, and S. D. Stoller, Model - checking Multi - threaded Distributed Java Programs , in Proceedings of the 7 th International SPIN Workshop on Model Checking of Software , pages 224-244, New York, 2000, Springer Verlag, which are herein incorporated by reference. The problem of generating different interleavings for the purpose of revealing concurrent faults was approached by seeding the program with conditional sleep statements at shared memory access and synchronization events. At run time, random, biased random, or coverage-based decisions were taken as to whether to execute seeded primitives. However, neither race detection nor the seeding approach helps detect bugs related to multi-layer memory models if the tests are executed on one-layer memory implementations.
Furthermore, the space of possible temporal orders of instruction executions by different threads that may be scheduled by a runtime environment, known as interleavings, is an exponential function of the program size. In the typical testing environment, little coverage of the space of possible interleaving is achieved. The term “coverage” concerns checking and showing that testing has been thorough. Coverage is any metric of completeness with respect to a test selection criterion for the program-under-test. The definition of coverage events is usually specific to a program-under-test, and constitutes a major part in the definition of the testing plan of the program.
The problem of testing multi-threaded programs is further compounded by the fact that tests that reveal a concurrent fault in the field or during stress testing are usually long and run under variable environmental conditions. For example, on a given machine, tasks launched asynchronously by the operating system may alter the machine's environment sufficiently to affect the results of two different executions of the same multi-threaded program. As a result, such tests are not necessarily repeatable. When a fault is detected, much effort must be invested in recreating the conditions under which it occurred.
In particular, the semantics of different versions of the Java™ two-layer memory model are a constant source of programmer misunderstandings and concurrent bugs. The Java memory model is described in the document, The Java Language Specification , James Gosling, Bill Joy, Guy Steele., Addison Wesley, 1996, and more recently in the document, JSR -133: Java Memory Model and Thread Specification , available on the Internet.
The memory model addresses the issue of heap synchronization. For various reasons, such as promoting efficient usage of multiprocessor machines, Java defines a two-layer model of the heap. Each thread operates on its own version of the heap, which in turn communicates with a global upper heap layer. The memory model defines the rules for this communication: when a thread executes certain operations, the executing environment must write the global heap onto the local one or vice versa. Another issue addressed by the memory model is instruction reordering. Many compiler optimizations are dependent on the ability of the compiler to reorder or duplicate instructions, issue prefetching requests, etc. However, a seemingly innocuous permutation at the thread level may change the program behavior because of interaction with other threads. Again, it is the responsibility of the memory model to define which permutations are allowed and which are not. The standard proposed in the above-noted JSR-133 model permits different kinds of heap synchronization and instruction reordering rules than its predecessor. Thus, programs that worked correctly under the old Java memory model may malfunction when run under JSR-133.
It is anticipated that the problems outlined above will become even more acute as new computer chips are equipped with two or more processors, and runtime implementations make use of the two-layer memory model.
SUMMARY OF THE INVENTION
According to a disclosed embodiment of the invention, a tool is provided for modifying the code of a multi-threaded computer program undergoing testing. The program executes in an environment that has a governing memory model. It is assumed that there is a global heap and a thread-local heap, which are synchronized from time to time. The code modifications are typically class modifications and are of two types: (1) reordered code instructions that remain in compliance with the memory model; and (2) addition of thread-local variables to functions, together with insertion of synchronizing instructions that force synchronization of the global and thread-local heaps at selected points in the functions. The modified programs are then executed for testing purposes. These modifications have the effect of changing the interleavings that occur among different threads, and increase the likelihood of exposing program flaws that may become evident under different memory models.
The invention provides a method of testing a concurrently operating original computer program that operates under a memory model, which is carried out by reordering a plurality of instructions of the program while remaining in compliance with the memory model to define a modified program, and generating tests using the modified program for execution in order to verify correct operation of the original computer program.
In one aspect of the method, reordering is done by exchanging two of the instructions.
In another aspect of the method, the program has classes, and reordering includes modifying one of the classes.
According to one aspect of the method, the memory model is a one-layer memory model.
According to another aspect of the method, the memory model is a two-layer memory model.
The invention provides a computer software product, including a computer-readable medium in which first computer program instructions are stored, which instructions, when read by a computer, cause the computer to perform a method for testing a concurrently operating second computer program that operates under a memory model, which is carried out by reordering a plurality of instructions of the second computer program while remaining in compliance with the memory model to define a modified second computer program, and generating tests using the modified second computer program for execution in order to verify correct operation of the original second computer program.
The invention provides a system for testing a concurrently operating original computer program that operates under a memory model, including a test generator operative to reorder a plurality of instructions of the program, while remaining in compliance with the memory model to define a modified program. The test generator is adapted to prepare a suite of tests using the modified program, and an execution engine for executing the tests in order to verify correct operation of the original computer program.
The invention provides a method of testing a concurrently operating original computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, which is carried out by adding a first variable to a function of the program. The first variable is thread-local, and is stored in the thread-local heap. The first variable corresponds to a second variable that is stored in the global heap. The method is further carried out by inserting synchronizing instructions at selected points in the function for synchronizing the global heap and the thread-local heap so as to equate a value of the first variable and a value of the second variable. The method is further carried out by preparing a suite of tests for execution using a modified program that includes the first variable and the synchronizing instructions in order to verify correct operation of the original computer program.
The invention provides a computer software product, including a computer-readable medium in which computer program instructions are stored, which instructions, when read by a computer, cause the computer to perform a method of testing a concurrently operating second computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, which is carried out by adding a first variable to a function of the second computer program. The first variable is thread-local, is stored in the thread-local heap, and corresponds to a second variable that is stored in the global heap. The method is further carried out by inserting synchronizing instructions at selected points in the function for synchronizing the global heap and the thread-local heap so as to equate a value of the first variable and a value of the second variable. The method is further carried out by preparing a suite of tests for execution using a modified second computer program that includes the first variable and the synchronizing instructions in order to verify correct operation of the original second computer program.
The invention provides a system for testing a concurrently operating original computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, including a test generator operative to add a first variable to a function of the program, the first variable being thread-local, and being stored in the thread-local heap. The first variable corresponds to a second variable that is stored in the global heap. The test generator is operative at selected points in the function to insert synchronizing instructions for synchronizing the global heap and the thread-local heap so as to equate a value of the first variable and a value of the second variable, and to prepare a suite of tests using a modified program that includes the first variable and the synchronizing instructions. The system includes an execution engine for executing the tests in order to verify correct operation of the original computer program.
The invention provides a method of testing a concurrently operating original computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, which is carried out by adding a first variable to a function of the original computer program, the first variable being thread-local and stored in the thread-local heap. The first variable corresponds to a second variable that is stored in the global heap. The method is further carried out by substituting a reference to the first variable for a reference to the second variable in the function, inserting a synchronizing instruction in the function that is subsequent to the reference to the first variable so as to equate the first variable and the second variable, and preparing tests for execution using a modified program that includes the first variable and the synchronizing instruction in order to verify correct operation of the original computer program.
The invention provides a computer software product, including a computer-readable medium in which first computer program instructions are stored, which instructions, when read by a computer, cause the computer to perform a method for testing a concurrently operating second computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, which is carried out by adding a first variable to a function of the second computer program, the first variable being thread-local and stored in the thread-local heap. The first variable corresponds to a second variable that is stored in the global heap. The method is further carried out by substituting a reference to the first variable for a reference to the second variable in the function, inserting a synchronizing instruction in the function that is subsequent to the reference to the first variable so as to equate the first variable and the second variable, and preparing tests for execution using a modified program that includes the first variable and the synchronizing instruction in order to verify correct operation of the second computer program.
The invention provides a system for testing a concurrently operating original computer program that operates as a plurality of threads under a memory model that includes a global heap and a thread-local heap, including a test generator operative to produce a modified program by adding a first variable to a function of the original computer program. The first variable is thread-local and is stored in the thread-local heap. The first variable corresponds to a second variable that is stored in the global heap. The test generator is operative for substituting a reference to the first variable for a reference to the second variable in the function, and inserting a synchronizing instruction in the function that is subsequent to the reference to the first variable so as to equate a value of the first variable and a value of the second variable, and preparing tests using the modified program.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the detailed description of the invention, by way of example, which is to be read in conjunction with the following drawings, wherein like elements are given like reference numerals, and wherein:
FIG. 1 is a block diagram of a testing system for concurrent computer programs that is operative in accordance with a disclosed embodiment of the invention; and
FIG. 2 is a flow chart illustrating a method of functional testing of a multithreaded computer program by code reordering in accordance with a disclosed embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent to one skilled in the art, however, that the present invention may be practiced without these specific details. In other instances well-known circuits, control logic, and the details of computer program instructions for conventional algorithms and processes have not been shown in detail in order not to obscure the present invention unnecessarily.
Software programming code, which embodies aspects of the present invention, is typically maintained in permanent storage, such as a computer readable medium. In a client-server environment, such software programming code may be stored on a client or a server. The software programming code may be embodied on any of a variety of known media for use with a data processing system. This includes, but is not limited to, magnetic and optical storage media such as disk drives, magnetic tape, compact discs (CD's), digital video discs (DVD's), and computer instruction signals embodied in a transmission medium with or without a carrier wave upon which the signals are modulated. For example, the transmission medium may include a communications network, such as the Internet. In addition, while the invention may be embodied in computer software, the functions necessary to implement the invention may alternatively be embodied in part or in whole using hardware components such as application-specific integrated circuits or other hardware, or some combination of hardware components and software.
The embodiments herein are disclosed in part with reference to particular memory models, for example variants of the above-noted Java memory mode. However, the invention is not limited to such examples, and may be practiced with many different memory models.
System Overview.
Turning now to the drawings, reference is initially made to FIG. 1 , which is a block diagram of a testing system for concurrent or distributed computer programs that is operative in accordance with a disclosed embodiment of the invention. A generic testing system 10 , used for testing concurrent software, such as multithreaded software, has several basic interacting components. The system 10 is merely exemplary; the principles of the invention can be applied to many different testing systems.
The testing system 10 enables the creation of tests that have various degrees of randomness. The testing system 10 typically contains provisions for introducing random modifications or provisions for randomization of the tests or biasing them toward conditions of interest, for example bug patterns as described in the document Concurrent Bug Patterns and How to Test Them , Eitan Farchi et al., in Proceedings IPDPS 2003:286, which is herein incorporated by reference.
Testing knowledge is stored in the system 10 . This includes a memory model, which can be a one-layer or two-layer memory model, or an even more complex memory model. This information may be stored in a database 15 , and may include testing constraints, coverage criteria, bug patterns, and configuration information for a generic test generator engine 22 .
The test generator engine 22 has a user input 20 , which influences the test generator engine 22 . The influence of the input 20 includes, for example, biasing hints. The test generator engine 22 can be modified using techniques known to those skilled in the art in order to generate reordered code in accordance with the principles of the invention, as explained in further detail hereinbelow. In some applications, the test generator engine 22 may be realized as a plug-in. Alternatively, it can be a standalone tool. The tool described in the above-noted document, Multithreaded Java Program Test Generation , is suitable for the test generator engine 22 .
The test generator engine 22 may receive some generic knowledge of the program specification, and can exploit this knowledge so as to generate sequences of instructions to form a suite of tests 30 for execution. The tests can be modifications of the program code or its running environment. Typically, the tests 30 include listings of multiple threads or processes that are executed concurrently by an execution engine 12 on an implementation of a system suitable for the program under test, and which have biased or randomly selected interleavings. The system can be a hardware system, a complex software implemented system, or a hardware simulator. Indeed, the computer program being tested may itself be a simulation program.
Execution of the tests 30 produces a response 34 from the system. The response 34 is submitted to a validation engine 36 , which has knowledge of the expected response, validates the response 34 , and produces validation results 38 . The validation engine 36 may analyze the coverage of the tests 30 . Typically, individual tests may be re-executed several times, in order to produce different interleavings.
As the space of possible interleavings of a multithreaded system is exponential, it is necessary to bias interleaving generation based on testing knowledge. Prior attempts have focused on biasing interleaving generation based on bug patterns, anomalies, and coverage criterion. The present invention focuses on problems relating to the governing memory model. By creating tests that are likely to expose concurrent program flaws that relate to the memory model, it is possible to produce legal interleavings that could not be realized heretofore.
As explained above, the governing memory model specifies the way in which compiler optimizations can reorder code and how the runtime environment must manage data transfer from the global heap. A compiler uses this information to generate faster, more efficient programs. The same information is exploited according to the invention for the purposes of test generation. The approach is as follows: before the program execution, and additionally or alternatively at class load time, and additionally or alternatively at points during the program execution, the class code is changed by a testing tool, which itself can be a computer program. The code can thus be modified substantially with or without human intervention. The modified code continues to meet requirements of the memory model, but some operations are reordered. Additionally or alternatively, data transfers to and from the heap are modified so as to create the effect of delay.
In the case of Java, the above-mentioned modifications can be performed by a tool that is not part of the Java virtual machine (JVM), but plugs into the JVM. This can be accomplished, using the Java Platform Profiling Architecture, as described in the document JSR -163, available on the Internet.
Alternatively, the Java just-in-time compiler (JIT), which is a part of the JVM, can be used. The output of the tool modifies the code that is executed by the execution engine 12 and the tests that are produced by the test generator engine 22 .
Code Transformations and Reordering.
The tool that is used according to the present invention introduces changes in the code of methods defined by a class, either statically (before execution), during class loading or reloading, or during class compilation or recompilation. Reloading or recompilation may be caused by the normal functioning of the JVM or by the tool itself. Specifically, the tool performs both code motion transformations and transformations that have the effect of delaying heap transfers. Such transformations must obey the restrictions imposed by the memory model; subject to this, they can be selected or based on coverage or heuristic considerations.
For example, according to the memory model described in the document The Java™ Virtual Machine Specification Second Edition , Lindholm, Tim, and Yellin Frank, available on the Internet, which is herein incorporated by reference:
(1) Within a thread, all events appear to be totally ordered. (2) For every heap variable, all events accessing the variable appear to be totally ordered. (3) For every lock, all events accessing this lock appear to be totally ordered. (4) At each synchronized block entry, variable values from the global heap are read into the thread-local heap. (5) At each synchronized block exit, variable values from the thread-local heap are written into the global heap.
To facilitate an understanding of code reordering, consider the example of Listing 1.
Listing 1
/* A, B are heap variables initialized to 0.
* r1, r2 are thread-local (e.g., stack-allocated)
* variables
*/
T1:
T2:
r1 = A
r2 = B
B = 1
A = 2
print r1
print r2
The possible outputs of this program if the instruction order is preserved are the pairs 0 0, 0 1, 1 0, 0 2, 2 0, but not the pairs 1 2 or 2 1. However, the memory model allows one to swap the order of the first two instructions in the thread T 1 . The first rule of the memory model is not violated since this change is transparent for all the events in the thread T 1 . The resulting code is shown in Listing 2.
Listing 2
/* A, B are heap variables initialized to 0.
* r1, r2 are thread-local (e.g., stack-allocated)
* variables
*/
T1:
T2:
B = 1
r2 = B
r1 = A
A = 2
print r1
print r2
One of the possible interleavings for this code is shown in Listing 3.
Listing 3
B = 1
//T1
r2 = B
//T2
A = 2
//T2
r1 = A
//T1
Print r1
//T1
Print r2
//T2
Thus, the possible outputs now include the pairs 1 2 and 2 1. Without recourse to the memory model, it would not be possible to produce this test using known techniques.
Reference is now made to FIG. 2 , which is a flow chart illustrating a method of functional testing of a multi-threaded computer program by code reordering in accordance with a disclosed embodiment of the invention. At initial step 40 , a method or code sequence within a program under test is selected for code reordering and transformations. It is assumed that a memory model is in force, which limits the reordering possibilities.
Next, at step 42 all or some of the shared variables accessed within the method or code sequence that was selected at initial step 40 are duplicated, for example, by the means of thread-local variables or new local variables. Initialization and manipulation of these duplicate variables depends on the rules laid down by the memory model. For example, in the current versions of the Java two-layer model, at least the transformations shown in the following steps are possible.
Next, at step 44 instructions are replaced. For example, if x is a non-volatile variable, an instruction of the form t=x, where t is local, can be replaced with lcl_x=x; t=lcl_x, where lcl_x is a local or thread-local variable.
Next, at step 46 , the first instruction of the pair that was replaced in step 44 can be moved to an earlier stage of the program, but not earlier than the nearest point where variable values from the global heap are read into the thread-local heap according to the memory model or x is read by a different instruction.
Similar transformations for step 44 and step 46 are possible when reading non-volatile fields. If x is a non-volatile variable, or un is a non-volatile field, an instruction of the form x=t or p.x=t, where t is local, can be replaced with lcl_x=t; x=lcl_x or p.x=lcl_x, where lcl_x is a local or thread-local variable. The last instruction of the pair can be moved to a later stage of the program but not later than the nearest point where variable values from the thread-local heap are written onto the global heap according to the memory model or x or p.x is written by a different instruction.
Instruction reordering as described above is performed using one of the well-known instruction scheduling algorithms under the restrictions imposed by the memory model. The reordering algorithm may do rescheduling randomly, pseudorandomly, or may be guided by pattern-based heuristics. For example, relevant techniques include swapping instruction order, speculatively promoting instructions or demoting instructions.
Control now proceeds to final step 48 . The method or code sequence as transformed may now be executed. Method execution is likely to result in a different interleaving than would be seen without the rearrangement.
EXAMPLE
There is a well-known bug pattern related to two-layer memory model, namely, the double-checked locking bug, an example of which is given in Listing 4.
Listing 4
class Foo{
public int x;
public Foo(int _x){x=_x;}
}
class Bar{
private static Foo foo = null;
public static void printFoo( ){
if (foo == null) {
synchronized(this){
if (foo == null) {foo = new Foo(17);}
}//synchronized
}
System.out.println(foo.x);
}
}
The problem arises if the thread performs the first test for nullity, which is non-synchronized, and finds that the variable foo is non-null. In this case, the synchronized block is never entered. If the code executes on a JVM with a one-layer memory implementation, the method printFoo( ) will always print 17. However, on a machine with two-layer memory, the following scenario is possible:
Thread T 1 executes Bar.printFoo( ), initializing Bar.foo (and Bar.foo.x). Note that at the exit from the synchronized blocks the updated variable values are copied from T 1 's copy of the heap to the global heap
Thread T 2 executes Bar.printFoo( ). Upon the method entry, T 2 's local version of the heap has the updated value of Bar.foo, but not Bar.foo.x. Therefore, the synchronized section is not entered, the global heap is not copied fully to T 2 's heap, and the method prints out 0.
The conventional techniques noted above cannot reproduce this bug on a JVM with a one-layer memory implementation. The tool according to the invention, however, could store the values of the accessed variables, and modify the code as shown in Listing 5:
Listing 5
class Foo{
public int x;
public Foo(int _x){x=_x;}
}
class Bar{
private static Foo foo = null;
public static void printFoo( ){
int lcl_x;
if (foo == null) {
lcl_x = 0;
synchronized(this){
if (foo == null) {
foo = new Foo(17);
lcl_x = foo.x;
}
}//synchronized
}else{
lcl_x = foo.x;
}
System.out.println(lcl_x);
}
}
The system would first replace, as described above, the direct access to foo.x (println(foo.x)) with a two-staged access: lcl_x=foo.x; println(lcl_x). Then the former instruction is promoted. It is replicated in the process, since the basic block where it is originally defined has several predecessors.
Now, a test execution engine could print out the value 0 on a JVM with a one-layer memory implementation. Use of data transfer delay, with or without code reordering, has the effect of varying the interval between the assignment of a shared variable by a first thread and its use by a second thread. Indeed, elaboration of the technique will occur to those skilled in the art, for example by assignments of a shared variable by different threads, and access of the variable by still other threads at different times. The technique thus permits many different interleavings to be evaluated by a testing system.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and sub-combinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description.
|
A tool is provided for modifying the code of a multi-threaded computer program undergoing testing. The program executes in an environment that has a governing memory model. It is assumed that there is a global heap and a thread-local heap, which are synchronized from time to time. The modifications are of two types: (1) code instructions are reordered while remaining in compliance with the memory model; and (2) thread-local variables are added to functions, together with inserted heap synchronizing instructions. The modified programs are then used by a test generator to prepare test cases for execution. The modifications have the effect of changing the interleavings that occur among different threads, and increase the likelihood of exposing flaws that may become evident under different memory models.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a Utility Application of prior pending provisional patent application serial No. 60/403,865 filed Aug. 15, 2002.
BACKGROUND OF INVENTION
[0002] This Invention is directed to methods for treating hydrocarbon-bearing formations i.e., to increase the production of oil/gas from the formation. More specifically, the invention relates to the placement of fluids for instance for stimulation treatment such as matrix and fracture treatments.
[0003] Hydrocarbons (oil, natural gas, etc.) are obtained from a subterranean geologic formation (i.e., a “reservoir”) by drilling a well that penetrates the hydrocarbon-bearing formation. This provides a partial flowpath for the oil to reach the surface. In order for oil to be “produced,” that is, travel from the formation to the wellbore, and ultimately to the surface, there must be a sufficiently unimpeded flowpath from the formation to the wellbore. If the formation is naturally “tight”, i.e. has poorly interconnected pores, or has been damaged by the accumulation of mineral or chemical deposits (scales, precipitates, polymer residues, etc.), resulting from prior treatments or from aging of the reservoir, the flowpath is altered and the production is lower than expected.
[0004] Stimulation techniques aim at increasing the net permeability of a reservoir. This is typically achieved through the use of fluid pressure to fracture the formation and/or the injection of chemicals through the wellbore and into the formation to react with and dissolve the deposits or the formation, therefore creating alternative flowpaths. This invention is primarily directed to the latter and thus relates to methods to enhance well productivity by dissolving formation minerals (e.g. calcium carbonate), or deposits by techniques known as “matrix acidizing”and “acid fracturing”.
[0005] Correct fluid placement plays a critical role in successful well stimulation. Treating fluids must be injected into reservoir zones with lower permeability or higher damage in order to stimulate them. This is true for both matrix acidizing and fracturing. However, injected fluids preferably migrate to higher permeability zones (the path of least resistance) rather than to the lower permeability zones, yet the ones that would most benefit from the treatment.
[0006] In response to this problem, numerous, disparate techniques have evolved to achieve more controlled placement of the fluid—i.e., to divert the acid away from naturally high permeability zones and zones already treated, and towards the regions of interest. These techniques can be roughly divided into either mechanical or chemical techniques.
[0007] Mechanical techniques include ball sealers (balls dropped into the wellbore and that plug the perforations in the well casing, thus sealing the perforation against fluid entry); packers and bridge plugs, including straddle packers (mechanical devices that plug a portion of the wellbore and thereby inhibit fluid entry into the perforations around that portion of the wellbore); coiled tubing (flexible tubing deployed by a mechanized reel, through which the acid can be delivered to more precise locations within the wellbore); and bullheading or attempting to achieve diversion by pumping the acid at the highest possible pressure—just below the pressure that would actually fracture the formation (described by Paccaloni in SPE 24781).
[0008] Chemical diversion techniques can be further divided into ones that chemically modify the wellbore adjacent to portions of the formation for which acid diversion is desired, and ones that modify the acid-containing fluid itself. The first type involve materials that form a reduced-permeability cake on the wellbore face thus reducing the permeability to the acid and diverting it to higher permeability regions. The second type includes foaming agents, emulsifying agents, and gelling agents, which alter the transmissibility of the rock and fluid system.
[0009] The primary fluids used in acid treatments are mineral acids such as hydrochloric acid, which was disclosed as the fluid of choice in a patent issued over 100 years ago (U.S. Pat. No. 556,669, Increasing the Flow of Oil Wells, issued to Frasch, H.). At present, hydrochloric acid is still the preferred acid treatment in carbonate formations. For sandstone formations, the preferred fluid is a hydrochloric/hydrofluoric acid mixture. With mineral acids, the major drawback is that they react too quickly and hence penetrate (as unspent acid) into the formation poorly. Second, they are highly corrosive to wellbore tubular components. Organic acids (formic and acetic acid in conventional treatments) are a partial response to the limitations of mineral acids. They are less corrosive and allow greater radial penetration of unspent acid but they also have numerous shortcomings, primarily cost and low reactivity.
[0010] Emulsified acid systems and foamed systems are other commercially available responses to the diversion problem, but they are fraught with operational complexity which severely limits their use—e.g., the flow rates of two different fluids, and the bottom hole pressure must be meticulously monitored during treatment.
[0011] Gelling agents, especially those not based on crosslinking chemistry but rather upon viscoelastic surfactants, are also used with alternating stages of acid treatment, where the gelling agent preferably decreases the permeability of selected zones and therefore favor the later treatment of the other zones. One system of this type is disclosed in U.S. Pat. No. 4,695,389 (see also, U.S. Pat. No. 4,324,669, and British Patent No. 2,012,830). Another viscoelastic surfactant-based gelling system, also proprietary to Schlumberger, is known as OilSEEKER™, and is disclosed in F. F. Chang, et al., Case Study of a Novel Acid-Diversion Technique in Carbonate Reservoirs, SPE 56529, p. 217 (1999).
[0012] Self diverting systems, that allow one-step treatment, have also been proposed for instance in U.S. Pat. No. 6,399,546, with a diverter contained within the acid-containing fluid.
[0013] These numerous techniques proceed by completely different ways such as modification of the wellbore interface or modification of the acid-containing fluid itself. They are usually very sensitive to any feature in the reservoir that will conduct these diverting agents out of the target zone, for instance a natural fracture and they may actually damage the formation and create rather than solve matrix damages if used improperly. The design of a matrix treatment is consequently very challenging.
[0014] Hence, the effectiveness of a treatment, and more particularly the diversion effectiveness, is very difficult to evaluate. During fracture treatments, analysis of surface treating pressures can be used in some cases to analyze it; however, this method does not work for acidizing since pressure surges at the surface may not be correlated to changes in flow profile downhole (see C. W. Crowe, Evaluation of Oil Soluble Resin Mixtures as Diverting Agents for Matrix Acidizing, SPE 3505, 1971 and J. W Burman, B. E. Hall, Foam as Diverting Technique for Matrix Sandstone Stimulation, SPE 15575, 1986).
[0015] As a result methods for determining actual fluid placement have mainly been limited to post treatment analysis. Some of the methods used have been radioactive tracers, comparison of pre- and post-treatment flowmeter logs, and pre- and post-treatment temperature logs.
[0016] One main disadvantage of using post treatment analysis to determine fluid entry is that nothing can be done to change things once the treatment is done. If fluid entry could be monitored during the treatment, changes could possibly be made to the treatment that would change the fluid profile along the wellbore. Therefore, real-time monitoring of fluid entry into the reservoir would be very useful information to have during treatment.
SUMMARY OF INVENTION
[0017] This invention provides a new engineering method that enables real-time monitoring of fluid placement, diverter effectiveness, and fracturing parameters during well treatments such as for instance well intervention/stimulation or water control treatments.
[0018] The method utilizes distributed temperature sensors so that the temperature vs. position of the fiber can be determined and a temperature profile along the entire fiber becomes available at any time during the treatment, allowing real-time monitoring of the treatment and adjustment is necessary.
[0019] According to one aspect of the present invention, the distributed temperature sensors are on an optical fiber through which laser generated light pulses are sent at timed intervals. The return light is analyzed and information, such as temperature and pressure vs. position on the fiber can be determined.
[0020] According to another aspect of the present invention, an array of Fiber Bragg Grating temperature sensors is used, In this later case, a continuous light source is used and the measurement is based on wavelength interrogation.
[0021] The fiber is preferably positioned in the well utilizing coiled tubing but may be also positioned through other positioning tools such as tubing, wireline tool. The fiber may be simply injected bare or coated with a composite or a metal coating.
[0022] The deployment is preferably carried out while rigging up for the service and is removed at the completion of the service.
[0023] Comparison of temperature profiles through the treatment zone at various times during the treatment, for example after an acid stage exits the end of the coiled tubing, can be used to determine where the fluid stage entered the formation. Since the temperature of most treating fluids will be cooler than the bottomhole temperature, a cooling effect from fluid entry should be visible. In some cases, it may also be possible to see heating of the reservoir due to the exothermic reaction of the acid with the rock. Monitoring of the pressure also provides information that will assist in treatment evaluation.
[0024] According to a preferred embodiment, the pressure is also monitored through the treatment interval during fracturing. Distributed pressure sensors may also be used. This allows for instance real-time diagnosis of imminent screenout or emerging fracture geometry. It also permits the on-site engineer to monitor fracture evolution and make adjustments to ensure tip-screen-out in high permeability zones.
BRIEF DESCRIPTION OF DRAWINGS
[0025] [0025]FIG. 1 shows the baseline temperature gradient in a well, as a function of the true vertical depth;
[0026] [0026]FIG. 2 shows the temperature gradient after the injection of a first treatment stage;
[0027] [0027]FIG. 3 shows the temperature gradient after injecting a second treatment stage;
[0028] [0028]FIG. 4 shows the differential temperature trace.
DETAILED DESCRIPTION
[0029] Analysis of differential temperature logs has been used in the oil and gas industry since the late 1960“s as related in SPE 1750—Tracing Fluid Movements with a New Temperature Technique, E. Johns, 1967 and SPE 1977—Some Applications of Differential Temperature Logging, L. R. Jameson. However, this method is rarely used, possibly because it requires well logging both before and after the treatment. Today, a more typical method of determining fluid entry is the use of radioactive (RA) tracers.
[0030] The distributed temperature sensing (DTS) technology was pioneered in the early 1980“s. It is based on optical time-domain reflectometry (OTDR), which is used extensively in telecommunications cable testing. Application in the oil and gas industry to date has been as permanent installations (see SPE 71676—The Use of Fiber-Optic Distributed Temperature Sensing and Remote Hydraulically Operated Interval Control Valves for the Management of Water Production in the Douglas Field, M. Tolan, M. Boyle, G. Williams, 2001 and SPE 76747—Permanent Fiber Optic Monitoring at Northstar: Pressure/Tempearture System and Data Overview, T. K. Kragas, B. F. Turnbull, M. J. Francis, 2002). OTDR technology sends short duration light pulses down the fiber optic cable and measures the arrival time and magnitude of the returning backscattered light to determine the location and type of faults in the cable. The backscattered light is generated by changes in density and composition as well as molecular and bulk vibrations.
[0031] Generally, pulses of light at a fixed wavelength are transmitted from a light source in surface equipment down a fiber optic line. At every measurement point in the line, light is back-scattered and returns to the surface equipment. Knowing the speed of light and the moment of arrival of the return signal enables its point of origin along the fiber line to be determined. Temperature stimulates the energy levels of the silica molecules in the fiber line. The back-scattered light contains upshifted and downshifted wavebands (such as the Stokes Raman and Anti-Stokes Raman portions of the back-scattered spectrum), which can be analyzed to determine the temperature at origin. In this way the temperature of each of the responding measurement points in the fiber line can be calculated by the equipment, providing a complete temperature profile along the length of the fiber line. This general fiber optic distributed temperature system and technique is known in the prior art. As further known in the art, it should be noted that the fiber optic line may also have a surface return line so that the entire line has a U-shape. One of the benefits of the return line is that it may provide enhanced performance and increased spatial resolution to the temperature sensor system.
[0032] DTS is used to detect water or gas influx, to monitor thermal EOR projects, and to monitor gas lift valves. It has been used with coiled tubing in the same way as the permanent installations.
[0033] This invention focuses on the use of fiber optic measurements during well intervention treatments. The fiber optic line is deployed at the time of service and removed after the completion of service. Distributed temperature measurements will be used to monitor where the treating fluids enter the formation. Fluid placement is a variable that is typically only inferred by pressure changes during a treatment. The ability to monitor fluid placement during the treatment will give stimulation engineers information that will allow them to make adjustments to obtain better injection profiles. This is especially true in matrix acid jobs where the goal may be to inject the treating fluid into zones that initially take fluid poorly.
[0034] An example procedure for use in acid treatments would work as follows:
[0035] The optical fiber is positioned in the well with its end at or slightly below the reservoir
[0036] The fiber is allowed to equilibrate until a baseline temperature profile is determined for the well across the treatment interval.
[0037] Since temperature is available at all depths at all times, a differential profile can be calculated by subtracting the temperature at each depth at the desired time from the temperature at depth at the baseline time. Positive changes would indicate heating (may be possible due to chemical reactions) and negative changes would indicate cooling (due to cooler fluids being injected).
[0038] Pump an injectivity test with a non-reactive fluid, such as brine. The differential profile should be calculated and evaluated before pumping the treatment in case an initial diverter stage is determined to be necessary. The brine will cool down the formation where it gets in contact with it. The change in temperature will indicate the areas open to flow. Combining the measurements with a temperature simulation of the injection will further the analysis and indicate the volume of fluids that have gone into each zone, thus providing the injectivities of each zone.
[0039] Pump a complete treatment stage and diverter. A treatment stage can be a single fluid or multiple fluids depending on the type of treatment being pumped and the reservoir being treated. Carbonates are typically treated with a single fluid, such as HCI. Sandstones typically have a 3 fluid treatment stage, preflush, main fluid, and overflush, before the diverter is pumped.
[0040] Shut down until the temperature stabilizes and a sufficient temperature differential is seen. Expected shut in time will vary depending on the reservoir properties and fluids pumped but should be on the order of minutes. Expected shut in time should not be greater than an hour.
[0041] Continue pumping the treatment, shutting in for fluid entry analysis after each diverter stage (as a minimum).
[0042] During the shut in, the temperature deviation from both the baseline and the temperature profile measured prior to the shut in are monitored continuously. The derivatives relative to time of those two curves are also calculated. The differences in cooling times and rates of cooling along the wellbore indicate in which layer of the reservoir the treatment fluid or diverter stage has gone. Performing a temperature simulation of the injection and matching the results of the simulation with the measurements will further the analysis and indicate the volume of fluids that have gone into each zone.
[0043] Differential temperature profiles should be calculated after each diverter stage and at the end of the first stage to follow the diverter to determine if the diverter is working. After diversion, the fluid should move to a different zone. If this does not occur, additional diverter may be required and the real-time monitoring allows real-time adjustment of the amount of diverter. Where coiled tubing is used, the temperature profile may also show that its position is not optimized and the treatment may be adjusted by changing the position of the coiled tubing injection point.
[0044] The analysis can be extended through the use of a coupled wellbore/reservoir temperature model. Combining the measured temperature with a temperature simulation of the injection can provide a method to indicate the individual zone injectivity. Performing a temperature simulation of the injection and matching the results of the simulation with the measurements can be used to determine the volume of fluids that have gone into each zone.
[0045] Determining the actual position of the injection is also valuable information. Post-treatment spinner logs can be used to assess where the fluid went, but then it is too late to change that injection profile. Real-time knowledge of where the diverter is going, may trigger the decision of re-positioning the coiled tubing to inject away from that zone and into the next zone that needs treatment. Knowing the “where” of actual treatment will help the operator in managing conformance in standard and gravel pack completions.
[0046] Managing conformance means ensuring the treatment goes into the zones that have the most production potential to optimize reservoir draining. For instance, in secondary and tertiary recovery projects the goal is to maximize injection and sweep of unswept zones. With gravel packing treating, it is suitable to make sure treatments are uniform so you will not “overtreat” any particular section of the pack which could lead to gravel pack failure
[0047] The main difference between the current method and past methods is that the distributed temperature sensing technology makes the temperature profile across the interval available at all times. Therefore calculation of the differential temperature profile can be done without making logging passes or moving the CT. It should also be possible to program the final data acquisition software to generate the differential profile at any time during the treatment upon command. This would make real-time fluid entry evaluation not only possible but easy to do.
[0048] Modifications of this basic procedure would have to be developed if foam diversion is used or if nitrified fluids are pumped. Availability of pressure at depth will allow much better evaluation of foam diversion because downhole foam quality can be more accurately estimated. It may also be possible to monitor foam degradation.
[0049] Real-time bottomhole pressure (BHP) through the use of optical fiber will also be very useful in hydraulic fracturing treatments. BHP is essential for determining accurate closure pressure and accurate pressure response during the fracturing treatment allows the on-site engineer to diagnose any imminent screenout and promptly go to flush to avoid time-consuming and potentially costly cleanout if screenout occurs. BHP also provides the engineers the data needed to design and monitor tip-screen-out treatment in high permeability formation and to use the fracturing software to perform post-job pressure match and optimize the future treatment design.
[0050] CoilFRAC is an especially cost-effective way to stimulate multiple zones in a single pipe trip. Since straddle packers are used for CoilFRAC, there is no way to obtain true BHP by simply measuring the annulus pressure. The BHP calculated from the surface pressure is highly inaccurate due to high friction through the coiled tubing and the CoilFRAC bottom hole assembly (BHA). Optical fiber installed inside the BHA and below the fracturing port can provide a direct measurement of the BHP.
[0051] Measurement of temperature profile can also be used to determine fracture height after a fracture treatment. The formation adjacent to the fracture will exhibit more cooling than the rock above and below. Therefore, the temperature profile along depth and its change with time provides the indication of fracture growth and the final height. The fracture height measurement tells the engineer whether the fracture is properly placed in the target zones and whether the fracture could propagate into water or gas zones, which are to be avoided. Based on the information, fracture design can be adjusted to achieve optimal well productivity.
[0052] Example data shown in the figures is synthetic and represent idealized results. FIG. 1 illustrates the baseline temperature gradient measured after attaining stabilized temperature gradient with the fiber optic positioned across the reservoir before starting the treatment. The temperature (hereby expressed in degrees Fahrenheit) depends linearly of the TVD (true vertical depth), hereby expressed in feet. The dashed lines between about 7500 feet and 8000 feet indicate the position of perforations.
[0053] [0053]FIG. 2 shows the stabilized temperature gradient for the same well after the first treatment stage. In this case, the treatment induces a diminution of the temperature in the perforation zone (compare to the baseline curve repeated for reference purposes).
[0054] After a second treatment stage, the stabilized gradient further evolves (see FIG. 3). The differential curve calculated at the end of the job, FIG. 4, shows clearly in this example that the treatment has entered both zones, thereby proving the effectiveness of the diverter.
|
The invention relates to a method for treating subterranean formation comprising providing distributed temperature sensors, injecting a treatment fluid and monitoring the temperature across the treatment interval during the injection process.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates to a method and apparatus for handling of calls for emergency services in telecommunications networks and, in particular, so-called intelligent networks.
[0003] The invention is also applicable to routing within an intelligent network of emergency services calls from mobile stations.
[0004] 2. Background Art
[0005] In existing telecommunications networks, particularly in North America, telephone calls for emergency services are routed to a Public Service Access Point (PSAP) which is staffed by emergency services operators and, for reasons of reliability and continuity of service, is accessed by way of a tandem switch dedicated to such emergency services. To access emergency services, the caller dials the emergency services access code, which in North America is 9-1-1. When the end office detects the digits 9-1-1, instead of routing the call like a normal voice call, it routes the call immediately to the 9-1-1 tandem switch which routes the call to the Public Service Access Point. In order to determine the most appropriate emergency services centre to provide the required services, the emergency services operator will determine the location of the caller by first obtaining the calling line identifier, either automatically if the tandem switch is provisioned with Automatic Number Identification (ANI), or by questioning the caller, and using it to access an Automatic Location Identification database and obtain the geographical location of the caller.
[0006] Although it is usual to provide a second ALI database as a “hot spare” to ensure reliability of service, this existing way of handling emergency services calls is not entirely satisfactory because, if the trunks between the end office and the dedicated tandem switch, or between the tandem switch and the PSAP, were blocked, that PSAP could not supply the necessary emergency service to that caller. A further disadvantage is that automatic location identification is not available for mobile users.
[0007] An object of the present invention is to overcome or at least mitigate these deficiencies of existing emergency services systems. To this end, the present invention provides for calls for emergency services to be routed using out-of-band or common channel signalling.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the present invention, there is provided a method of handling emergency services calls in an intelligent network having at least one Service Point (SP) equipped with software for providing service features and having access to databases including a routing table, a plurality of Service Switching Points (SSP) equipped with call processing software having point-in-call triggers for interrupting processing of a call and exchanging signalling messages with the Service Point to obtain instructions for further processing of the call, and one or more emergency services operator stations (PSAP), the Service Switching Points and Service Point being interconnected by an out-of-band signalling system, the Service Switching Points being interconnected by trunks for calls therebetween, and the one or more emergency services operator stations being each connected by trunks or lines to a respective one of said Service Switching Points, the said routing table listing a routing number identifying a network location for each of said one or more emergency services operator stations, the method comprising the steps of:
[0009] (i) at a particular Service Switching Point, presetting a point-in-call trigger to operate at a predetermined point in a call for emergency services,
[0010] (ii) subsequently, when said particular Service Switching Point is processing an emergency services call, interrupting processing of the call and transmitting to the Service Point a query signalling message requesting routing information,
[0011] (iii) at the Service Point, upon receipt of the query signalling message, accessing said routing table in dependence upon parameters in the query signalling message and obtaining a routing number corresponding to a selected emergency services operator station, forming a response signalling message including the routing number and returning such response signalling message to said particular Service Switching Point,
[0012] (iv) at said particular Service Switching Point, upon receipt of said response signalling message, detecting the routing number, and routing the call to the emergency services operator station.
[0013] The method may include the prior steps, at the Service Switching Point, of attempting to complete the emergency services call on the basis of the dialled digits received from the calling party, and detecting that the call did not complete, the point-in-call trigger being selected to operate following failure of such initial call completion attempt.
[0014] Alternatively, the point-in-call trigger may be set to interrupt processing of all calls upon receipt of the dialled digits from the calling party.
[0015] According to a second aspect of the present invention, there is provided apparatus for handling emergency services calls in a telecommunications network, the apparatus comprising at least one Service Point equipped with software for providing service features and databases including a routing table, a plurality of Service Switching Points equipped with call processing software having point-in-call triggers for interrupting processing of a call and exchanging signalling messages with the Service Point to obtain instructions for further processing of the call, and at least one emergency services operator station, the Service Switching Points and Service Point being interconnected by an SS7 signalling system, the Service Switching Points being interconnected by trunks for calls therebetween, and the emergency services station being connected by trunks to one of the Service Switching Points, the routing table listing a routing number for each of the emergency services stations, each Service Switching Point comprising:
[0016] means for presetting a point-in-call trigger to operate at a predetermined point in a call for emergency services, and
[0017] means operative during processing of a call for emergency services to interrupt processing of the call and transmit to the Service Point a query signalling message requesting routing information, each Service Point comprising:
[0018] means operative, upon receipt of the query signalling message, for accessing the routing table in dependence upon parameters in the query signalling message and obtaining a routing number for a selected emergency services station, forming a response signalling message including the routing number and returning such response signalling message to the requesting Service Switching Point, each Service Switching Point further comprising means operative, upon receipt of said response signalling message, for routing the call to the network address for completion to the emergency services station.
[0019] The Service Switching Point may comprise means operative to attempt to complete the emergency services call on the basis of the dialled digits, and the point-in-call trigger is set to interrupt call processing upon failure of such attempt.
[0020] Alternatively, each Service Switching Point may have a trigger set to interrupt all calls upon receipt of the dialled digits from the originating station and, in dependence thereupon, generate said signalling message requesting routing instructions.
[0021] According to a third aspect of the invention, there is provided a telecommunications network comprising an intelligent network portion comprising a Service Point (SP), a plurality of Service Switching Points (SSP), one or more Public Service Access Points (PSAP) and a Signal Mediation point (SMP), and a mobile network portion comprising a Mobile Services Switching Centre (MSC) for routing calls from a mobile users in cell sites associated with such MSC and a Home Location Register (HLR), the MSC and SSPs being interconnected by trunks for routing calls therebetween, the MSC and SSPs being connected to the SMP by Signalling System No. 7 (SS7) signalling links, the SMP being connected to the SCP and the HLR by respective SS7 links, the SP having access to a routing table including entries correlating routing numbers of PSAPs with cell site identifiers, the SMP having basic SP SS7 applications part software for handling mobile or wireline TCAP messages and additional conversion software and tables for translating TCAP message parameters according to mobile protocols to TCAP message parameters using intelligent network protocols, and vice versa,
[0022] the method comprising the steps of:
[0023] at the MSC:
[0024] upon receipt of a 9-1-1 call from a mobile station, forming a TCAP query message addressed to the destination point code of the HLR and routing the message to the SMP, the message including a mobile identification number (MIN) for the mobile station, a cell site number, and a mobile network address for the MSC, and the dialled digits,
[0025] at the SMP:
[0026] detecting the dialled digits identifying the call as an emergency services call;
[0027] translating the parameters in the message as received into corresponding AIN/IN parameters according to the intelligent network protocol being used by the SP,
[0028] forming an AIN/IN TCAP message including the translated parameters, the network address of the MSC and the cell site number being combined in an original Calling Party number,
[0029] overriding the destination point code of the HLR and routing the message instead to the SP,
[0030] at the SP,
[0031] accessing the mobile routing table using the original Calling Party number from the received query and obtaining a routing number for a PSAP,
[0032] including the PSAP network address in a TCAP response message and sending this response message to the SMP, at the SMP,
[0033] translating the intelligent network parameters of the TCAP response message into corresponding mobile network parameters,
[0034] and routing the response message to the MSC,
[0035] at the MSC,
[0036] extracting the PSAP network address from the TCAP message and routing the emergency services call thereto via one or more of the SSPS.
[0037] According to a fourth aspect of the invention, there is provided Signal Mediation Point apparatus comprising SCP software for processing and routing TCAP messages and conversion software for translating parameters of such TCAP messages formulated according to one or more mobile protocols into parameters according to one or more intelligent network protocols, and vice versa, the SMP having signalling links for connection to a Mobile Switching Centre, a Service Control Point and a Home Location Register, the conversion software being operative, upon receipt of a query from the MSC containing a destination point code for the HLR and dialled digits of an emergency services call to detect said digits, translate the parameters into corresponding intelligent network parameters, change the destination point code to that of the SCP, and route the message to the SCP, and on receipt of a response from the SCP, to detect the emergency services dialled digits again, translate the parameters into corresponding mobile network parameters, and route the response message to the MSC.
[0038] The conversion software may determine a network address of the mobile switching centre and a cell site identifier and combine both into an original Calling Party number in the intelligent network TCAP message sent to the SCP.
[0039] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, of preferred embodiments of the invention, which are described by way of example only.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0040] [0040]FIG. 1, labelled PRIOR ART, is a simplified schematic diagram illustrating equipment in existing telephone systems for handling “9-1-1” calls to emergency services operators;
[0041] [0041]FIG. 2 is a simplified schematic diagram illustrating a portion of a so-called “intelligent network” embodying a first embodiment of the invention;
[0042] [0042]FIG. 3 is a simplified schematic diagram of a modification of the first embodiment of the invention;
[0043] [0043]FIG. 4 illustrates a second embodiment of the invention for handling emergency services calls from mobile users;
[0044] [0044]FIG. 5 illustrates software modules within a signal mediation point of the network of FIG. 4; and
[0045] [0045]FIG. 6 illustrates message flows within the signal mediation point.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0046] Referring to FIG. 1, labelled PRIOR ART, existing telephone systems, particularly in North America, comprise a Public Service Access Point (PSAP) 10 , which is a station staffed by emergency services operators and accessed by way of a tandem switch 12 dedicated to such emergency services. In order to enable automatic identification of the location of the caller requesting emergency services, the PSAP 10 has access, by way of a data link 14 , to an automatic location identification (ALI) database 16 . A second ALI 16 ′ connected by way of a separate data link 14 ′ is provided as a “hot spare” to ensure reliability of service. To access emergency services, a caller using station apparatus 18 connected to an end office 20 dials the emergency services three-digit access code, which, in North America, is 9-1-1. The end office 20 detects the digits 9-1-1 and routes the call immediately to the 9-1-1 tandem switch 12 , which routes the call to the PSAP 10 . If the tandem switch 12 is provisioned with Automatic Number Identification (ANI), the calling line identifier will be available to the operator automatically. If it is not, the operator will question the caller to obtain the necessary information. The operator will use the calling line identifier to access the Automatic Location Identification database 16 , in order to obtain the geographical location of the caller, determine the most appropriate (usually the closest) emergency services centre to respond to the call, and relay the information to that centre using known “special” call transfer procedures and the usual data network interconnecting PSAPs and emergency services centres.
[0047] If the data link 14 to the Automatic Location Identification database 16 were to fail, the second ALI database 16 ′ could be used to ensure reliability of service. If both of the ALI databases were inaccessible, the operator could still ask the caller for his or her geographical location. However, if the trunks 22 between the end office 20 and the dedicated tandem switch 12 , or the trunks 24 between the tandem switch 12 and the PSAP 10 , were blocked, the PSAP 10 could not supply the necessary emergency service to that caller.
[0048] If a normal voice call could not be completed, some form of alternate routing via another office might be used. For emergency services calls, however, alternate routing via other offices, especially using SS7 signalling, has not, hitherto, been used for reliability reasons. The originating office may attempt different trunks but, once its list is exhausted, has no alternative but to reject the emergency services call. The present invention proposes providing alternate routing of emergency services calls within intelligent networks employing out-of-band signalling in such a way that reliability requirements are met.
[0049] The out-of-band network signalling system adopted by the International Consultative Committee for Telephone and Telegraph (CCITT), is known as Signalling System No. 7 (SS7). For an overview of SS7, the reader is directed to an article entitled “Signalling System No. 7: A Tutorial” by A. R. Modarressi and R. A. Skorg, IEEE Communications Magazine , July 1990, which is incorporated herein by reference. The kind of SS7 system used in North America is known as Common Channel Signalling System No. 7 (CCS7).
[0050] Telecommunications systems known as “Intelligent Networks” (IN) or “Advanced Intelligent Networks” (AIN) employ Signalling System No. 7 (SS7) to exchange messages between network elements to deploy selected services, and between network node switching elements to set up and route calls. The messages are handled by the SS7 data communications system which is separate from the trunks which carry the calls themselves. (For a general description of intelligent network components and operation, the reader is directed to U.S. Pat. Nos. 5,581,610 and 5,438,568 which are incorporated herein by reference.)
[0051] The main elements of such intelligent networks include Service Switching Points (SSPs), Signal Transfer Points (STPs) and Service Control Points (SCPs) connected to each other by SS7 data links for carrying signalling. All of these components have similar Message Transfer Part (MTP) and Signalling Connection Control Part (SCCP) communications software to enable them to communicate with each other via the SS7 data communications network. A Service Control Point is an “intelligence centre” with specific logic and access to application databases enabling it to deliver various combinations of features, such as 1-800 number service and call redirection. A Signal Transfer Point (STP) is a signalling hub or concentrator, typically connecting several Service Switching Points to an SCP. A Service Switching Point (SSP) is a network node normally associated with a stored program central office switch equipped with Signalling System Number 7 (SS7) messaging links to permit communication with the SCPs and which, in addition to the usual call processing software, has special Service Signalling Function (SSF) software. The SCP has comparable Service Control Function (SCF) software.
[0052] The Service Signalling Functions include (i) Transaction Capabilities Application Part (TCAP) messaging, which SSPs and SCPs use to determine how to process a particular call, and (ii) Integrated Services User Part and Capability (ISDNUP) messaging which the SSP switches use to set up a path for a particular call once it has been determined whence the call should be routed.
[0053] The SSP's AIN software includes a plurality of “Point-in-Call triggers” which can be provisioned or set to interrupt call processing momentarily and initiate a TCAP query to the SCP for instructions on how to complete the call processing. Based upon the instructions received in a TCAP message in reply, the originating end office switch seizes a trunk to a neighbouring switch and creates an Initial Address Message which it sends to the neighbouring switch via the SS7 network. The Initial Address Message includes various parameters which will control routing of the call to its destination.
[0054] The SSP is a logical entity. For convenience, the SSPs will be described herein as performing various functions which, in reality, will be performed by the associated physical switch.
[0055] An embodiment of the present invention in which SS7 is used to provide emergency services will now be described with reference to FIG. 2, which illustrates a portion of an “intelligent network” telecommunications system. In FIG. 2, a first subscriber apparatus 30 is connected by subscriber loop 32 to a Service Switching Point 34 which comprises an end office switch. A first Public Service Access Point 36 is connected to SSP 34 by trunks 38 for voice calls. A second Service Switching Point 40 , which comprises a second end office switch, has a second subscriber apparatus 42 connected to it by subscriber loop 46 . For purposes of this description, the subscriber apparatuses 30 and 42 will be assumed to have Calling Party numbers NPA-NX1-XXXX and NPA-NX2-XXXX, respectively. A second Public Service Access Point 44 is connected to SSP 40 by trunks 47 . The two Service Switching Points 34 and 40 are interconnected by trunks 48 . The two Public Service Access points 36 and 44 share a common Automatic Location Identification database (ALI) 50 . A third Public Service Access Point 52 with which is associated a second Automatic Location Identification database 54 is connected by trunks 56 to a third Service Switching Point 58 which is connected to first Service Switching Point 34 by trunks 60 .
[0056] The three Service Switching points 34 , 40 and 58 are connected to a Signal Transfer Point 62 by SS7 messaging links 64 , 66 and 68 , respectively, and the Service Transfer Point 62 is connected to a Service Control Point 70 by SS7 messaging link 72 .
[0057] The Service Control Point 70 has the usual SCF software and databases enabling it to function according to Advanced Intelligent Network (AIN) requirements. The SMS is not shown in FIG. 2 since its functions do not affect this embodiment of the invention. For details of the requirements of network elements of AIN networks, the reader is directed to the various accepted or proposed AIN standards, especially, TR-NWT-001284 AIN 0.1 SSP Generic requirements; TR-NWT-001285 AIN 0.1 SCP interface; GR-1298-CORE AIN 0.2 Generic requirements; and GR-1299-CORE AIN 0.2 SCP interface.
[0058] SCP 70 is dedicated to 9-1-1, for reliability reasons, but supports wire-line and wireless calls as will be described later. It has special 9-1-1 feature software and its database will have networked 9-1-1 entries in its routing table 74 , which is shown separately from the SCP 70 . This special 9-1-1 software will enable the SCP 70 to process 9-1-1 signalling messages only and access the 9-1-1 routing tables. Otherwise, it will be like known SCP software.
[0059] The system of FIG. 2 could route 9-1-1 calls using a variety of Point-In-Call triggers. Examples of 9-1-1 call routing will now be described with reference to FIG. 2 and sample entries for routing table 74 .
[0060] Where the SSP 34 and the associated PSAP 36 are interconnected by trunks, as in FIG. 2, it is appropriate to use the Automatic Flexible Routing (AFR) trigger. It should be noted that, for convenience of illustration, the PSAPs 36 , 44 and 52 are shown connected directly to the respective SSPs 34 , 40 and 58 . In practice, regulations may require each PSAP 36 / 44 to be connected to a tandem office, at least until it has been accepted that embodiments of the present invention render such dedicated tandem switches unnecessary. Hence, each of the Service Switching Points 34 and 40 can be taken as representing the end office 20 and tandem switch 12 of FIG. 1.
[0061] Assuming that the “Automatic Flexible Routing” trigger at SSP 34 has been provisioned, when a caller using subscriber apparatus 30 dials 9-1-1, the end office switch at SSP 34 will first translate the dialled digits in the usual manner and attempt to route the call to PSAP 36 , via one of the trunks 38 . If all trunks 38 are busy, which could happen if there were a catastrophic event, or the trunks 38 are not available to take the call for other reasons, as indicated in FIG. 2, the call will not complete. Consequently, when the switch's route list has been exhausted, and after checking for any code gapping requirements, the Automatic Flexible Routing trigger at the switch of SSP 34 will cause the call-processing software to interrupt call processing and send a Network_Busy TCAP query to the SCP 70 , via SS7 link 64 , Signal Transfer Point 62 and link 72 , to request alternate routing instructions. Among other things, the TCAP query will contain the Calling Party number, i.e. NPA-NX1-XXXX, and the Called Party number, i.e. 9-1-1.
[0062] The SCP 70 will respond with an Analyze_Route response message.
[0063] The SCP 70 will detect the Calling Party number in the received TCAP message, access its 9-1-1 Routing Table (see Table I) to determine that primary PSAP was PSAP 36 , and select the routing number of an alternative PSAP.
TABLE I Wireline N-9-1-1 Routing Table 74 Calling Party # Primary PSAP Alternative PSAP NPA-NX1 PSAP 36 PSAP 44; PSAP 52 NPA-NX2 PSAP 44 PSAP 34; PSAP 52
[0064] As shown in Table I, both PSAP 44 and PSAP 52 are available. The SCP 70 will select one of them, say PSAP 44 , and return to SSP 34 an Analyze_Route TCAP message with the network address, in this example the routing number NPA-NX2-BBBB of PSAP 44 in the Called Party field. optionally, it might also include a route index. Upon receipt of this Routing Number, the switch at SSP 34 will resume call processing and use ISDNUP messaging to route the call to PSAP 44 by way of trunks 48 , and SSP 40 will complete the call via trunks 47 based upon the 9-1-1 digits in the Original Called Party field of the ISUP messages. PSAP 44 will access Automatic Location Identification database ALI 50 to determine customer information, such as specific medical condition of the caller, i.e. owner of station apparatus 30 .
[0065] It should be appreciated that this system is quite flexible and could accommodate various other trunks being unavailable. For example, if trunks 47 between PSAP 44 and SSP 40 were down also, i.e. both PSAP 36 and PSAP 44 were inaccessible, the SCP 70 would route the call to PSAP 52 via SSP 58 . Thus, if the SCP 70 had received a Network Busy query because PSAP 44 were unavailable, within a recent time period, it would mark its routing table accordingly.
[0066] If, for some reason, the SCP 70 was unaware that the trunks 47 to PSAP 44 also were unavailable, and gave SSP 34 the routing number for PSAP 44 as an alternative, SSP 34 would route the call via trunks 48 to SSP 40 . SSP 40 would try to complete the call via trunks 47 and itself encounter an AFR trigger when it could not complete. Consequently, SSP 40 would send a Network_Busy TCAP query to SCP 70 . Upon receipt of this second query, the SCP 70 would access its routing table 74 for an alternative route to PSAP 40 . The SCP 70 would “know” that PSAP 36 was temporarily unavailable.
[0067] Consequently, in the Analyzed_Route TCAP message it returned to SSP 40 , SCP 70 would give the routing number for PSAP 52 and route the call to PSAP 52 via SSP 58 . FIG. 2 does not show a direct trunk between SSP 40 and SSP 58 , so SSP 40 would have to route the call to SSP 52 via trunks 48 , SSP 34 , trunks 60 and SSP 58 . This would entail loop-back in the trunks 48 , but this could be tolerated in these circumstances. In a practical system, of course, there would probably be a direct trunk from SSP 40 to SSP 58 .
[0068] Provision may be made for limiting the alternate PSAP selection according to time-of-day, or other conditions, simply by including in the Routing Table 74 additional entries as shown, for example, in Table II.
TABLE II PSAP selection by Time-of-Day Time of Day between 12:00 am and 6:00 am Calling Party # Primary PSAP Alternative PSAP NPA-NX1 PSAP 36 PSAP 52; PSAP_OutOfArea NPA-NX2 PSAP 44 PSAP 52; PSAP_OutOfArea
[0069] In this case, for example, only PSAP 52 is fully staffed between 12:00 midnight and 6:00 am.
[0070] Upon receipt of a 9-1-1 call query, the Service Control Point 70 would check the time of day and, if it were between midnight and 6.00 am, route the 9-1-1 call to PSAP 52 . To determine the caller's particulars, PSAP 52 would access its own ALI database 54 which will include similar information to that in ALI database 50 . In this case, there are no other active PSAP's in the area served. Consequently, in the event that PSAP 52 could not handle the call, for example because all of trunks 56 were busy, or ALI 54 inaccessible, the SCP 70 would route the 9-1-1 call to a PSAP in another area, i.e. the SCP 70 would obtain from the routing table 74 a routing number for the OutOfArea PSAP and return it to the originating SSP 34 . In the event that the OutofArea PSAP did not have access to an ALI database with information for the caller, the operator could seek the necessary information from the caller.
[0071] It will be appreciated that routing to a PSAP in a different area could be an option in the unlikely event that a major catastrophe rendered all three PSAP's unavailable simultaneously.
[0072] Whereas, in the embodiment of FIG. 2, each SSP has a direct connection to a PSAP and only uses the SS7 system when it fails to complete the 9-1-1 call directly, it is envisaged that, eventually, the majority of SSP's will access a PSAP via the network. There will not necessarily be a dedicated tandem switch for 9-1-1 calls. It is also envisaged that, as Local Number Portability and other such services are introduced, it will be preferable for every call to be routed only after a query to the SCP for a routing number. In such a situation, instead of using the Automatic Flexible Routing trigger after a normal completion attempt, a “three-digit” trigger responsive to dialled digits could be used to initiate a TCAP query on every call, including 9-1-1 calls. In North America, such a trigger is already used for other three digit numbers, such as 4-1-1 to select directory enquiries.
[0073] An example of such triggering on every call will be described with reference to FIG. 3 which shows a portion of the network similar to that of FIG. 2 but modified so that there is only one Public Service Access Point 44 , with an associated Automatic Location Identification database 50 , connected as before to SSP 40 . In addition to the SSPs 34 , 40 and 58 , there is a fourth SSP 76 connected by trunks 78 and 80 to SSPs 58 and 40 , respectively, and by SS7 link 82 to STP 62 . In addition, an emergency services location 84 (for Fire and Medical services) is shown connected to SSP 40 by trunks 86 , for voice calls, and to PSAP 44 by a data link 89 of the usual data network which interconnects PSAPs, ALIs and emergency services locations. The emergency services location 84 could also be connected by trunks 88 (shown in broken lines) to SSP 76 , in which case the SSP 40 could route calls to it via SSP 76 .
[0074] The call processing software at each of the SSPs 34 , 40 , 58 and 76 has a three-digit trigger set to trigger on receipt of the dialled digits 9-1-1. Hence, when a calling party at station 30 at SSP 34 dials 9-1-1, SSP 34 will immediately query the SCP 70 by sending it an Info_Analyzed TCAP query containing the dialled digits as the Called Party number and NPA-NX1-XXXX as the Calling Party number. The SCP 70 will access its 9-1-1 routing database, which will be similar to that shown in Tables I and II and determine the Routing Number of PSAP 44 and return it to SSP 34 in an Analyze_Route TCAP response. On receipt of the response, SSP 34 will route the call via SSP 40 to PSAP 44 . As before, when PSAP 44 receives the call, it will automatically access its ALI database 50 to determine the customer's particulars, preferably using Automatic Number Identification, as before. once the location has been identified, the PSAP operator will route the call to the emergency services location 84 . Of course, if PSAP 44 is not available, SCP 70 may provide routing to an alternative, which may be out of area, as before.
[0075] It should be appreciated that both AFR Point-in-Call triggers and three-digit 9-1-1 Point-in-Call triggers could be used together. For example, the originating SSP end office could trigger on the 9-1-1 digits and route the call to the appropriate PSAP. In the event that, at some point, the trunks were not available, an AFR trigger could initiate a TCAP query for an alternative route to complete the call to the designated PSAP or, if that were not possible, to complete the call to an alternative PSAP as described with reference to FIG. 2.
[0076] It is also envisaged that an 0_Disconnect trigger could be provisioned (as defined in AIN 0.2) so as to initiate a query for an alternate route, or an alternate PSAP, if an active emergency services call were interrupted, for example, by a loss of connection.
[0077] It should also be appreciated that, if SSP 40 were an end office with a dedicated 9-1-1 tandem switch, as in FIG. 1, the SSP 34 and office could use an AFR trigger to obtain an alternative PSAP if the trunks between the end office and tandem switch of SSP 40 were “down”.
[0078] It should be appreciated that the above-described embodiments of the invention are not limited to the use of the AFR triggers for initiating queries to the SCP 70 . It would be possible to use instead the Termination Attempt Trigger (TAT) which is line specific.
[0079] It is envisaged that, eventually, the SSPs might use “three digit” Point-In-Call triggering on the dialled digits 9-1-1 without first attempting to complete the call normally. At present, however, it is not thought to be feasible to trigger on every 9-1-1 call, i.e. without first attempting to complete the call, but rather to attempt completion and issue a query only when the initial attempt fails.
[0080] In any of the above-described embodiments, station apparatus dedicated for use in emergencies could be accommodated. For such apparatus, an originating Call Point-in-Call trigger could be used so that, as soon as the dedicated station apparatus went “off hook”, the associated SSP would generate a TCAP query for routing instructions.
[0081] An advantage of the present invention is that it can also provide automatic location identification for 9-1-1 calls from mobile stations, i.e. cellular telephone users.
[0082] At present, call routing in the conventional mobile system is distinct from that in the conventional wire-line system. The existing North American mobile telecommunications network already has SS7 communication capability using IS41 messages, which are somewhat similar to TCAP messages in AIN networks. Elsewhere, Global System for Mobile Communications (GSM) messages are used instead. As illustrated in broken lines in FIG. 1, in a conventional North American network, calls to and from a mobile user 90 are relayed via transceivers in intervening cell sites to a base transceiver station (BTS) 96 connected to a mobile services switching centre (MSC) 98 by way of a base station controller (BSC) 100 . A database 102 containing a Visitor Location register (VLR) is associated with MSC 98 . The MSC will also have access to a Home Location Register (HLR) which, for convenience, is shown as part of the same database 102 . In practice, each MSC will have a local VLR but will access a remote HLR. The HLR stores permanent data on subscribers who purchased a subscription from the operator to whom the HLR belongs. The VLR is a temporary register for visiting users. When a mobile station from another area enters the area covered by MSC 98 , the MSC 98 will request data about the visiting mobile station from its home HLR via the signalling system. The HLR/VLR database 102 could be located at the MSC 98 . Alternatively, as shown in FIG. 1, the MSC 98 could communicate with a remote HLR/VLR database 102 by way of a SS7 link 104 . (It should be noted that, in conventional wireline switching systems, the routing tables are at the switches whereas, in mobile networks, the routing tables are at the HLR. Hence, the mobile switching centre MSC 98 must generate a TCAP query for every call.)
[0083] In practice, there would probably be several switches, whether SSPs or conventional switches, connected to the mobile switching centre MSC 98 by trunks. A normal call would be routed via any one of those according to what the HLR/VLR database 102 determined to be appropriate having accessed its routing tables. However, all 9-1-1 calls received by MSC 98 from mobile users would be sent to end office 20 for completion to the associated PSAP 10 via tandem switch 12 . There would be no possibility of the HLR/VLR database 102 providing a routing number to route the 9-1-1 call elsewhere. Consequently, the conventional mobile network is inflexible and unreliable because an outage of the trunks between end office 20 and PSAP 10 , or between the MSC 98 and the end office 20 , will result in there being no 9-1-1 service capability for mobile users accessing the network via MSC 98 . Moreover, for 9-1-1 calls from mobile users, automatic location identification is not available; the operator must ask the caller for the necessary information as to his/her geographical location.
[0084] An embodiment of the present invention which provides flexible or alternate routing of 9-1-1 calls from a mobile user, and, in some cases, automatic location identification, will now be described with reference to FIG. 4. The portion of the “intelligent network” shown in FIG. 4 comprises some wireline components similar to those of FIG. 2, namely two Service Switching Points SSP 34 and SSP 40 interconnected by trunks 48 ; Public Service Access Points 36 and 44 connected by trunks 32 and 47 to SSP 34 and SSP 40 , respectively; station apparatuses 30 and 42 connected to SSP 34 and SSP 40 , respectively; and a Service Control Point 70 . An STP 62 ′ is shown connecting SSP 40 to the SMP 106 by way of SS7 links 66 ′ and 66 ″.
[0085] In addition, the network portion of FIG. 4 includes some wireless elements similar to those shown in FIG. 1, namely a mobile user 90 communicating with a MSC 98 via transceivers in cell sites CS 1 and CS 2 , a base transceiver station 96 and a base station controller 100 .
[0086] A significant difference is that the STP 62 of the network of FIG. 2 is replaced by a Signal Mediation Point (SMP) 106 which is connected to SSP 34 , SSP 40 , MSC 98 , SCP 70 and HLR 102 by SS7 links 64 , 66 , 108 , 110 and 112 , respectively. Generally, the SMP 106 comprises similar software and data to those of an SCP. It differs, however, in that it also has software and data for converting from wireline parameters to wireless parameters, and vice versa. Hence, as will be described in more detail later, the SMP 106 can function as a STP but can also modify the message content, which a STP cannot normally do.
[0087] The Routing Table 114 accessed by the SCP 70 includes mobile information in addition to the entries of Routing Table 74 of FIG. 2. For example, as shown in Table III, the additional mobile information includes an entry for the Calling Party Number of the mobile user 90 , namely NPA-NX4-XXXX; the MSCID for MSC 98 ; cell site identifiers for cell sites CS 1 and CS 2 and, for each cell site identifier, Primary and Alternate PSAP routing numbers. Conveniently, the cell site identifiers are linked to the corresponding PSAP locations on a geographical basis.
TABLE III Mobile N-911 Routing Table Mobile-Calling Cell Primary Party Number MSCID Site PSAP Alternate PSAP NPA-NX4-XXXX NPA-NX3 XXX1 PSAP-1 PSAP-2, PSAP-3 NPA-NX3 XXX2 PSAP-2 PSAP-1, PSAP-3 Time of Day From 12 am to 6 am NPA-NX4-XXXX NPA-NX3 XXX1 PSAP-1 PSAP_OutofArea NPA-NX3 XXX2 PSAP-3 PSAP_OutofArea
[0088] The SMP 106 will have similar data to that in columns 1-3 of Table II enabling it to determine the cell site identifier from the cell site number in the incoming query from the MSC 98 .
[0089] Also shown in FIG. 4 is a Service Management System (SMS) 116 which provides for provisioning and updating of customer data in the databases at the SCP 70 , the SMP 106 and the ALI 50 by way of X.25 links 118 , 120 and 122 , respectively, enabling it to synchronize the data in them. The SMS 116 is a known element of intelligent networks and its normal functions are defined in the various standards, such as AIN 0.1. In FIG. 4, the various trunks between the SSPs are not shown. Only the trunks between MSC 98 and SSP 34 , and between SSP 34 and SSP 40 are shown, together with the SS7 links.
[0090] The MSC 98 has ISDNUP capability enabling it to exchange ISDNUP messages with the wireline service switching points SSP 34 and SSP 40 to set up the trunks for the call.
[0091] The MSC 98 communicates with the HLR 102 by way of the SMP 106 , rather than direct. For a normal call, the MSC 98 will use IS 41 messages to communicate with the HLR 102 by way of the SMP 106 to obtain the necessary routing number or route index and then will route the call via the appropriate trunk group. Although the MSC 98 is shown with trunks to SSP 34 only, in practice it would be connected to other SSPs also. It is no longer limited to routing all 9-1-1 calls to the one SSP 34 , however, but could route a 9-1-1 call to a PSAP elsewhere in the network.
[0092] When the mobile station user first switches on the cellular telephone of mobile station 90 , it will automatically transmit a message identifying itself. When the MSC 98 receives this message, it will incorporate the mobile station's ID into an IS41 message and send it to the HLR 102 , via the SMP 106 , to effect registration. The HLR 102 will check the identification against its database (not shown) to ensure that it is valid. When, subsequently, the mobile user 90 makes or receives a normal call, the MSC 98 will exchange IS41 messages with the HLR 102 , via the SMP 106 , to set up the call.
[0093] If a mobile user enters the area, a temporary registration process will be effected using the VLR register of database 102 , in known manner.
[0094] For normal calls from mobile user 90 , including initial registration calls, the SMP 106 acts like a STP, i.e. it is virtually transparent and simply does whatever correlation is necessary to route the message from the MSC 98 to the HLR 102 , or vice versa. It does not change the content of the message.
[0095] For a 9-1-1 call from mobile user 90 , however, the process is different. The Signalling Mediation Point 106 intercepts the query sent from the MSC 98 to the HLR/VLR database 102 and redirects it to the SCP 70 instead. At least at present, the SCP 70 will not be able to “understand” IS41 queries, so the SMP 106 translates the query to AIN or IN format, whichever is required by SCP 70 . The SCP 70 accesses its routing table 114 , obtains the routing number of the appropriate PSAP, 36 or 44 , and returns a response to the MSC 98 via the SMP 70 . The SMP 106 translates the response from the SCP 70 from AIN/IN format to IS41 format before conveying it to the MSC 98 .
[0096] The various software components of the SMP 106 which are involved in this transaction are depicted in FIG. 5 and typical call flow through the SMP 106 in FIG. 6. Thus, as shown, the SMP 106 contains Message Transfer Part (MTP) and Signalling Connection Control Part (SCCP) modules and Originating Point Code/Destination Point Code (OPC/DPC) tables which allow it to function like a STP, i.e. detect information in the Service Information Octet (SIO) and route TCAP messages accordingly.
[0097] The SMP 106 also has components normally found in a Service Control Point, namely a TCAP APPLICATIONS module, a component layer with four TCAP domain modules namely IS-41 Mobile Applications Part Module (ISM MAP), a GSM MAP, and AIN and IN domains, and CUSTOMER DATA. The SMP 106 also has a SMS software module for interfacing with the SMS 116 to allow updates, etc. Operation of these components is according to the established standards and so will not be described herein.
[0098] In addition, the SMP 106 has CONVERSION software for converting between IS41/GSM protocol parameters and AIN/IN protocol parameters, as will be described in more detail later.
[0099] It should be noted that FIG. 5 is a conceptual illustration. In practice, functions of the various modules will overlap. The MTP module of SMP 106 may handle messages from SSP switches directly, as indicated at 120 in FIG. 5, or indirectly, in the latter case via a STP, as indicated at 122 .
[0100] As illustrated by broken line path 124 in FIG. 6, “normal” Message Signal Units (MSU), including FISU, LSSU and SNM messages from SSPs 34 and 40 or the MSC 98 simply traverse the physical layer L 1 and link layer L 2 of the MTP and are redirected, in known manner, using the Origin Point Code and Destination Point Code (OPC/DPC) tables and the SIO, back out again to their appropriate destinations.
[0101] If a TCAP message for a normal call is received, it will follow the path shown by chain link line 126 and be screened by the higher layers. The CONVERSION software will not detect the digits 9-1-1 and so will not do any translation.
[0102] If the message is an IS41 or GSM RouteRequest message for a mobile 9-1-1 call, and hence has these digits in the dialled digits field, it will follow path 125 and be routed as before to the CONVERSION SOFTWARE module, but in this case the CONVERSION software will detect the 9-1-1 dialled digits and translate the parameters into AIN or IN parameters.
[0103] The CONVERSION software will pass the converted parameters to the appropriate AIN/IN component layer module which will include them in an Info_Analyzed message including the destination Point Code of the appropriate SCP 70 . The Info_Analyzed message will be processed through the MTP layers and routed to the SCP 70 , which will process it in the usual way. When the SCP 70 issues an Analyze_Route message in reply, the SMP 106 will process it in the reverse order to provide a corresponding IS41 RouteRequest response message.
[0104] Table IV shows the mapping between IS41 or GSM messages and AIN 0.1 messages and between parameters in those messages.
TABLE IV IS-41 GSM AIN 0.1 Message: Route Request Provide Info_Analyzed/ Roaming Number Analyze_Route Parameters: MIN MSISDN Calling Party Number (of Mobile 90) Routing Number Roaming Number Destination Number (10 digits) Original Calling Number: NPA-NXX-XXXX MSCID IMSI NPA-NXX Cell Site # Cell Site # XXXX Dialled Digits Dialled Digits Dialled Digits
[0105] For the specific example of FIG. 4, the Original Calling Number will comprise the NPA-NX3 of the MSC 98 and the four digit identifier XXX2 of cell site CS 2 .
[0106] The IS41 parameter MIN is a mobile identification number assigned to, and permanently recorded in, the cellular telephone set 90 . In North America, it comprises a ten digit number in North American dialling plan format. However, elsewhere it could be in a different format, and even comprise from 7 to 20 digits, depending upon the service provider. Such a number could not be recognized by SCP 70 , in which case the SMP 106 's conversion software would convert the MIN into a Calling Party number in the form NPA-NXX-XXXX used in AIN 0.1.
[0107] If an SSP receives a call for a mobile user, such as mobile user 90 , the NPA-NX4 number, it will route the call automatically to MSC 98 .
[0108] The MSC 98 itself will have a first network address MSCID assigned to it within the mobile network and used for communication with the HLR. Within the wireline network, however, it has a second network address NPA-NXX assigned to it. The SMP 106 will convert from either to the other.
[0109] The Original Calling Number must have 10 digits. It includes the NPA-NXX of the MSC 98 as its first six digits. The last four digits are the cell site identifier XXXX.
[0110] The destination number of the selected PSAP will be included in the AIN/IN response message from the SCP 70 and will be converted into the IS-41 Routing Number used by the mobile switch MSC 98 as the address to which the call is to be routed.
[0111] Thus, assuming that mobile station 90 (FIG. 4) makes a 9-1-1 call and is using IS-41, the corresponding message sent to the SMP 106 by the MSC 98 , and addressed to the HLR/VLR 102 , will comprise a RouteRequest query including a “toggle” flag set to indicate that it is a query rather than a response. (If the GSM protocol is used, the message will be a Provide Roaming Number message with a flag to determine whether it is a query or a response.) The Route Request message will include the MIN of the mobile user 90 , the digits 9-1-1 as the Dialled Digits, the MSCID for MSC 98 , and the complete Cell Site number, i.e. identifying the sector within cell CS 2 within which the 9-1-1 call originated (the latter as determined by the base transceiver station).
[0112] On receipt of the IS 41 message, the SMP 106 will detect that the dialled digits comprise the digits 9-1-1. Consequently, the conversion software of SMP 106 will convert the parameters of the IS41 message according to Table IV and include them in an Info Analyzed message. It will also supply to the SCCP the destination point code of SCP 70 which the SCCP/MTP layers will use to route the Info_Analyzed message to the SCP 70 . The SCP 70 will access its routing table 114 using the Original Calling Number which comprises the address NPA-NX3 of mobile switch 98 and the four digit cell site number XXX2 identifying the origin of the call within cell site CS 2 to determine the primary PSAP for that particular cell site, in this case PSAP 44 because it is closest. Once again, the SCP 70 will have alternative PSAPs available as shown in Table III and will make the determination as described previously.
[0113] The SCP 70 will then select the routing number for the selected PSAP 44 , include it as the Called Party number in a TCAP Analyze_Route message and send the message to the SMP 106 . It will leave the Calling Party number, mobile switch NPA-NX4 and Original Calling Number fields unchanged. Upon receipt of this TCAP Analyze_Route message, the SMP 106 's TCAP APPLICATIONS layer will correlate the response with the query using the Transaction I.D. in known manner. The SMP 106 will convert the parameters back into IS41 format according to Table IV and include them in an IS41 message which it will return to mobile switch MSC 98 . The MSC 98 will use the new Routing Number to route the call to the SSP 40 which serves as an end office for the PSAP 44 . The SSP 40 will detect the Routing Number in the Called Party number field and complete the call to the PSAP 44 . Of course, the SSP 40 could be a combination of an end office and a tandem office, such as those already in existence and described with reference to FIG. 1.
[0114] It should be noted that, in AIN, the Routing Number could e placed in either the Destination Number or the Called Party umber field and the terminating SSP could complete the call.
[0115] It should be appreciated that the MSCID/cell site information in the original calling Number could be used for Automatic Location Identification by the PSAP. The ALI 50 would then be provided with software and data to identify a geographical location of a cell site from this MSCID/cell site information. Because the SCP 70 selects the appropriate PSAP based upon the cell site number from which the call originated, the mobile user might no longer be at the location where emergency services were needed. It would be the responsibility of the PSAP operator to interview the caller and determine whether or not the caller was still at the site of the emergency when the 9-1-1 call was placed.
[0116] It should be appreciated that the SMP, with its capability for converting between wireline and wireless protocols, is not limited to translation of 9-1-1 calls but could be used for providing other AIN/IN services to mobile users.
[0117] It should be appreciated that although only conversion from IS41 to AIN has been described in the specific example, a person skilled in this art would be able to effect conversion from GSM to AIN or IN, or from IS41 to IN, in an analogous manner and without undue experimentation.
[0118] Although the foregoing description of a preferred embodiment relates to a so-called “intelligent network”, it should be appreciated that a skilled person would be able to implement the invention in other systems which use out-of-band signalling.
[0119] Although embodiments of the invention have been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and not to be taken by way of the limitation, the spirit and scope of the present invention being limited only by the appended claims.
|
Emergency services calls may be alternate-routed in an intelligent network having at least one Service Control Point (SP) with access to a routing table, a plurality of Service Switching Points (SSP) equipped with point-in-call triggers and one or more emergency services stations (PSAP) The routing table lists a routing number for each of the emergency services stations. The method comprising the steps of:
(i) at a Service Switching Point, presetting a point—in-call trigger to operate at a predetermined point in a call for emergency services,
(ii) subsequently, during processing of an emergency services call, interrupting processing of the call and transmitting to the SCP a query signalling message requesting routing information,
(iii) at the SCP, accessing the routing table in dependence upon parameters in the query signalling message and obtaining a routing number for a selected emergency services operator station, forming a response signalling message including the routing number and returning such response signalling message to the SSP,
(iv) at the SSP, detecting the routing number, and routing the call to the emergency services operator station. There is also provided a method of translating signalling message parameters from a mobile protocol to an intelligent network protocol, and vice versa, to enable emergency services calls from mobile users to be routed to one or more PSAPs in the network.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/844,765, filed on May 13, 2004.
BACKGROUND
[0002] This invention relates generally to packaging integrated circuits.
[0003] Integrated circuits, such as microprocessors, may be packaged in various configurations. One such configuration is called a land grid array package. With land grid array packaging, integrated circuit die may be coupled to circuit boards through sockets that electrically and mechanically couple the integrated circuit die to the circuit board. In some cases, the connection may be via socket spring fingers which contact lands on the integrated circuit packages to make a land grid array connection system.
[0004] Often, a number of components may be connected together to form a stack. In one example a voltage regulator module board may be assembled on a motherboard through a land grid array connector. The voltage regulator module and motherboard are clamped together between a bolster plate under the motherboard. A heat sink may be positioned on top of the voltage regulator module board. Pairs of standoffs on the bolster plate are used to control the space in between the bolster plate and the heat sink.
[0005] Due to the dimensional tolerances of the mechanical parts, the distance between the bolster plate and the heat sink varies on individual assembly. Part of this stack tolerance can be absorbed by the flexibility of the land grid array springs. However, the bending range of land grid array springs is limited and cannot absorb the entire stack tolerance.
[0006] In the meantime, a certain level of pressure is required to press the land grid array onto the land pads on the motherboard to meet the requirement of good electrical design.
[0007] Thus, there is a need for better ways to connect integrated circuits to boards in the form of stacks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an enlarged, cross-sectional view through one embodiment of the present invention;
[0009] FIG. 2 is a cross-sectional view taken generally along the line 2 - 2 in FIG. 1 ;
[0010] FIG. 3 is a perspective view of a spring plate in accordance with one embodiment of the present invention;
[0011] FIG. 4 is a perspective view of a spring plate in accordance with another embodiment of the present invention; and
[0012] FIG. 5 is a system schematic according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , a land grid array package stack 10 may include a voltage regulator module heat sink 12 mounted on a voltage regulator module board 14 . Under the board 14 may be a voltage regulator module socket or connector 16 . The connector 16 may be positioned over a motherboard 18 which, in turn, is positioned over an insulator 20 in one embodiment. The board 14 , connector 16 , board 18 , and insulator 20 may be mounted on a set of standoffs 30 which allow relative vertical movement of the stack 10 while controlling the side to side or lateral movement thereof. A screw 50 , in turn, is connected through the standoffs 30 to a bolster plate 22 on the bottom of the stack 10 to hold the stack 10 together. Between the bolster plate 22 and the board 18 is positioned a spring plate 24 .
[0014] In some embodiments, the spring plate 24 provides the required pressing load on the back of the board 18 and thereafter on the land grid array connector 16 , while absorbing the stack tolerance. As mentioned above, due to the dimensional tolerance of the mechanical parts, the distance between the bolster plate 22 and the heat sink 12 may vary on individual assembly. While part of this tolerance can be absorbed by the flexibility of the land grid array connector springs, the entire tolerance cannot be so absorbed. Thus, the spring plate 24 may function to absorb that tolerance. In some embodiments, the spring plate can supply a recovery force while reducing or even minimizing the tilting or uneven contact of the land grid array connector 16 on the board 18 .
[0015] To this end, the spring plate 24 may include two or more pairs of independent spring legs 32 as shown in FIG. 2 . The spring plate 24 may be formed of stamped metal in one embodiment of the present invention. For example, the spring plate 24 may be made of BeCu alloy which has a lower Young's modulus and a higher yield strength than steel.
[0016] A set of four spring legs 32 may be positioned on the center bar 34 of the spring plate 24 in one embodiment. The spring legs 32 may be partially cut out of the rest of the plate 24 and may be bent upwardly, towards the board 18 , as the spring legs extend away from the center bar 34 . The free ends 40 of the spring legs 32 may be bent over to prevent gouging of the mating surfaces. The span in the spring legs 32 may be less than half of the plate 24 width in some embodiments.
[0017] Clips 26 and 28 may be provided to ease assembly. For example, in one embodiment, the clips 28 extend downwardly from one half of the plate 24 while the clips 26 extend upwardly from the other half of the plate 24 , as shown in FIG. 3 . In other words, the clips 26 may engage the sides of the board 18 while the clips 28 engage the sides of the bolster plate 22 in one embodiment. The center bar 34 may include U-shaped openings 42 to receive the standoffs 30 in one embodiment of the present invention.
[0018] In some embodiments of the present invention, the spring plate 24 provides a low profile spring to absorb the stack tolerance while maintaining the desired pressure force in a limited space.
[0019] The spring legs 32 may be made by cutting and forming sheet metal in one embodiment of the present invention. For example, stamping may be utilized for this purpose.
[0020] The free ends 40 of the spring legs 32 are closer to the edges of the plate 24 , while the lower ends sit closer to the plate center bar 34 . The free ends 40 contact the object being supported. Larger spacing may be achieved between the free ends 40 due to this configuration which can supply a recovery force to reduce or minimize the tilting of the connector 16 relative to the board 18 .
[0021] The height of the free ends 40 depends on the application and may be minimized to maintain a low profile in some embodiments. The free state height can be no larger than 10 percent of the plate 24 width in one embodiment of the present invention. The preload height can be less than one millimeter in one embodiment of the present invention. The use of the rounded free ends 40 may avoid any concentrated contact and scratching of other components in some embodiments.
[0022] The spring plate 24 uses a closed design as shown in FIG. 3 with turned free ends 40 . The arms 32 may be straight as shown in FIG. 3 . The plate 24 may provide better structural integrity in some embodiments.
[0023] Alternatively, an opened design may be utilized in the plate 24 a as shown in FIG. 4 . In the opened design, there are no turned over free ends 40 . In addition, the arms 32 may be curved. The opened design may provide for more flexibility in some embodiments.
[0024] In one embodiment of the present invention, the length of each spring leg 32 may be 16 millimeters and the span of the spring leg may be 4 millimeters. The free state height of the raised end 40 may be 1.5 millimeters with a plate thickness of 0.4 millimeters in such an embodiment. Such a structure can absorb a working stack tolerance range of about 0.6 millimeters, while maintaining the total pressing force at greater than 40 pounds.
[0025] Referring to FIG. 5 , in accordance with one embodiment of the present invention, a system 50 may be implemented by a motherboard 18 and a voltage regulator module board 14 . The motherboard 18 may include a processor 52 , a system memory 56 , and a bus 54 . The connector 16 couples the voltage regulator module 58 to the bus 54 . While FIG. 5 shows one system implementation of the present invention, those skilled in the art will appreciate that the present invention is in no way limited to any particular system implementation.
[0026] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
|
A spring plate may be provided between a bolster plate and a board in order to mount components on the opposite side of the board. In some embodiments, the spring plate may provide additional stack tolerance and forceful bias to hold the stack tightly together.
| 7
|
BACKGROUND OF THE INVENTION
Practice devices, both mechanical and electrical for baseball pitchers, are known in the prior art. Some such devices are primarily for amusement purposes while others seek to enhance the skill of the pitcher. No known prior art pitching practice apparatus is structured with the degree of sophistication and precision necessary to enable an experienced baseball pitcher, such as a professional, to improve his pitching skill by the use of the practice apparatus. Accordingly, it is the objective of the present invention to satisfy this need for a practice apparatus whose precision operation can and will significantly improve the pitching skill of the user of the apparatus, regardless of the skill level of the user, whether beginner, experienced amateur or professional.
In accomplishing the above objective, the apparatus in its essence provides a frontal mechanical target which precisely depicts the baseball strike zone in width and height. Behind this target is an electro-optical sensing means which senses the location of a pitched ball passing through it both horizontally and vertically with reference to the strike zone. Electrically coupled with the electro-optical sensing means, such as an orthogonal axis photoelectric system, is a visual display which depicts with precision the location and the path of movement of the pitched ball in the strike zone, with reference to home plate in both the horizontal and vertical planes. The display, which is appropriately embodied in a computer terminal, also provides a permanent visual record of each pitch with reference to the strike zone and home plate through a conventional computer terminal printer.
The apparatus also includes a conventional speed gun and speed display terminal by means of which the speed of each pitch is accurately monitored and visually displayed. Optionally, a closed circuit television system is included in the apparatus comprising a video camera aimed at the pitcher and an associated video recorder which can be electrically coupled to a computer display terminal. Through this means, a video record of the pitcher's throwing motion and technique on the pitching mound is produced and can be displayed, whereby the pitcher can discover his mistakes in form and delivery and seek to improve them.
The apparatus additionally includes a convenient foot-operated reset switch near the pitcher's mound for the purpose of returning the electronic components to a blank or cleared state after each pitch of the ball.
Other features and advantages of the invention will become apparent to those skilled in the art during the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a baseball pitching practice apparatus according to the invention in its entirety.
FIG. 2 is an enlarged perspective view of the apparatus minus the display and recording components.
FIG. 3 is a front elevation of the apparatus as shown in FIG. 2.
FIG. 4 is a side elevation of the apparatus.
FIG. 5 is a plan view thereof.
FIG. 6 is an exploded perspective view of mechanical target components.
FIG. 7 is a perspective view of a ball return trough support detail.
FIG. 8 is a fragmentary perspective view of a ball rebound panel and its support system.
FIG. 9 is a fragmentary perspective view of a back stop support detail.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, FIG. 1 depicts a baseball pitching apparatus according to the invention in its entirety, and with its components assembled for use.
FIG. 2 shows the apparatus without the visual display portion 20 in FIG. 1 and without an optional closed circuit television system 21 also present in FIG. 1. The components 20 and 21 will be further described.
The apparatus in FIGS. 2 through 9 comprises a frontal mechanical pitching target 22 consisting of two opposing groups of thin horizontal resilient equal length strips 23 lying in a common vertical plane and being spaced apart vertically equidistantly in each group, with their interior ends arranged in slightly spaced relationship at the transverse center of the apparatus. Preferably, the mechanical target strips 23 are formed of plastics material, such as polycarbonate or an equivalent material.
The interior end portions of the mechanical target strips 23 are colored white or blaze orange to delineate a rectangular target area 24 corresponding to the strike zone. The baseball strike zone, as is well known, measures 17-1/2" across home plate and is a variable dimension vertically corresponding to the distance between the arm pits and the tops of the knees of batters.
The pitching target 22 is supported at the front of the apparatus by an upright rectangular tubing frame 25 including spaced vertical frame bars 26. A target support tube 27 is adjustably mounted on each vertical bar 26 and has secured thereto and extending laterally outwardly therefrom a metal plate 28 having plural strips 29 of VELCRO or equivalent fastener means thereon. Immediately adjacent the forward sides of plates 28 are protective cushion pads 30 of foam rubber or the like secured to plywood backing plates 31 having VELCRO strips 32 on their rear faces to mate with the strips 29 for securing the pads 30 to the opposite sides of the mechanical target 22.
The outer end terminals 33 of target strips 23 lie rearwardly of the plates 28 and have apertures 34 formed therethrough to receive threaded studs 35 on the plates 28, projecting rearwardly thereof. Vertically extending polycarbonate strips 36 behind the end terminals 33 also have apertures 37 which register with the apertures 34 to receive the studs 35 therethrough. The elements 28, 33 and 36 are secured in assembled relationship by nuts 38 and washers 39 received by the studs 35.
Somewhat rearwardly of the mechanical target 22 is a second rectangular vertical tubing frame 40 of greater height and width than the frame 25. The second frame 40 serves to support an electro-optical sensing system 41, such as a vertical and horizontal axis photoelectric system to sense the exact location of the pitched baseball within the strike zone. The system 41 comprises a pair of opposite side invisible light projecting and receiving or sensing units 42 and 43 and a similar pair of top and bottom invisible light projecting and receiving or sensing units 44 and 45. The side and top and bottom electro-optical units are disposed and operate within a common vertical plane defined by the frame 40. It is completely immaterial as to which side of the frame 40 supports the projecting and sensing units, and it is similarly immaterial whether the projecting and sensing units of the system are on the top or bottom of the frame 40. In any case, invisible light beams are directed in a common plane, both horizontally and vertically, by the system 41 rearwardly of the mechanical target 22. Therefore, a baseball passing through the target 22 will interrupt a horizontal and a vertical beam or beams, which interruption establishes precisely the location of the baseball within the strike zone.
The vertical and horizontal electro-optical units of the system 41 are of the same height and width as the strike zone defined by the white or blaze orange mechanical target area. Therefore, a baseball within the strike zone area of the mechanical target 22 will penetrate the strike zone defined by the horizontal and vertical rays of the system 41. Pitched balls which miss the strike zone of target 22 will also miss the strike zone of electro-optical system 41 and will not be sensed by such system.
The side and top and bottom units of the electro-optical unit 41 are supported on the frame 40 by vertical and horizontal support sleeves 46 and 47 which receive the side vertical bars and horizontal top bar of the frame 40. The bottom horizontal unit 45 is similarly supported by a horizontal sleeve 48 which receives a somewhat depressed bottom horizontal bar 49 of the frame 40. Because of the depressed bar 49, the bottom unit 45 of the system 41 does not project above the floor of the apparatus defined by the bottom of a ball return trough 50, to be described.
The tops of frames 25 and 40 are interconnected by a pair of spaced inclined brace bars 51 having secured thereon a fabric guard panel 52 whose purpose is to protect the upper electro-optical unit 44 from being struck by baseballs. The cushion pads 30 are for the protection of the mounting structure shown in FIG. 6 for the mechanical target strips 23. The side units 42 and 43 are spaced apart sufficiently not to be in danger of being damaged by baseballs which are anywhere near the strike zone.
The apparatus further includes means to measure and indicate the speed of the pitched ball, comprising a conventional overhead speed gun 53 supported by an arm 54, attached to the top of frame 25 at its transverse center. A conventional ball speed display terminal 55 operatively connected with the speed gun 53 forms a part of the visual display system 20 previously noted in FIG. 1. The elements 53 and 55 are state-of-the-art equipment.
As a convenience feature for establishing the proper heights of the units 42 and 43 and the mechanical target 22 on the frames 40 and 25, a tape measure 56 is provided on the bottom of the unit 43, FIGS. 4 and 5.
Substantially rearwardly of the frame 40 is a third and smaller rectangular frame 57 which is vertical and parallel to the frames 25 and 40. The bottoms of the forward and rear frames 25 and 57 are rigidly interconnected by two horizontal bottom frame bars 58 which are somewhat forwardly convergent. The arrangement forms a sturdy integrated frame structure for the apparatus.
Held within the rear vertical frame 57 by a system of coil springs 59 is a taut rectangular rebound or ball return panel 60, preferably formed of polypropylene or the like. Surrounding the frame 57 and rebound panel 60 is an enlarged back stop 61 formed of suitable netting. This enlarged back stop spans the top and two sides of the frame 57. It is supported at its top by two diagonal arms 62 removably held in socket elements 63 on the frame 57. At its bottom, the netting back stop 61 is secured to a pair of folding horizontal arms 64, pivotally secured at 65, FIG. 9, to anchors 66, rigidly attached to the frame 57.
The ball return trough 50 formed of canvas or the like has opposite side tubular hems 67 which receive therethrough horizontal longitudinal forwardly convergent support bars 68, whose opposite end portions are supported by rests 69 on the frames 57 and 25 at an elevation above the bottom of the apparatus. The floor 70 of the ball return trough 50 is secured at its rear end by a series of VELCRO loops 71 to a crossbar 72 and is similarly secured to rear diagonal braces 73 of the framework, FIG. 4. The front of the trough 50, FIG. 3, has a tubular hem 74 which receives a support bar 75 held in rests 76 identical to the rests 69 in FIG. 7.
The mechanical construction of the apparatus shown in FIGS. 2 through 9 is quite simple and quite easy to erect and dismantle.
The display portion 20 of the apparatus, FIG. 1, further includes a state-of-the-art computer terminal 77 having a video display screen, on which is depicted the strike zone by a plan view of home plate 78 on one side of the display screen and a side elevation of the strike zone above an edge view of home plate 78 on the other side of the display screen. The computer terminal 77 is operatively coupled by state-of-the-art circuitry with the electro-optical sensing system 41, so that the exact location of each pitched ball within the strike zone, both horizontally and vertically, is depicted on the video screen. The flight path of the ball, whether straight or curved, is also depicted on the screen as shown in FIG. 1.
A permanent record of the location and flight path of each pitched ball is, or can be, made on a print-out sheet 79 of a conventional printer 80 operatively coupled to the computer terminal.
The closed circuit TV system 2l, preferably behind the netting back stop 61 includes a video camera 81 and an associated video recorder 82, both operatively connected with the computer terminal 77. The video system gives the apparatus an added dimension, in that the pitcher P can have his pitching motion monitored and recorded for observation at any desired time on the viewing screen of the computer terminal, as previously discussed. The video system could be omitted from the apparatus for the sake of economy in some cases, in which case the apparatus would still indicate the speed and location of each pitch and make a printed record thereof, as described.
Finally, the apparatus includes a foot-operated reset switch 83 on or near the pitching mound, whereby the pitcher can clear the electronic components of the apparatus after each pitch. All of the electronic components and their interconnecting circuitry are state-of-the-art and need not be further described to enable a full understanding of the invention.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.
|
A pitching practice apparatus includes a frontal mechanical strike zone target at which the pitcher aims the ball and which contains yielding elements enabling the ball to pass rearwardly through a photoelectric sensing plane having sensing beams on two orthogonal axes. Behind the photoelectric sensing arrangement which precisely locates the position of the ball in the strike zone horizontally and vertically is a spring-mounted ball return panel against which the pitched ball impinges and is returned to the pitcher by rebounding from the panel. A ball return trough forming the floor of the apparatus extends between the ball return panel and the frontal strike zone target.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to lancet devices for particular use in skin incision procedures particularly to determine bleeding time elapsed before proper platelet aggregation, and more particularly to disposable devices for actuating the skin incision procedure.
In order to reduce trauma to the patient during skin incision procedures, automated lancet devices have been developed which eliminate the patient's view of both the skin incision and the lancet blade itself. As described, for example, in U.S. Pat. Nos. 4,078,552; 4,628,929; 4,735,203, the lancet blade can be housed within a small device which provides a spring-driven mechanism for thrusting and retracting the blade. While such devices obstruct the patient's view, the linear blade path produces a cleaving action and limited control over the depth of incision, as well as considerable patient discomfort and required healing. U.S. Pat. No. 5,133,730 describes a lancet device in which a drive spring is integrally molded with a living hinge in the molded housing, as well as an integrally molded trigger. The integral spring is arranged to produce a rotary lancet blade motion enabling a cleaner, slicing incision, however, the integral spring and blade retraction structure require complex molding and manufacture of the devices.
These and other disadvantages are eliminated by the lancet actuator mechanism in accordance with the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention, a lancet actuator device and mechanism for sequentially advancing and retracting a lancet blade include a housing having an opening for operating projection of the lancet blade. The actuator mechanism includes a drive spring structure insertably mounted in the housing and arranged to drive pivotal motion of the lancet blade including sequential thrusting of the blade from the housing aperture followed by immediate pivotally reverse retracting of the blade from the aperture into the housing as the spring deengerizes.
In preferred embodiments of the lancet actuator, a torsion spring bears upon and drives both the pivotal thrusting and retracting motion of the blade structure. In particular preferred embodiments, the lancet actuator device is constructed for single use disposibility and assembled with the torsion spring in pre-stressed condition and a manual trigger structure which blocks pivotal motion of the blade structure until the skin penetration operation is initiated. Following a single skin penetration operation, the unwound torsion spring retains the retracted blade within the housing for handling safety in disposal.
A "telltale" indicator of lancet mechanism operation is provided by a formation on the housing which leaves an impression of impact by the blade during its operative rotary motion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the assembled lancet actuator and device in accordance with the present invention;
FIG. 2 is an exploded perspective view of the assembled actuator shown in FIG. 1;
FIG. 3 is an enlarged sectional view along a plane indicated by line 3--3 in FIG. 1;
FIGS. 4-6 are sequential views of the operating positions of the assembled actuator mechanism shown in FIGS. 1-3;
FIG. 7 is an enlarged fragmentary sectional view along a plane indicated by line 7--7 in FIG. 3; and
FIG. 8-11 are internal views of a second embodiment of a lancet actuator in accordance with the present insertion and illustrate sequential operating positions of the actuator mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, an embodiment of a lancet actuator assembly in accordance with the present invention is generally designated by reference character 10. The illustrated embodiment of actuator 10 is designed for single-use disposibility and employs a pre-loaded, sterilized lancet blade, 12, 12 which is integrally formed on a carrier arm 14. The carrier arm 14 is pivotally mounted within the vertically split molded housing 16, by means of a pivot bearing pin 18 which extends through an aperture 20 in the carrier arm 14. The housing portion 16a has an opening slot 22 in the bottom wall 24 through which the pivoting lancet blade 12,12 is driven to project in the skin incision operation as described hereinafter.
In the illustrated embodiment, the pivotal motion of the blade 12 and carrier 14 is driven by a torsion spring generally designated 26 which has an end arm 28 coupled to bear on the carrier arm 14 by insertion through a hole 14a and the opposite end arm 30 is rotatably anchored by insertion through a journal bore 32 in a boss 34 internally projecting from the housing portion 16a as particularly shown in FIGS. 2 and 3. In the illustrated embodiment of the lancet actuator 10, the torsion spring 26 is pre-stressed in the position of configuration shown in FIG. 4 and imposes force urging the carrier 14 downwardly toward the opening slot 22, however in the preoperational position as shown in FIG. 4, the downward biasing force is releasably restrained by a trigger arm generally designated 36 which has a depending and laterally extending foot stop 38 against which the lower nose surface 40 of the blade carriage 14 is releasably abutted and retained.
In operation of the illustrated embodiment of the lancet actuator 10, the "pre-cocked" actuator 10 (FIG. 4) is placed so that the bottom wall 24 engages the target skin (not shown) of the patient. The skin penetration operation is initiated by manually depressing the projecting trigger end 42 of the trigger member 36 which will displace the trigger member 36 to the right from the position shown in FIG. 4 to the position shown in FIG. 5 so that the opposite trigger end 44 impacts and detaches the frangible, breakaway tab 46 integrally formed on the housing portion 16a. Absence of this breakaway tab from the actuator 10 will indicate that the device has been used (perhaps only triggered) and is to be discarded. Primarily, the displacement of the trigger member 36 also moves the foot stop 38 therewith which releases engagement by the carrier surface 40 enabling the biasing force from the spring 26 to downwardly propel and pivot the blade carriage 14 and project the blade 12 through the opening slot 22 to the skin incision extension position of FIG. 5. The rotary motion of the blade 12 produces a slicing skin incision as opposed to a linear cleaving action, and the rotary slicing produces a cleaner incision and healing of the skin as well as improvement in the coagulation timing determination.
Referring again to FIG. 5, thrusting of the blade 12 and maximum extension thereof through the housing wall slot 22 defining precise skin incision depth is controlled by a blade contact stop surface 48 on the interior of the housing bottom wall 24 which receives impact by the carrier nose surface 40 to block further blade thrust. Additionally, the housing bottom wall 24 also has an upwardly projecting rib 50 terminating in an apex 52 which upwardly projects slightly beyond the stop surface 48 and is therefore crushed or blunted from impact by the carrier nose surface 40 prior to impact thereof against the stop surface 48; the crushed apex 52 thereby serves a "telltale" indicator that the actuator 10 has been triggered and the rotary motion of the carrier 14 has previously operated correctly.
From the position in FIG. 5, continued unwinding force of the spring 26 bearing upon the momentarily stopped thrusting of the blade carrier 14 at maximum incision depth also produces a reactionary force indicated by arrow A which maintains a generally clockwise momentum and pivot of the coil portion 27 of the torsion spring 26 which automatically induces a sequentially continuous reversal in the motion of the carrier 14. This motion reversal retracts the blade 12 inwardly withdrawing into the housing from the slot 22 as the continued leftward momentum of the spring coil portion 27 into the position shown in FIG. 6 allows the spring arm 28 to pull on and draw the reverse pivot of the carrier 14 and blade 12 upwardly into the housing portion 16a. Two arcuate guide flanges 54 and 56 internally project from the housing portion 16a and provide inner surface for a stabilized sliding of the spring coil 27 thereagainst on its rotary path during the operational uncoiling in the skin incision operation, as well as preventing any potential twisting of the unwinding coil portion 27.
In the illustrated embodiment of the actuator 10, the blade 12 can only project from the housing slot 22 during a single, deliberately triggered operation, because the entirely enclosed drive mechanism prevents any re-winding of the spring 26, so that after a single skin incision operation, the lancet assembly 10 cannot be re-cocked or reused and will be discarded, effectively preventing any cross-contamination of blood. In addition, following a single operation of the actuator 10, the unwound condition of the spring 26 maintains the internal, pivotally retracted position of the carrier 14 and blade 12 as shown in FIG. 6 in which the terminally residual coiling of coil portion 27 restrains the carrier 14 against a second thrusting of the carrier 14 toward the housing slot 22, and the blade 12 cannot be exposed from the housing which prevents any hazard to handling for disposal of the actuator 10.
Referring now to FIGS. 9-11, a modified embodiment of a lancet actuator assembly 110 in accordance with the invention is illustrated in which the blade carrier 114 has an elongate slot 117 which is only slightly wider than the diameter of one end leg 128 inserted therethrough from a torsion drive spring 126. The opposite spring end (not shown) is fixed to the split housing portion 116. In the pre-cocked assembly 110, the spring end 128 bears on the lower edge of the slot 117 to impose a rotary downward bias force on the blade carrier 114 which can pivot on the housing pivot pin 118 but is initially restrained by abutment of the nose surface 140 against the retainer foot 138 formed on the trigger member 136.
In operation, a frangible safety tab 146 formed on the housing 116 is manually detached to unblock the path of the trigger member 136 which can then be depressed to displace the stop 138 and release the rotary motion of the blade carrier 114 as shown in FIG. 9. Unwinding of the drive spring coil 127 propels the spring end 128 from right to left through the carrier slot 117 and at the same time, the spring end 128 drives the downward rotary motion of the carrier 114 from the position shown in FIG. 9 to the position shown in FIG. 10 in which the blade 112 is thrusted through the lower housing wall slot 122, whereupon the carrier nose surface 140 impacts the housing stop surface 148 to terminate maximum rotary thrust and define the skin incision depth of the blade 112. Continued unwinding of the spring coil portion 127 produces a reversal and upward force of the spring end 128 against the upper edge of the blade carrier slot 117 as the spring end 128 continues travel therethrough, resulting in sequentially continuous reversal in the pivotal motion of the carrier 114 so that it retracts the blade 112 into the housing 116 in withdrawal from the slot 122. Residual unwinding force imposed by the spring coil 127 maintains the blade carrier against a return stop surface 150 internally formed on the housing 116. Since the torsion spring cannot be rewound, the actuator 110 is again designed for single use disposibility. Additionally, an indicator of previous operation, for example, an impact "telltale" similar to that of the first actuator embodiment 10 can be provided (not shown).
While preferred embodiments of the present invention is shown and described, it is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the spirit and scope of the appended claims.
|
A lancet actuator device and mechanism for sequentially advancing and retracting a lancet blade include a housing having an opening for operating projection of the lancet blade. The actuator mechanism includes a drive spring structure insertably mounted in the housing and arranged to drive pivotal motion of the lancet blade including sequential thrusting of the blade from the housing aperture followed by immediate pivotally reverse retracting of the blade from the aperture into the housing as the spring deengerizes.
| 0
|
TECHNICAL FIELD
The present invention relates generally to the field of hang gliding and, more particularly, to a safety device that indicates when a pilot has failed to hook in a flight harness on a hang glider so that the condition may be corrected prior to launch.
BACKGROUND OF THE INVENTION
A hang glider is a lightweight, kite-like glider from which a harnessed pilot hangs while gliding down from a hill or cliff. A hang glider includes a sail that provides lift to the glider and pilot as the glider cuts through the air. The pilot wears a flight harness that is attached to the glider at a single, centralized "hang point". When the flight harness is properly hooked in, the pilot is held suspended beneath the sail with his hands resting on the glider control bar. The pilot manipulates the glider control bar to simply shift his weight relative to the hang point and thereby control the speed and direction of glider movement.
Hang gliding is an exhilirating sport that comes as close as is presently possible to allowing man to soar like a bird in free flight. Those who have experienced the phenomenon are left with a feeling of awe. The senses are simply overwhelmed as the air brushes over your face and plays against the sail of the glider while the ground rushes by below. There is simultaneously experienced both a sense of total peace and excitement. It is these abstract qualities that probably best explain the ever increasing popularity of the sport.
While the number of hang gliding enthusiasts continues to grow, it must not be overlooked that there is a dark side to the sport. Hang gliding is an inherently dangerous activity. There are a number of ways in which a hang glider pilot may be injured or even killed. One of the primary ways is the failure of the pilot to remember to hook in his flight harness on the hang glider prior to launch.
When a pilot fails to properly hook in, the pilot simply cannot hold onto or control the hang glider after launch. The problem is particularly critical where the pilot is launching from a cliff. There is no room for error during such a launch and a failure to properly hook in would likely cause serious injury or even death.
Up to the present point in time, the only way to avoid a failure to properly hook in was for the pilot to deVelop his or her own habit pattern. Typically such a pattern includes a "hang check". The pilot conducts a hang check by attempting to hang under the sail of the glider before lifting the glider from the ground for launch. When properly hooked in, the pilot is suspended with his weight supported by the flight harness attached to the glider at the hang point. If not properly hooked in, the pilot conducting a hang check simply drops to the ground. When this occurs, the pilot is, of course, alerted to the fact that he is not properly hooked in. The pilot can then proceed to hook in his harness prior to launch.
The problem with relying on such a habit pattern is, of course, obvious. There are many distractions that could break the pattern. For example, wind conditions may be fluctuating and thereby divert the pilot's attention. The pilot may also be closely watching other gliders in flight in the launch area and forget not only to properly hook in but also to conduct a hang check to verify this condition.
The risk that a distraction may break the habit pattern is simply not acceptable given the severe consequences of a failure to properly hook in. This is particularly true when it is realized that the problem of failure to hook in is totally preventable. A need, therefore, is identified for an apparatus to improve the safety of hang gliding by eliminating this statistically significant cause of hang gliding accidents.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a simple and inexpensive apparatus for improving the safety of a hang glider.
Another object of the present invention is the provision of a safety apparatus for indicating the failure of a pilot to hook in a flight harness on a hang glider prior to launch.
Yet another object of the present invention is to provide a hang glider safety apparatus that is automatically activated upon erection of the hang glider so as to eliminate the need to remember to actuate the safety system.
Still another object of the present invention is the provision of a safety apparatus for a hang glider that is both lightweight and compact and may be retrofitted to existing hang gliders to improve their safety without adversely affecting their handling.
Still another object of the present invention is the provision of a hang glider safety apparatus that sounds an alarm when the flight harness is not hooked in as the pilot lifts the hang glider from the ground for launch.
Additional objects, advantages, and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described herein, a safety apparatus is provided for indicating failure of a pilot to hook in a flight harness on a hang glider. The apparatus includes a circuit having a power source, a harness hook in sensing means and an alarm means. The power source is connected to the alarm through the harness hook in sensor. Thus, an alarm sounds only when the pilot fails to properly hook in the flight harness on the hang glider. Advantageously, the sounding of the alarm warns the pilot that the harness is not properly hooked in prior to launch. In this way, this potentially dangerous condition can be corrected and the launching of the hang glider by a pilot who is not hooked in is prevented. Thus, this statistically significant cause of hang gliding accidents is avoided.
The circuit may also include an on/off switch. Preferably, the on/off switch is mounted to a frame member of the hang glider so that the circuit and thereby the apparatus is activated in direct response to erection of the hang glider. Advantageously, automatic activation eliminates the possibility of the pilot forgetting to activate the safety device.
In accordance with a further aspect of the present invention, the circuit may also include a means for deactivating the alarm when the erected hang glider is at rest on the ground. The deactivating means, like the harness hook-in sensor may be a pressure sensitive limit switch. Preferably, the limit switch is mounted to the bottom face of the control bar of the hang glider. Thus, when the glider is at rest on the ground, the weight of the glider rests on the limit switch disposed between the bottom surface of the control bar and the ground. This serves to trip the switch and open the circuit thereby preventing the activation of the alarm. Thus, annoying and unnecessary alarm soundings are avoided without actually turning off the apparatus. Consequently, the possibility of the pilot forgetting to reactivate the apparatus prior to launch is eliminated.
Once the glider is raised from the ground, the limit switch is biased so as to return to its normally closed position. Thus, the circuit is completed between the harness hook in sensor and the alarm. In the event the harness has been properly hooked in, the limit switch of the harness hook in sensor is opened and, therefore, no alarm sounds. Where, however, the harness has not been properly hooked in, the limit switch of the harness hook in sensor remains closed completing the entire circuit and sounding the alarm.
It should be recognized that many hang gliders for beginners include wheels on the control bar that prevent the bottom surface of the control bar from engaging the ground. A means for deactivating the circuit may, however, still be provided on such a glider. More specifically, a limit switch as described above, may be mounted to the noseplate and another to the tail of the hang glider. When a hang glider is resting on the ground, either the noseplate or tail is contacting the ground. Thus, these switches operate in the same manner as the deactivation switch attached to the control bar described above.
In accordance with still another aspect of the present invention the circuit may include a test switch. When activated by the pilot, the test switch closes the circuit directly between the power source and the alarm. Thus, the test switch allows the pilot to very simply verify activation and proper operation of the safety apparatus.
Still other objects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments, and its several details are capable of modifications in various, obvious aspects all without departing from the invention. Accordingly, the drawing and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing incorporated in and forming a part of the specification, illustrates several aspects of the present invention, and together with the description serves to explain the principles of the invention. In the drawing:
FIG. 1 is a perspective view of a pilot and hang glider in flight;
FIG. 2 is a detailed side elevational schematic view showing certain aspects of the circuit of the safety apparatus of the present invention;
FIG. 3 is a detailed schematic view to show the harness hook in sensor of the apparatus; and
FIG. 4 is a schematic circuit diagram of the safety apparatus of the present invention.
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawing.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 showing a hang glider 10 in flight under the control of a pilot 12. As is known in the art, the hang glider 10 includes a sail 14 stretched between leading edge members 16 of a lightweight, tubular framework including a keel 18, crossbar 20 and king post 22. As the hang glider 10 cuts through the air, the sail 14 fills to form an air foil that directs air so as to provide lift to the glider and pilot 12.
As shown, the pilot 12 is suspended beneath the sail 14 of the glider 10 by means of a flight harness 24. The flight harness 24 is attached to the glider 10 at a single hang point by means of a carabiner 26. More specifically, the carabiner 26 is attached to a carabiner 28 that is mounted to the distal end of a webbing strap 30 (see also FIG. 2). The opposite end of the webbing strap 30 is fixed to the keel 18 of the glider 10.
When a pilot 12 is properly hooked in as shown in FIG. 1, he is suspended beneath the sail 14 from the hang point. In this position, the pilot 12 can shift his weight relative to the hang point by grasping and either pulling or pushing one or both sides of the control bar 32. For example, if the pilot 12 shifts his weight to the left, the glider 10 turns to the left. As a further example, if the pilot 12 shifts his weight forward, the hang glider 10 dives. Thus, it should be appreciated that by shifting his weight, the pilot 12 is able to control both the speed and direction of glider movement.
When a pilot 12 fails to properly hook in, it is the connection between the carabiner 26 at the end of the harness 24 and the carabiner 28 attached to the glider 10 that is not made. In the event a pilot 12 launches his glider 10 without hooking in, he is neither in a position to hold onto nor control the glider. In such a situation a crash occurs possibly resulting in serious injury or even death. This is particularly true in mountainous areas where a pilot 12 may leap from a cliff at launch.
The apparatus of the present invention is designed to warn the pilot 12 prior to launch when he has failed to properly hook in so that the condition may be corrected. In this way, the present apparatus reduces the risk of launch accidents thereby improving the safety of this inherently dangerous sport.
The safety apparatus of the present invention includes a control circuit, generally designated by reference numeral 34, shown schematically in FIG. 4. The circuit 34 includes a power source 36, such as a nine volt dry cell battery. This battery 36 may, for example, be mounted to the glider 10 along the keel tube 18 as shown in FIG. 2.
The battery 36 is connected through a on/off switch 38 to an alarm 39 (see also FIG. 4). As is known in the art, a hang glider 10 may be disassembled in a relatively simple manner into a more compact form to allow easier handling during transportation to and from a launch site. Preferably, the on/off switch 38 is designed to deactivate the safety apparatus of the present invention when the hang glider 10 is disassembled and activate the safety apparatus only when the hang glider is assembled as is necessary for launch.
This may be achieved by mounting the normally open on/off switch 38 to the keel 18 as shown in FIG. 2. More specifically, the actuator button 40 of the on/off switch is positioned so as to be engaged by the cross bar when the cross bar 20 is locked into place along the keel 18 utilizing the heart bolt 42. This serves to close the switch 38 and complete the circuit 34 (Note action arrow A).
It should be appreciated that the on/off switch 38, as described above, provides a number of distinct advantages. Since the safety apparatus is always deactivated when the hang glider 10 is disassembled, annoying and unnecessary alarms as is otherwise might be expected during handling, transportation and storage of the glider, are avoided. By eliminating these false alarms, the service life of the battery 36 is also extended. In addition, the automatic activation of the safety apparatus only when the glider 10 is erected for launch eliminates the possibility of the pilot becoming distracted during pre-launch setup of the glider 10 and forgetting to activate the apparatus. Of course, this is a very important feature of the present invention since this particular cause of possible failure of the safety apparatus to operate is fully avoided.
As also shown in FIGS. 2 and 4, the circuit 34 is also designed to include a test switch 44. Whenever a pilot 12 wishes to verify that the safety apparatus is operational, the pilot need only push the test switch actuator button 46. when the button 46 is pushed, the test switch 44 closes the circuit between the battery 36 and the alarm 39 which is thereby activated.
The battery 36 is also connected through a harness hook in sensor 48 mounted on the carabiner 28 and one or more deactivating switches 50 to the alarm 39. The sensor 48 and deactivating switches 50 operate together to activate the alarm 39 only in response to two simultaneously existing conditions. In effect, the circuit is only closed and an alarm is only sounded when (1) the assembled glider 10 is raised from the ground as in preparation for launch and (2) a flight harness 24 is not hooked into the carabiner 28.
Both the hook in sensor 48 and deactivating switches 50 may comprise normally closed, pressure sensing limit switches responsive to moderately light pressure (i.e. 2-4 ounces). The deactivating switches 50 may be mounted to the glider 10 on the bottom surface of the control bar 32, on the bottom face of the noseplate 51 and/or on the bottom face of the tail 52 (see FIG. 1). When the glider 10 is positioned at rest on the ground, one or more of these points contacts the ground. Thus, the weight of the glider 10 is applied to the interdisposed deactivating switch or switches 50. This serves to trip the levers (not shown) of the deactivating switches 50 so as to open the normally closed switches (note action arrows B in FIG. 4) and prevent deactivation of the alarm 39. In this manner, the circuit 34 is automatically deactivated when the glider 10 is at rest on the ground. Thus, the pilot 12 need not turn off the safety apparatus to prevent annoying and unnecessary alarms.
As a further advantage, it should be appreciated that when the pilot 12 lifts the glider 10 from the ground (as is necessary to launch), the circuit 34 is automatically reactivated. Thus, there is no responsibility placed on the pilot 12 to remember to turn on the safety apparatus. More specifically, when the glider 10 is lifted from the ground, all weight is removed from the switches 50. Consequently, the switches 50 return to their normally closed position (see action arrow C in FIG. 4) to complete the circuit between the battery 36, the hook sensor 38 and the alarm 39.
When a pilot 12 that is not properly hooked in raises the glider 10 for launch, the circuit 34 is fully closed and the alarm 39 sounds. The resulting buzz or beep of the alarm 39 alerts the pilot that he still must hook in. Once the pilot 12 hooks the harness carabiner 26 into the carabiner 28, the alarm is deenergized by the opening of the switch of the hook in sensor 48 (note action arrow D in FIG. 4).
More specifically, when a pilot 12 is not properly hooked in, the trip lever 54 of the hook in sensor 48 is not weighted. Thus, the switch 48 remains in the normally closed position completing the circuit 34 and thereby causing the alarm 39 to sound. In contrast, when the pilot 12 hooks in properly, the weight of the harness 24 and carabiner 26 pulls the trip lever 54 of the hook in sensor 48 downwardly (note action arrow E in FIG. 3) from the dash line to the full line position. This serves to open the switch 4 thereby preventing the alarm 39 from sounding.
In summary, numerous benefits have been described which result from employing the concepts of the present invention. Advantageously, the apparatus of the present invention substantially eliminates the possibility of a pilot 12 failing to properly hook in his flight harness 24 to a hang glider 10. By eliminating this potential cause of injuries and/or deaths, the safety of the hang gliding sport is greatly increased. Further, since the apparatus is both compact and lightweight, it may be easily added to existing hang gliders without adversely affecting their handling.
The apparatus also includes a number of additional features providing further advantages of substantial import. The on/off switch 38 is designed for automatic operation. When the hang glider 10 is disassembled, the safety apparatus is deenergized. This serves to not only save the power supply but prevents annoying and unnecessary alarm soundings. Conversely, when the hang glider 10 is erected for flight, the safety apparatus is automatically activated. This automatic activation serves to eliminate the possibility of the pilot forgetting to activate the safety apparatus.
The safety apparatus also includes a hook in sensor or switch 48 and a series of deactivating switches 50 that, advantageously, only allow the activation of the alarm when the glider 10 is raised from the ground as in preparation for launch and a flight harness 24 is not hooked into the carabiner 28. In this manner, the sounding of false alarms is minimized to provide maximum operational integrity to the system.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
|
A safety apparatus for a hang glider that indicates any failure of a pilot to properly hook in a flight harness. The apparatus includes a circuit having a power source, such as a dry cell battery, connected to an alarm through a harness hook in sensor. When the pilot fails to properly hook in the harness, an alarm sounds. The circuit also includes an on/off switch that activates the circuit only in direct response to erection of the hang glider. Thus, the circuit is deactivated when the hang glider is disassembled for transport to or from a launch site and during storage. Consequently, annoying alarm soundings are avoided and battery life is increased. In addition, the circuit includes a deactivation switch that prevents the alarm from sounding when the hang glider is resting on the ground. Finally, a test switch is provided to allow manual testing to confirm proper activation and operation of the circuit.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a torsion-damping flywheel, particularly for a motor vehicle, of the kind comprising two parts mounted for relative rotational movement about a common axis, and circumferentially acting springs interposed between these two parts. The invention relates more especially to an improvement making it possible to reduce the axial space requirement of the springs and to facilitate assembly.
2. Description of the Related Art
In a motor vehicle, a torsion-damping flywheel of the kind referred to above is conventionally provided between the crankshaft and the input shaft of the gearbox, in order to filter out the vibrations which arise over the whole length of the kinematic chain extending between the engine and the drive shafts. Advantageously, such a torsion damping flywheel is associated with the clutch, and in this case, the output assembly may comprise a solid annular plate constituting the thrust plate of the clutch. The input part, connected to the crankshaft, conventionally carries the starter ring gear for engagement with the engine starter. Such an inertial flywheel is described for example in French Pat. No. 2 571 461.
One of the objects of the invention is to simplify a device of this kind and, in particular, to reduce the number of its component parts, while reducing its overall axial space requirement.
SUMMARY
With this in mind, the invention provides a torsion damping flywheel comprising two parts mounted for relative rotational movement about a common axis, namely an input part connected to a driving shaft, and an output part, and springs interposed between said parts to generate a circumferentially-directed damping action, said output part comprising a hub and two discs forming part of a torque limiter disposed between two flat annular bearings, characterised in that the two discs are arranged to define, in a radial direction and externally relative to said torque limiter, two guiding flanges spaced relative to each other and in which there are disposed the openings accommodating said springs, and wherein a single annular flange, engaged between the two discs and cooperating with the said springs, is attached to an inertial plate of the said input part by assembly means located externally relative to said springs.
The invention in particular arises from the finding that the friction liners of the torque limiter undergo practically no wear during the service life of the damping flywheel and, in consequence, the spacing between the two discs may be considered as being constant, making these two elements capable of holding the springs in all circumstances. Furthermore, it follows from the preceding definition that the axial space requirement of the damping flywheel is reduced, all other things being equal, since there is only one flange, cooperating with the springs, linked to the inertial plate. Indeed, the openings for the springs can be of smaller diameter, since the rear recess has a smaller aperture for receiving the single flange. Accordingly, the springs may also have a smaller diameter.
Moreover, the inertial plate which is connected to the engine crankshaft is selected as a function of the characteristics of the engine. It is therefore desirable that the inertial plate should be adapted for mounting separately from the other parts of the damping flywheel, especially since it is sometimes necessary to test the engine uncoupled from the kinematic links and equipped only with this inertial mass. All this could not be envisaged before now, because of the complexity of the shock-absorber mechanism as a whole, comprising the springs, the friction means and the torque limiter. Some of these elements run the risk of being mislaid or being damaged before or during assembly. The invention also makes it possible to overcome this difficulty.
With this object in view, the invention also comprehends a torsion damping flywheel as defined above, which is characterised in that it comprises a sub-assembly joined to the inertial plate and comprises in particular the flange, the springs, the hub and the torque limiter including the two discs and the thrust plate. This sub-assembly, which comprises both elements associated with the said first part and elements associated with the said second part, is designed in a manner such that its component elements cannot easily be detached from each other. The thrust plate can be changed subsequently after mounting of the sub-assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a damping flywheel in radial section; and
FIGS. 2, 3 and 4 show details of the friction means for different variants.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The damping flywheel 11 essentially comprises two parts 12, 13 mounted for relative rotational movement about a common axis x,x'. The drawing shows an input part 12 connected directly to a driving shaft (not shown), such as the crankshaft of an internal combustion engine, and an output part 13, which in this case includes a solid disc 14 forming the thrust plate of a clutch. The input part 12 is primarily constituted by a disc-shaped inertial plate 16, carrying the starter ring gear 17, and by a single annular flange 19. The output Part comprises, in addition to the disc 14, a hub 22 and two discs 23, 24 being part of a torque limiter the elements of which are axially interposed between a first annular bearing 25 comprising a collar of hub 22 and a flat second annular bearing 26 on the disc 24. More particularly, this torque limiter, known per se, comprises an axial assembly constituted by a first friction liner 27a, which is flat, cooperating with the annular bearing face 25, and disc 23; two springs 28, 29 acting in the axial direction and forming here Belleville-type spacers; and disc 24 and a second friction liner 27b, also flat, cooperating with the annular bearing face 26. The second friction liner 27b is cemented to the disc 24, so that the dismantling or replacement of the disc 14 can be carried out safely, without any risk of escape of the liner. The disc 14 forming the thrust plate is attached to the hub 22 by screws 32. This hub is fastened to the external cage of a ballbearing 34, the internal cage of which is supported by a shoulder ring 35 fastened coaxially to the inertial plate 16 by means of screws 36. The discs 23, 24 are adapted to define, radially and externally relative to the torque limiter (that is to say, relative to the assembly formed by the elements described above), two guiding flanges 23a, 24a spaced relative to each other, in which are disposed the openings 38 accommodating the springs 39 arranged so as to act in circumferential direction between the input part 12 and the output part 13.
These springs are each mounted between two sockets 40, articulated to the edges of the openings 38, as described in the above-mentioned prior patent. The single flange 19 is engaged and interposed between the two discs. It comprises members cooperating with the springs, through the intermediary of the sockets and is fastened to the inertial plate 16 by screws 41 located externally relative to the springs 39. These screws are mounted in threaded bores 30 of the inertial plate.
Owing to the fact that the flange 19 is single, it is possible to reduce the size of the openings of the sockets and, consequently, to reduce the diameter of the springs 39, and thereby the axial space requirement of the inertial flywheel.
It is clearly apparent at this stage of the description that the damping flywheel is designed to comprise a sub-assembly connectable to the inertial plate and to constitute a unit adapted to be constructed and mounted independently of this inertial plate. In particular, the mounting of the inertial plate and the mounting of this sub-assembly may be carried out at separate stations, providing the possibility of testing the inertial plate independently of the kinematic links. This sub-assembly, the elements of which cannot accidentally detach themselves from each other, comprises: the flange 19, the springs 39 and the sockets 40, the hub 22, the torque limiter including the two discs 23, 24 and finally the ball bearing 34. Retaining clamps 42 are fixed to flange 19 and adapted to prevent the axial escape of the disc 24 (that is to say, of the disc most remote from the inertial plate 16) during the mounting of the device or in the course of an operation involving the dismantling of the disc 14 constituting the thrust plate. These clamps 42 can be mounted simply by interposition between the flange 19 and the heads of some of the screws 41. Preferably they are directly joined to this flange by welding or riveting. The mounting of the sub-assembly defined above can be facilitated if the flange 19 is equipped with positioning studs (not visible in the drawing) parallel to the x'x-axis and engaging with corresponding holes in the inertial plate 16.
The disc 14, constituting the thrust plate of the clutch, is not necessarily a part of the sub-assembly described above (it could be a hindrance in the mounting of the sub-assembly). In most cases, the plate is mounted by means of the screws 32, after assembly of the sub-assembly with the inertial plate 13. Because of this, the thrust plate can subsequently be changed without difficulty in case of deterioration or wear.
Dry friction means 48 are also part of the sub-assembly mentioned above. These friction means, provided to act along the full length of the angular interface of the two parts of the damping flywheel, are disposed between the hub 22 and the inertial plate 16. They comprise a continuous friction ring 49 made of a synthetic material, and a spring 50, shown here in the form of a Belleville collar. A retaining member 60 is mounted in an annular groove formed in the cylindrical surface 64 of the hub 22, against which the ring 49 is guided for axial sliding movement, and this member cooperates with an inclined surface of the ring 49. This inclined surface prevents the member 60 from disengaging from its groove under the action of collar 50 prior to the mounting of the sub-assembly on the inertial plate 16. It will be noted that, owing to the presence of member 60 acting as an abutment, the friction means 48 are properly attached to the sub-assembly, the collar 50 being locked fast between the ring 49 and a face 51 of the hub, whilst the ring 49 has extensions 55 axially slidably engaged in the unthreaded portions of at least some of the holes 64 which receive the screws 32.
In the variant of FIG. 2, the ring 49 has a flexible, moulded lip 68, which is engaged in a groove 62a of hub 22. Prior to mounting, the lip 68 abuts against the shoulder 69, whilst during mounting the lip 68 retracts on passing the sloping portion 67 to straighten up thereafter. The friction ring 49 is therefore not separable from the hub 22.
In the variant of FIG. 3, the friction means can be attached to the inertial plate 16, the ring 49b having extensions 55 slidably engaged in bores 70 of plate 16.
The Belleville collar 50 or, in a variant, a corrugated collar, is interposed between the plate 16 and the collar 49b, while a member 71, engaged in a groove 72 of the plate 16, serves as retaining means by cooperating with an inclined stop 73.
In the variant of FIG. 4, the retaining member 60 can be mounted partly in a groove of the hub and partly in a groove of ring 49. During assembly it is brought into contact with the bearing 67, being caused to contract in the groove 66 and then to expand.
In all cases, the retaining means (56, 60) are adapted to limit the axial play of the friction means, so that the latter remain fast with the part to which they are contacted prior to assembly or after dismantling of the two parts.
Moreover, in order to avoid incrustation phenomena by the springs 39 in the faces of the flange 19, the flange is advantageously subjected to a hardening treatment in at least those of its zones which are located in the proximity of these springs. Such a treatment may for example consist of nitriding or a localized high-frequency hardening. It will be noted that the single flange is of a simple form, without stampings.
|
A torsion damping flywheel, particularly for fitting to the clutch of a motor vehicle, has two parts mounted for relative rotational movement about a common axis including an output part comprising two discs forming part of a torque limiter which define externally two guiding flanges housing springs for controlling the relative movement of the two parts. The arrangement simplifies the flywheel by reducing the number of component parts and the axial space requirement.
| 5
|
The present invention relates a method for manufacturing an electromagnetic shielding gasket.
It also relates to an automatic machine for carrying out this method, as well as a gasket obtained by this method and/or this machine.
BACKGROUND OF THE INVENTION
Various kinds of electromagnetic gaskets have already been proposed which are useful for ensuring the electric continuity of assembled parts and therefore for creating a barrier against electromagnetic radiation.
Thus, there has been proposed gaskets obtained by moulding or extrusion and made of conductive elastomeric materials which form an electromagnetic shield as well as providing an environmental shield when the gasket is interposed between two parts. However, the manufacture of these gaskets is still very costly.
Gaskets are also made from electrically conductive wire mesh which form a gasket of interlocked wires. Such gaskets do not have a satisfactory resiliency, can be crushed easily and take a permanent compression set so that the electromagnetic energy can pass through the gasket.
Electromagnetic shielding gaskets are also formed of a core of an elastomeric material and of a wire sleeve knitted over the core. Consequently, the sleeve and the core of the gasket form a loose assembly the control and the handling of which are therefore not easy. Additionally, it requires that the process of core vulcanization and the process of knitting the wire sleeve around this core be done consecutively, which is a long and costly procedure.
Further, it has been known to flatten a knitted mesh, wrap it around a core and clench it along one side of the core rather than knitting the mesh over the core. The retention of the mesh around the core is generally poor and the process requires several consecutive, separate steps; forming and vulcanizing the core, knitting the mesh, flattening the mesh and wrapping it around the core.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention has as an object to remedy the above drawbacks by providing an electromagnetic shielding gasket, the manufacture of which is cheap and which gasket possesses excellent electromagnetic shielding properties. The gasket and method of forming it enables one to rapidly adapt and mount the gasket in place resulting in a substantial decrease in mounting time and cost with respect to the known gaskets.
For this purpose, the invention has as an object a method for manufacturing an electromagnetic shielding gasket comprising a core of an elastomeric material and at least one layer of electrically conductive textile material surrounding this core, formed by the steps of forming the core, preferably by extrusion, coating the core with the aid of electrically conductive textile materials and calibrating or sizing the coated core by passing it through at leas one die, which, in addition to the sizing, embeds the bands of textile material at least partially into the elastomeric material of the core.
It is therefore understood that, owing to this method, not only the process of coating the core with the aid of textile material is rapid and cheap, but also the textile material will be embedded into the elastomeric material of the core which remedies the retention drawbacks of the prior gaskets and in particular of those comprising a core over which a conductive wire sleeve is simply knitted or wrapped around.
According to another feature of the method of the invention, a heating of the coated core is effected after the sizing so as to vulcanize or set the core.
According to still another feature of this method, the coated core is shaped into a desired final shape either after the heating or after the calibration, in which case the gasket which has been shaped after the calibration can then be heated.
According to an embodiment of this invention, the extrusion, coating and calibration can be obtained by co-extruding the core and the bands of textile material.
Another object of the invention is a machine for carrying out the method complying with the above features and of the type comprising at least one means for forming an elastomeric core, preferably an extruder, and a means for feeding and coating at least one band of an electrically conductive textile material around the extruded elastomeric material, and downstream of the feeding means, at least one die for calibrating the elastomeric core-textile band assembly.
According to another feature of this machine, a heating oven is provided downstream of the calibration die.
This invention concerns also an electromagnetic shielding gasket obtained by the method and/or the machine complying with the above objects, this gasket comprising at least one layer of an electrically conductive textile material incorporated at its core-contacting part into the elastomeric material of the core.
The core can be made of any appropriate solid or foamed elastomeric material, whereas the layer of electrically conductive textile material is formed of bands, the fibers of which are formed in a tight or loose manner, such as woven, knit or non woven conductive mesh or textile.
Other features and advantages of the invention will appear more clearly as the following detailed description proceeds with reference to the appended drawing, given by way of example only.
IN THE DRAWINGS
FIG. 1 is a very diagrammatic view of a machine permitting automatically manufacturing in a continuous manner a shielding gasket according to this invention;
FIG. 2 is a plane view of an example of gasket formed with the aid of the gasket manufactured by the machine of FIG. 1 and shaped with the aid of appropriate tools; and
FIGS. 3 and 4 are cross-sectional views of a gasket according to this invention with a circular and rectangular cross-section respectively.
DETAILED DESCRIPTION OF THE INVENTION
According to the preferred embodiment shown in FIG. 1, a machine according to the principles of the invention comprises a forming means 1 for creating an elastomeric core 2 of the gasket, a means (not shown) for winding one or several bands 3 of an electrically conductive textile material about the core 2, a die means 4 for calibrating or sizing the core 2--band 3 assembly, an oven 5 and a bobbin 6 for winding up and storing the gasket just manufactured.
The forming means 1 preferably comprises an extruder opening 7 with any cross-section desired for obtaining a core 2 of the selected cross section, such as a circular, rectangular or polygonal in cross-section, as seen in FIGS. 3 and 4.
The extruded core 2 can be made of any appropriate elastomeric material such as for example polychloroprene, silicone and fluorosilicone rubbers, polyurethane, fluorinated elastomers, epichlorhydrin, thermoplastics and thermostable elastomers such as polyvinyl chloride, polyamides or polypropylene, or the well known elastomers or any combination of these materials depending on the intended applications of the gasket.
In addition, the elastomeric core 2 can be foamed or unfoamed, and/or solid or hollow so as to vary the compression/deflection characteristics of the gasket depending on the intended application.
The bands 3 for coating the core 2 are formed of electrically conductive threads or fibers 8 which can be interlocked, for example by weaving, knitting, braiding, bonding or other well known means. The threads may be formed in a tight or more or less loose manner.
These conductive threads or fibers can, for example, be made of nickel, stainless steel, copper, aluminum, coated steel, as well as other well known conductive materials.
Once the core 2 is wrapped by the bands 3, the assembly passes through the opening 9 of the sizing die 4, as clearly seen in FIG. 1, which not only calibrates this assembly to the proper diameter, but also incorporates at least a portion of the bands 3 into the elastomeric material of core 2, as seen at 10 in FIGS. 3 and 4.
More precisely, in the area shown at 10, it is seen that the parts of bands 3, which are in contact with core 2 and the elastomeric material forming this core, interpenetrate each other, so that as the assembly leaves the die 4 it forms an integral, homogeneous, flexible element which presents all the required qualities of electromagnetic shielding gaskets.
Although not compulsory, this element or gasket can be heated in a continuous manner, in the housing or oven 5 before being wound up on bobbin 6. The coated core can then be shaped into an appropriately shaped gasket. The gasket may not need to be heated after sizing, depending upon the material used for the core and its end use. Further, if one desires, one may take an unheated gasket, form it to a specific, desired shape and then heat the core to cause the gasket to retain the desired shape.
An example of a shape for the gasket J is shown in FIG. 2. The gasket can be used for ensuring the electromagnetic shielding between a housing and its lid. This gasket J comprises curvated portions 11 in order to avoid having the screws for fastening the lid to the housing pass through the gasket, and at 12 are shown the end-to-end joined and possibly welded ends of J made with the aid of appropriate tools, which are well known in the gasket art.
As previously explained, the shielding gasket according to this invention can have any appropriate shape such as a circular or polygonal shape in cross-section (see FIGS. 3 and 4), depending on the intended uses of said gasket.
Therefore, according to the invention, an electromagnetic shielding gasket has been obtained which can be manufactured in a continuous manner, which is very advantageous concerning the cost of manufacture, shaping, and mounting time, and which presents remarkable performances due in particular to the fact that the electrically conductive textile is bonded with the core of the gasket and that the gasket has been properly sized.
Besides, such a gasket presents a good compression/deflection characteristics, as well as a very satisfactory behavior and resiliency in the presence of mechanical vibrations, which was not the case with the previously known shielding gaskets.
Of course, the invention is by no means limited to the embodiment described and illustrated which has been given by way of example only.
Thus, the extrusion, the coating of the core and the calibration could be obtained by co-extrusion of the core and of the bands instead of carrying out successively these three processes as previously explained.
While this invention has been disclosed with reference to a preferred embodiment, other embodiments can achieve the same result. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents as fall within the true spirit and scope of this invention.
|
The present invention relates to a process of forming an electromagnetic shielding gasket by forming a core of elastomeric material, coating the core with bands of an electrically conductive textile material, passing the coating core through a die to calibrate the coated core, heating the coated core to cure the elastomeric material and winding up the cured core.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electric energy storage device and a method for manufacturing the same, more particularly, to an electric energy storage device including a gel type ionic conducting polymer electrolyte separator which enhances storage capacitance and reduces resistance, and a manufacturing method thereof
[0003] 2. Description of the Related Art
[0004] Capacitors are generally classified into three categories electrostatic capacitors, electrochemical capacitors and electrolytic capacitors. The electrostatic capacitors include a ceramic capacitor, a glass capacitor and a mica capacitor. The storage capacitance of the electrostatic capacitor is between approximately 1.0 μF and 10 μF.
[0005] The electrochemical capacitors are called supercapacitors. The electrochemical capacitors include an Electric Double Layer Capacitor (EDLC), a metal oxide pseudocapacitor and a conducting polymer capacitor. The storage capacitance of the electochemical capacitors is between approximately 1 mF and 3,000 F.
[0006] Some capacitors such as an aluminum electrolytic capacitor and a tantalum electrolytic capacitor are types of the electrolytic capacitors. The storage capacitance of the electrolytic capacitor is normally hundreds of times larger than that of the electrostatic capacitor.
[0007] In general, an electrode of the electrolytic capacitor is made by etching a valve metal, such as aluminum (Al), and by carrying out a chemical process or an electrochemical process. An electrode of the electrolyte capacitor is manufactured by sintering a valve metal powder, such as an aluminum powder or a tantalum powder, to have a large specific surface area. Then, the electrode is immersed in an electrolyte to form the electrolytic capacitor.
[0008] [0008]FIG. 1 is a cross-sectional view of an electrolytic capacitor according to a related art. Referring to FIG. 1, an electrolytic capacitor of the related art is comprised of a cathode 10 which includes a valve metal and an oxide layer 5 , an anode 15 corresponding to the cathode 10 , a separator 20 between the cathode 10 and the anode 15 , an electrolyte (not shown) injected into the separator 20 , terminals 11 and 16 respectively attached to the cathode 10 and the anode 15 , and a case for sealing the cathode 10 , the anode 15 and the separator 20 .
[0009] The oxide layer 5 is formed on the valve metal which is formed by etching a foil or sintering a metal powder. The oxide layer 5 is generally composed of an aluminum oxide (Al 2 O 3 ) or tantalum oxide (Ta 2 O 5 ) made by the electrochemical method.
[0010] The separator 20 between the anode 15 and the cathode 10 has an ionic conductivity. It also insulates the anode 15 from the cathode 10 . The electrolyte is permeated into the anode 15 and the cathode 10 , which stores the charge and provides a conducting medium for the ions.
[0011] The electrolytic capacitor is widely applied to various electronic devices because of its large storage capacitance, low resistance and low manufacturing cost. Yet, the size and the resistance of the electrolytic capacitor need to be further reduced given the recent development of various electronic devices such as notebook computers and cellular phones.
[0012] Considering the need for reducing resistance and minimizing the size of the electrolytic capacitor, a solid electrolytic capacitor, including an electronic conducting material which is injected into cathode, will likely be in demand. The electronic conducting material is composed of manganese oxide (MnO 2 ), tetracyanoquinodimethane (TCNQ) or polypyrrole (PPY).
[0013] However, the electrolytic capacitor of the related art has some disadvantages which are described hereinbelow.
[0014] [0014]FIG. 2 is a perspective view of an electrolytic capacitor having a cylindrical shape according to a related art. Referring to FIG. 2, the electrolytic capacitor of the related art is comprised of a cathode 35 , an anode 45 , first and second separators 30 and 40 , respectively attached to the cathode 35 and the anode 45 . The electrodes 35 and 45 and the separators 30 and 40 are wound together to form the electrolytic capacitor. The resistance or the size of such electrolytic capacitor, however, is not easily reduced through the manufacturing process of the electrolytic capacitor.
[0015] An electrolytic capacitor includes either a solid electrolyte such as a tantalum electrolytic capacitor or an aluminum PPY electrolytic capacitor, or a liquid electrolyte. In case of using a solid electrolyte, the capacitor generally consists of an anode, and an electronic conducting electrolyte as cathode and terminals. On the other hand, in case of using a liquid electrolyte, the capacitor consists of an anode, a cathode, a separator and terminals.
[0016] As for the electrolytic capacitor including the electronic conducting solid electrolyte, a thin layer of cathode is formed on the anode after the anode has been manufactured by etching a metal foil or sintering the metal powder, followed by the formation of an oxide layer on the etched foil or the sintered powder.
[0017] In the electrolytic capacitor including the ionic conducting liquid, the cathode, the separator and the anode are approximately 0.05 mm, 0.05 mm and 0.1 mm thick, respectively. That means that the electrolytic capacitor including the liquid electrolyte is much thicker than the electrolytic capacitor including the solid electrolyte. In addition, a liquid electrolyte of the electrolytic capacitor generally has low ionic conductivity.
[0018] Hence, the electrolytic capacitor including the ionic conducting liquid electrolyte has more resistance than that of the electrolytic capacitor including the electronic conducting solid electrolyte, since the thickness of the separator needs to be at least approximately 0.05 mm in order to prevent the separator from being torn and the conductivity of the liquid electrolyte is much lower than that of the electronic conducting solid electrolyte.
SUMMARY OF THE INVENTION
[0019] Considering the above-described problems and disadvantages, it is an object of the present invention to provide an electrolytic capacitor including a liquid electrolyte, which has a low resistance and a large storage capacitance, and a manufacturing method thereof
[0020] It is another object of the present invention to provide a manufacturing method for an electric energy storage device using wound electrodes with a gel type ionic conducting polymer electrolyte separator to increase productivity and yield.
[0021] To achieve the above objects, the present invention provides an electrolytic capacitor including an ionic conducting polymer electrolyte separator composed of common solvent and polymer. The common solvent functions as an electrolyte as well as a dissolvent of the polymer. The polymer is composed of at least one selected from the polymer groups of polymer of polyacrylate series, polyvinylidenefluoride (PVdF), copolymer of polyvinylidenefluoride and polymer of polyether series.
[0022] According to one example of the present invention, a common solvent is composed of propylene carbonate (PC) including alkylammonium compounds such as tetraethylammoniumtetrafluoroborate (Et 4 NBF 4 ) or amide compounds such as tertiary amide. In this case, the polymer is composed of polyacrylonitrile (PAN) and polyvinylidenefluoride, wherein the weight ratio between the polyacrylonitrile and the polyvinylidenefluoride is approximately 1:1 to 5:1. However, the preferred weight ratio between the common solvent and the polymer is approximately 4:1 to 10:1.
[0023] In another example of the present invention, the polymer is composed of polymethylmethacrylate (PMMA) and polyacrylonitrile. In this case, the weight ratio between the polymethylmethacrylate and the polyacrylonitrile is approximately 1:1 to 4:1.
[0024] According to still another example of the present invention, the common solvent is composed of gamma-butyrolactone (γ-BL) including alkylammonium compounds such as tetraethylammoniumtetrafluoroborate or amide compounds such as tertiary amide. The polymer is composed of polyacrylonitrile and the weight ratio between the common solvent and the polymer is approximately 5:1 to 8:1.
[0025] In still another example of the present invention, the common solvent is composed of propylene carbonate and gamma-butyrolactone including alkylammonium compounds, such as tetraethylammoniumtetrafluoroborate or amide compounds, such as tertiary amide. In this case, the amount of the propylene carbonate is more than that of the gamma-butyrolactone and the polymer is composed of polyacrylonitrile and polyvinylidenefluoride or polyethylene oxide.
[0026] Also, in order to achieve the above objects of the present invention, the electrolytic capacitor of the present invention further includes a first electrode on which the separator is formed and a second electrode corresponding to the first electrode, wherein the separator, the first electrode and the second electrode are wound together. Preferably, the first electrode is a cathode.
[0027] According to one embodiment of the present invention, a first electrode which has a larger width than the second electrode, is longer than the second electrode.
[0028] According to another embodiment of the present invention, an isolating member is formed at the end portion of the first electrode or a portion of the second electrode where the end portion of the first electrode is positioned. The isolating member is composed of a tape or a paper.
[0029] In addition, the electrolytic capacitor of the present invention has an additional electrolyte which is injected into the first and second electrode. It is identical to the common solvent of the separator or different from the common solvent of the separator, thereby enhancing the performance of the electrolytic capacitor and reducing the manufacturing cost of the electrolytic capacitor.
[0030] To achieve the above objects of the present invention, the present invention provides an electric energy storage device having an ionic conducting electrolyte, including a gel type ionic conducting polymer electrolyte separator, a first electrode on which the separator is formed, and a second electrode corresponding to the first electrode, wherein the separator, the first electrode and the second electrode are wound together.
[0031] Also, to achieve the above objects of the present invention, the present invention provides a method for manufacturing an electric energy storage device including the steps of: forming an ionic conducting polymer electrolyte separator including i) preparing common solvent for an electrolyte and for dissolving polymer and ii) dissolving the polymer at least one selected from the group consisting of polymer of polyacrylate series, polyvinylidenefluoride, copolymer of polyvinylidenefluoride and polymer of polyether series in the common solvent. The step of forming the separator may further includes a step of heating a mixture of the common solvent and polymer, and a step of coating the mixture on a current collector.
[0032] According to the present invention, the electrolytic capacitor has an increased unit storage capacitance with minimized size by using the gel type ionic conducting polymer electrolyte separator. Also, the resistance of the electrolytic capacitor is reduced by using the gel type ionic conducting polymer electrolyte separator. Consequently, the electrolytic capacitor of the present invention enables enhancement of a high frequency response characteristic, enlargement of the available frequency region and increase of the allowable ripple current of the electrolytic capacitor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The above objects and other advantages of the present invention will become more apparent by describing in detail the preferred embodiments thereof with reference to the attached drawings in which:
[0034] [0034]FIG. 1 is a cross-sectional view of an electrolytic capacitor accoding to a related art;
[0035] [0035]FIG. 2 is a perspective view of an electrolytic capacitor having a cylindrical shape according to a related art;
[0036] [0036]FIG. 3 is a schematic perspective view illustrating the winding of an electrolytic capacitor of the related art;
[0037] [0037]FIG. 4 is a plain view of an electrolytic capacitor having a gel type ionic conducting polymer electrolyte according to one embodiment of the present invention;
[0038] [0038]FIG. 5 is a schematic view illustrating a process for winding an anode and a cathode with a gel type ionic conducting polymer electrolyte separator according to another embodiment of the present invention;
[0039] [0039]FIG. 6 is a schematic view illustrating a process for winding an anode and a cathode having a gel type ionic conducting polymer electrolyte separator according to still another embodiment of the present invention; and
[0040] [0040]FIG. 7 is a schematic perspective view of a multi layer type electrolytic capacitor according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Hereinafter, various embodiments of the present invention will be explained in more detail with reference to the accompanying figures. However, it is understood that the present invention should not be limited to the following preferred embodiments set forth herein.
First Embodiment
[0042] In order to overcome the problems and disadvantages of a separator used in the conventional electrolytic capacitor including a liquid electrolyte, various examples of the preparation of a gel type ionic conducting polymer electrolyte separator of the present invention are provided as follows:
EXAMPLE 1
[0043] Preparation of a Gel Type Ionic Conducting Polymer Electrolyte Separator by Using Propylene Carbonate (PC) Including Tetraethylammoniumtertafluoroborate (Et 4 NBF 4 ).
[0044] For manufacturing a gel type ionic conducting polymer electrolyte separator, 1 mole(i.e., 7 g) of tetraethylammoniumtertafluoroborate (Et 4 NBF 4 ) is dissolved into 32 g of common solvent. In the present example, the common solvent is propylene carbonate (PC) which dissolves the polymer and functions as an electrolyte.
[0045] Subsequently, the polymer consisting of 3 g of polyacrylonitrile (PAN) and 1 g of polyvinylidenefluoride (PVdF) is homogeneously dissolved in the common solvent at the room temperature to form a mixture of the common solvent and polymer.
[0046] After the mixture is heated at 120° C. for one hour, the mixture is coated on a current collector to form a gel type ionic conducting polymer electrolyte separator. Table 1 shows ionic conductivities of the conventional ionic conducting electrolyte separator and the gel type ionic conducting polymer electrolyte separator according to the present example.
TABLE 1 ionic manufacturer thickness conductivity separator composition (country) (μm) (mS/cm) Celgard3501 polypropylene CELGARD (U.S.) 25 0.59 MER2.5 pulp Nippon Kodoshi 40 1.06 Corporation (Japan) CTW5755 pulp and rayon Nippon Kodoshi 55 2.02 Corporation (Japan) TF4035 rayon Nippon Kodoshi 35 2.63 Corporation (Japan) present {(PAN:PVdF) = (3:1)}: . 35 4.30 example (Et 4 NBF 4 /PC) = 1:8
[0047] As shown in Table 1, the gel type ionic conducting electrolyte separator has an excellent ionic conductivity of about 4.30 mS/cm which is twice higher than the ionic conductivity of the conventional ionic conducting polymer electrolyte separator. When the thickness of the gel type ionic conducting polymer electrolyte separator is reduced to approximately 25 μm, the ionic conductivity of the gel type ionic conducting polymer electrolyte separator may increase up to 6.02 mS/cm since the ionic conductivity of the electrolytic separator is linearly in inverse proportion to the thickness of the electrolyte separator.
EXAMPLE 2
[0048] Preparation of a Gel Type Ionic Conducting Polymer Electrolyte Separator by Using PC Including Et 4 NBF 4
[0049] In this example, 1 mole (7 g) of Et 4 NBF 4 is dissolved into 32 g of PC as common solvent which dissolves the polymer and functions as an electrolyte like example 1. Here, the polymer is composed of 1 g of PAN and 2 g of polymethylmethacrylate (PMMA), which belongs to the polymer of polyacrylate series.
[0050] After the polymer is homogeneously dissolved in the common solvent at the room temperature to form a mixture of the common solvent and polymer, the mixture is heated at 120° C. for 40 minutes for homogeneous viscosity. Subsequently, the mixture is coated on a current collector to form a gel type ionic conducting polymer electrolyte separator.
[0051] When the PMMA and the PAN are dissolved in the PC with Et 4 NBF 4 , the gel type ionic conducting polymer electrolyte separator produced ionic conductivity of 5.0 mS/cm. In other words, the polymer electrolyte separator of the present example having thickness of 35 μm shows better ionic conductivity than that of the polymer electrolyte separator of example 1.
EXAMPLE 3
[0052] Preparation of a Gel Type Ionic Conducting Polymer Electrolyte Separator by Using Gamma-butyrolactone (γ-BL) Including Tertiary Amide.
[0053] In the present example, gamma-butyrolactone (γ-BL) including tertiary amide is used as common solvent instead of PC with Et 4 NBF 4 .
[0054] After 1 mole (4 g) of tertiary amide is dissolved into 20 g of (γ-BL which functions as the common solvent, the polymer consisting of 4 g of PAN is homogeneously dissolved into γ-BL to form a mixture of the common solvent and polymer.
[0055] After the mixture is heated at 110° C. for one hour, the mixture is coated on a current collector and cooled at the room temperature to form a gel type ionic conducting polymer electrolyte separator having thickness of 35 μm.
[0056] The gel type ionic conducting polymer electrolyte separator of the present invention has ionic conductivity of 2.74 mS/cm which is lower than that of the separator manufactured by using PC with Et 4 NBF 4 . The gel type ionic conducting polymer electrolyte separator of the present example can be homogeneously mixed with PAN because γ-BL has a higher affinity with PAN compared to that with PC. Also, the gel type ionic conducting electrolyte separator of the present example has the ionic conductivity lower than that of example 1 or 2 due to the increase of the viscosity of ion conducting medium.
EXAMPLE 4
[0057] Preparation of a Gel Type Ionic Conducting Polymer Electrolyte Separator by Using PC and γ-BL with Et 4 NBF 4 .
[0058] After polypropylene carbonate including Et 4 NBF 4 and gamma-butyrolactone having Et 4 NBF 4 are mixed by the weight ratio of 1:1, polymer composed of the polyacrylate series and polyether series is dissolved to manufacture a gel type ionic conducting polymer electrolyte separator. In the present example, the polymer is composed of polyacrylonitrile, polyvinylidenefluoride and polyethylene oxide.
[0059] When the common solvent is only comprised of the γ-BL with Et 4 NBF 4 , the ionic conducting polymer electrolyte separator failed to reach a gel state after the mixture of common solvent and polymer was coated on a current collector. Hence, PC is mixed with γ-BL to form the gel type ionic conducting polymer electrolyte separator.
[0060] In the present example, the weight ratio between PAN and PVdF is preferably 1:1 to 5:1 when PC with Et 4 NBF 4 is mixed with γ-BL as the common solvent. If the gel type ionic conducting polymer electrolyte separator includes PAN in accordance with such ratio, the ionic conductivity of the gel type ionic conducting polymer electrolyte separator greatly decreases. Also, the mechanical strength of the gel type ionic conducting polymer electrolyte separator decreases, such that an electrolytic capacitor cannot be formed when the gel type ionic conducting polymer electrolyte separator includes a certain quantity of the PAN which fails to meet such ratio.
[0061] Although the mixture of common solvent and polymer are mainly described in the above examples, diethylcarbonate (DEC), dimethyl carbonate (DMC), ethymethyl carbonate (EMC) or ammoniumdihydrogenphospate can be also added to the common solvent to enhance low and high temperature characteristics and the ionic conductivity of the electrolytic capacitor, respectively. However, the characteristics and the manufacturing processes of the polymer electrolyte will not be changed by those additives since the characteristics and the manufacturing processes of the gel type ionic conducting polymer electrolyte are determined by the common solvent and polymer.
Second Embodiment
[0062] In addition to the examples for preparing the gel type ionic conducting polymer electrolyte separator as set forth above in examples 1-4 of the first embodiment, an additional electrolyte having excellent ionic conductivity is injected into electrodes and a gel type ionic conducting polymer electrolyte separator after the electrodes and the gel type ionic conducting polymer electrolyte separator are wound to form an electrolytic capacitor. Gamma-butyrolactone or acetonitrile (CH 3 CN) including the above-mentioned solution such as Et 4 NBF 4 is used as the additional electrolyte.
[0063] Regarding the electrolytic capacitor having the gel type ionic conducting polymer electrolyte separator manufactured by the above-described examples, the electrolytic capacitor normally works when the gel type ionic conducting polymer electrolyte separator is sufficiently thick. This is due to the fact that the gel type ionic conducting polymer electrolyte can permeate into the electrodes and into the interface between the electrodes and the gel type ionic conducting polymer electrolyte separator. If the thickness of the gel type ionic conducting polymer electrolyte separator is insufficient, the operation of the electrolytic capacitor may be limited. Thus, additional electrolytes may be injected to enhance the performance of the electrolytic capacitor. In this case, the additional electrolytes may be identical to the common solvent for manufacturing the gel type ionic conducting electrolyte separator or may be different from the common solvent of the gel type ionic conducting electrolyte separator. If the additional electrolyte differs from the common solvent of the gel type ionic conducting electrolyte separator, the performance of the electrolytic capacitor may improve since the common solvent of the gel type ionic conducting electrolyte separator and the additional electrolyte can act separately.
[0064] In one example of the present embodiment, the acetonitrile in which 1 mole of Et 4 NBF 4 is dissolved is additionally injected into the electrodes and the gel type ionic conducting electrolyte separator, while PC including 1 mole of Et 4 NBF 4 is used as common solvent during the manufacturing process for the gel type ionic conducting polymer electrolyte separator. Also, γ-BL with Et 4 NBF 4 is used as an additional electrolyte according to another example of the present embodiment. Furthermore, PC including Et 4 NBF 4 can be injected as the additional electrolyte, thereby enhancing the performance of the electrolytic capacitor of the present embodiment.
[0065] According to the present embodiment, in case that PC including Et 4 NBF 4 is used as the common solvent and also used as the additional electrolyte which is injected into the electrodes and the gel type ionic conducting electrolyte separator, the electrolytic capacitor has a resistance of 20 mΩ at the resonance frequency of the capacitor. At that time, the electrolytic capacitor has diameter of 10 mm and height of 30 mm.
[0066] On the other hand, the resistance of the electrolytic capacitor having the same dimension of the above capacitor is 15 mΩ at the resonance frequency when the acetonitrile including Et 4 NBF 4 is injected as the additional electrolyte after PC including Et 4 NBF 4 is used as the common solvent of the gel type ionic conducting polymer electrolyte separator. Therefore, the electrolytic capacitor shows a superior performance when the common solvent and the additional electrolyte are different from each other.
Third Embodiment
[0067] In the present embodiment, a method for directly coating the gel type ionic conducting polymer electrolyte separator onto an electrode of an electrolytic capacitor will be described.
[0068] It is advantageous to have the gel type ionic conducting polymer electrolyte separator coated on the electrode. In other words, when the gel type ionic conducting polymer electrolyte separator is directly coated on the electrode after the gel type ionic conducting polymer electrolyte separator is prepared, the coating process is simply accomplished in comparison with the conventional process for attaching the separator to the electrode.
[0069] In addition, when the gel type ionic conducting polymer electrolyte separator is directly coated on the electrode, the gel type ionic conducting polymer electrolyte forms a film. Thus, the adhesion strength between the gel type ionic conducting polymer electrolyte separator and the electrode greatly increases to enhance the interface adhesion between the gel type ionic conducting polymer electrolyte separator and the electrode. Specifically, when the gel type ionic conducting polymer electrolyte separator is directly formed on a powder type activated carbon which is coated on an electrode, a composite of the gel type ionic conducting polymer electrolyte and the activated carbon is formed since the gel type ionic conducting polymer electrolyte becomes a film after the gel type ionic conducting polymer electrolyte is permeated into pores of the activated carbon. Thus, the interface adhesion between the gel type ionic conducting polymer electrolyte and the electrode can greatly increase and the activated carbon can be solidly attached to the electrode by forming the composite of the gel type ionic conducting polymer electrolyte and activated carbon.
[0070] In order to increase the storage capacitance of an electrolytic capacitor having an ionic conducting electrolyte, the etching ratio of a metal of an electrode should be increased since the resistance of the electrode may increase when the etching ratio of the electrode increases. However, the electrolytic capacitor can have a thin electrode having a large capacitance if an electrode includes an activated carbon which is coated on a current collector as a cathode of the electrolytic capacitor. The activated carbon is a porous material which has a specific surface area of approximately 2,000 m 2 /g. The cathode of the electrolytic capacitor may have a storage capacitance of over 10 mF/cm 2 when the activated carbon having thickness of approximately 0.01 mm is coated on the cathode. In light of such problems, the cathode of the related art including the etched metal has a storage capacitance of approximately 0.5 mF/cm 2 . However, the cathode including the activated carbon can have a storage capacitance twenty times larger than that of the cathode of the related art including the etched metal.
[0071] In the present embodiment, the cathode of the electrolytic capacitor is manufactured by coating the activated carbon on the current collector and by directly forming the gel type ionic conducting polymer electrolyte in the pores and on the surface of the activated carbon. Therefore, the electrolytic capacitor can have an excellent storage capacitance and exceedingly enhanced performance because of the thin cathode and greatly increased capacitance. The gel type ionic conducting polymer electrolyte separator also has a superior mechanical strength and high ionic conductivity.
[0072] For example, the 6.3V electrolytic capacitor of the related art has a storage capacitance of about 2.2 to 3.3 mF when the electrolytic capacitor has diameter of 13 mm and height of 20 mm. The electrolytic capacitor of the present invention, however, has a storage capacitance of 5 mF when the electrolytic capacitor of the present invention has the dimension identical as that of the conventional electrolytic capacitor. The electrolytic capacitor of the present embodiment includes a cathode manufactured by directly coating 0.03 mm of the gel type ionic conducting polymer electrolyte separator on a cathode previously manufactured by coating 0.015 mm of an activated carbon on an aluminum foil having thickness of 0.02 mm.
[0073] An anode of the electrolytic capacitor has an oxide layer formed thereon. Because the anode having the oxide layer may be damaged during the manufacturing process, the oxide layer is recuperated by applying a predetermined voltage to the electrolytic capacitor for an aging process after the electrolytic capacitor is completed. Gas is generated during the recuperation of the oxide layer. If the gel type ionic conducting polymer electrolyte separator is directly coated on the anode, the storage capacitance of the electrolytic capacitor may reduce and the resistance of the electrolytic capacitor may increase since the gas generated during the aging process is confined between the anode and the gel type ionic conducting polymer electrolyte separator. In order to prevent such problems, it is more advantageous to directly coat the gel type polymer electrolyte separator on the cathode of the electrolytic capacitor.
Fourth Embodiment
[0074] In the present embodiment, a method for winding electrodes and separator of an electrolytic capacitor will be described as follows:
[0075] [0075]FIG. 3 is a schematic perspective view illustrating the winding of an electrolytic capacitor according to the related art.
[0076] Referring to FIG. 3, in the electrolytic capacitor of the related art including porous paper or polyproplene as a separator, electrodes 65 and 75 and separators 60 and 70 , respectively, are wound together wherein widths of the first and second separators 60 and 70 are respectively wider than those of the anode 65 and the cathode 75 to prevent an electrical short between the anode 65 and the cathode 75 .
[0077] However, in the present embodiment, the electrode having the gel type ionic conducting polymer electrolyte separator should be wider and longer than the other electrode, respectively, so as to prevent the electrical short between the electrodes of the electrolytic capacitor in case of using the gel type ionic conducting polymer electrolyte separator. That is, the width of the gel type ionic conducting polymer electrolyte separator does not need to be larger than the electrodes as the separators of the related art in FIG. 3.
[0078] One of the variations of this embodiment is that a gel type ionic conducting polymer electrolyte film may be attached to the electrode after the gel type ionic conducting polymer electrolyte is coated on a substrate to have a film shape followed by attaching the substrate, which is a separator, on an electrode. However, such manufacturing process demands more cost and excessive processing time.
[0079] [0079]FIG. 4 is a plain view showing electrodes of the electrolytic capacitor having the gel type ionic conducting polymer electrolyte separator according to one embodiment of the present invention. As shown in FIG. 4, in order to prevent the electrical short between one electrode and the other electrode having the gel type ionic conducting polymer electrolyte separator, width and length of a second electrode 105 are respectively shorter than those of a first electrode 100 . The gel type ionic conducting polymer electrolyte separator is coated on the first electrode 100 .
[0080] As mentioned above in the third embodiment, the gel type ionic conducting polymer electrolyte separator is preferably coated on the cathode of the electrolytic capacitor. Stated differently, it is advantageous to coat the gel type ionic conducting polymer electrolyte separator on the cathode, which has wider width and longer length that those of the anode.
[0081] [0081]FIG. 5 is a schematic view illustrating a process for winding the anode and the cathode with the gel type ionic conducting polymer electrolyte separator according to a preferred example.
[0082] The electrical short between the electrodes may occur when the end portion of the electrode having the gel type ionic conducting polymer electrolyte separator is located at the end portion of the other electrode during the process of winding the electrodes.
[0083] Referring to FIG. 5, a first electrode 120 having the gel type ionic conducting polymer electrolyte separator is previously wound by at least half a revolution, and then the first electrode 120 is wound with a second electrode 125 . The first electrode 120 is longer than the second electrode 125 at the winding starting position. Simultaneously, the first electrode 120 is also longer than the second electrode 125 at the ending position. The cathode is initially wound by at least half a revolution, and then the cathode and the anode are wound together. Also, the cathode is further wound by at least half a revolution after the winding of the anode is completed.
[0084] [0084]FIG. 6 is a schematic view illustrating the process for winding the anode and cathode having the gel type ionic conducting polymer electrolyte separator according to another preferred example. As shown in FIG. 6, in order to prevent the electrical short between first and second electrodes 130 and 135 at the winding position, the end portion of the first electrode 130 is covered with an insulating member 140 . The gel type ionic conducting polymer electrolyte separator is formed on the first electrode 130 . The insulating member 140 can be a paper, a tape or other insulating materials. Also, the insulating member 140 can be formed on a portion of the second electrode 135 where the end portion of the first electrode 130 is positioned to prevent the electrical short between the electrodes 130 and 135 .
[0085] When the electrodes 130 and 135 are wound with the insulating member 140 , the electrical short between the electrodes 130 and 135 cannot occur even though the end portion of the first electrode 130 is located at the end portion of the second electrode 135 .
[0086] Meanwhile, in case where the gel type ionic conducting polymer electrolyte separator is used, the electrolytic capacitor can introduce various shapes, such as a square pillar, a rectangular pillar, a triangular pillar or a pentagonal pillar along with a cylindrical shape, because the gel type polymer electrolyte separator is directly coated on the electrode of the electrolytic capacitor.
[0087] [0087]FIG. 7 is a schematic perspective view showing a multi layer type electrolytic capacitor according to the present invention. Referring to FIG. 7, when the electrolytic capacitor is a multi layer type, the gel type ionic conducting polymer electrolyte separators formed on first electrodes 150 also work as bonding agents between first electrodes 150 and second electrodes 155 , thereby easily accomplishing the process of stacking the electrodes 150 and 155 , alternately.
[0088] According to the present invention, the unit storage capacitance of the electrolytic capacitor can be greatly increased but the size of the electrolytic capacitor is decreased by using the gel type ionic conducting polymer electrolyte separator. Also, the electrolytic capacitor reduces the resistance by the gel type ionic conducting polymer electrolyte separator so that the electrolytic capacitor enables enhancement of high frequency response characteristic, enlargement of the available frequency region of the capacitor and increase of the allowable ripple current of the capacitor.
[0089] Although the preferred embodiments of the invention have been described, it is understood that the present invention should not be limited to those preferred embodiments, but various changes and modifications can be made by one skilled in the art within the spirit and scope of the invention as hereinafter claimed.
|
An electric energy storage device includes a first electrode, a gel type ionic conducting polymer electrolyte separator formed on the first electrode, and a second electrode corresponding to the first electrode. The energy storage device has an increased unit storage capacitance and more minimized size by using the gel type ionic conducting polymer electrolyte separator. Also, the energy storage device produces a reduced resistance by the gel type ionic conducting polymer electrolyte separator, such that the high frequency response characteristic is improved, the available frequency region is enlarged and the allowable ripple current is increased. A method for manufacturing the electric energy storage device includes the steps of forming an ionic conducting polymer electrolyte separator including i) preparing common solvent for an electrolyte and for dissolving polymer and ii) dissolving polymer at least one selected from the group consisting of polymer of polyacrylate series, polyvinylidenefluoride, copolymer of polyvinylidenefluoride and polymer of polyether series in the common solvent.
| 8
|
This is a division of application Ser. No. 915,477, filed June 14, 1978, and now abandoned.
SUMMARY OF THE INVENTION
This invention relates to the field of lapidary and more particularly to apparatus for use in manual or hand cabbing various types of rock and stone into cabochons of gemstone quality.
An object of the invention is to provide a kit for use in hand cabbing of gemstones and the like, the kit comprising a box frame having an hollow interior portion, a selection of flexible sheet members, means for fastening a selected one of the sheet members to the box frame with a portion of the sheet member being partially disposed within the hollow interior portion, at least one preform stone, at least one dop stick, dop adhesive means for attaching the dop stick to the preform stone, a shaping stone and a supply of polishing material.
Another object of the invention is to provide such a hand cabbing kit wherein the selection of flexible sheet members includes a selection of abrasive sheets and at least one polishing cloth.
A further object of the invention is to provide such a kit wherein the abrasive sheets are abrasive screen material.
A still further and important part of the invention is to provide hand cabbing apparatus comprising a frame including a base and upstanding walls about the periphery of the base, a sheet of coated abrasive material extending over the base, and attaching means for attaching the coated abrasive material to the frame.
Other important objects of the invention will hereinafter appear and the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claimed subject matter, and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of apparatus which, taken together, form a kit for use in hand cabbing of gemstones.
FIGS. 2-6 comprise plan, elevation and end views of a first embodiment of a novel box-like frame having coated abrasive material attached thereto to illustrate a basic component of the inventive hand cabbing apparatus.
FIGS. 7-10 are perspective views illustrating a second embodiment of the invention.
FIGS. 11 and 12 illustrate a third embodiment of the invention.
FIGS. 13-15 illustrate a fourth embodiment of the invention.
FIGS. 16 and 17 illustrate a fifth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates, in unassembled form, a series of elements which together form a kit for use in hand cabbing of gemstones. The kit, generally indicated by the numeral 10, is comprised of a base frame or box frame 12, a selection of coated abrasive material 14, a supply of polishing cloths 16, a pair of side rails 18 for attaching the abrasive material 14 and/or polishing cloths 16 to the base frame 12, a supply of elastic bands 20 for holding the side rails 18 in place on the box frame 12, a series of end caps 22 which fit into the ends of side rails 18 for retaining the elastic members 20, a shaping stone 24 formed of bonded abrasive material, a file board 26 having a selection of abrasive grains on opposite sides thereof, differently shaped dop sticks 27 and 28, a pair of preform stones 29, a supply of dop tape 30 which may be trimmed to size to fit either dop stick 27 or dop stick 28 and used to adhere one of the preform stones 29 thereto, a supply of pre-polish material 31 and polish material 31' which are used in connection with polishing cloths 16, and a set of instructions 32 for use by neophites and professionals in utilizing the invention.
FIGS. 2-6 illustrate in assembled form various elements of the kit 10, namely, box frame 12 which is preferably a unitary, molded, plastic material; abrasive material 14 which is preferably formed of a reticulated, mesh screen-like material having abrasive grain such as silicone carbide and the like adhered to both sides thereof; side rails 18 which may be hollow, extruded plastic tubes or wooden dowels and the like, elastic bands 20 for holding the abrasive material 14 to the box frame 12; and end caps 22 for retaining the elastic bands 20 in assembled position.
As can be seen in FIG. 1 and FIGS. 2-6, box frame 12 is comprised of a base 34, a pair of elongated, upstanding side walls 36 and a pair of end walls 38 to provide a generally rectangular box-like member having a hollow interior portion for collecting bits of stone and abrasive material during a grinding operation. Base 34 is particularly shaped to include a bottom or exterior surface 40 containing a series of elongated longitudinally extending ribs 42 such that, in profile or transverse section, the bottom 40 provides a convex working surface, the use of which will be subsequently described. End walls 38 are shaped to include curved surfaces 44 which are recessed slightly below the upstanding side wall 36 for a purpose to be hereinafter described. Side walls 36 are provided with indentations or recesses 46 which are shaped to conform to side walls 18. In addition, side rails 36 are preferably provided along their upper edge with hollow portions 48 for a purpose to be subsequently described.
As is best shown in FIGS. 2-6, a sheet of abrasive material 14 (first coarse, then medium and then fine) is positioned across the side walls 36 and located within the pair of recesses 46 and held therein by side rails 18 which, in turn, are secured within the recesses 46 by use of a pair of elastic members 20. As is best shown in FIG. 4, the abrasive material 14 is positioned to extend downwardly into the hollow portion of frame 12, below the uppermost portion of side walls 36, to substantially follow the curved surface 44 of end wall 38. In this configuration, a preform stone 29, which is attached to dop stick 27 by dop tape 30, can be moved back and forth to slowly grind or shape a portion of the stone 29. Ideally, with the dop stick 27 held vertically, reciprocating movement along the longitudinal axis of the frame 12 will cause opposite edges of the stone 29 to be shaped simultaneously without any grinding action being performed upon the lowermost surface of the stone. By utilizing such a reciprocating, longitudinal stroke, the stone 29 may be shaped into a smooth dome, either circular, or oval, etc.
As is shown in FIG. 5, the convex bottom or exterior surface 40 is useful in that the abrasive material 14 may be held in place thereon by the side rails 18 and, with a reciprocating motion of the dop stick 27, a flat surface may be ground on the stone 29. In this regard, the slight convex shape of surface 40 allows for easier grinding or sanding of a flat or nearly flat surface; unless you have an extremely flat surface in which the abrasive grit is embedded, a person would only be able to grind or sand the edges and not the middle. FIG. 6 illustrates that the bottom surface 40 is also useful during pre-polishing and final polishing of the stone 29 by substituting a piece of polishing cloth 16 in place of the abrasive material 14.
In view of the foregoing description of the first embodiment of the invention, it is apparent that the frame 12 is useful in an upright position, as is shown in FIG. 4, and in a reversed position as is shown in FIGS. 5 and 6.
FIGS. 7-10 illustrate a second embodiment of apparatus which is useful in connection with the present invention. A box frame 112 includes a base 134, longitudinally extending upstanding side walls 136, and spaced end walls 138 each of which is provided with an upper curved surface 144. A sheet of coated abrasive material 114 is placed about the frame 112 and held in place by a sleeve member 150 which includes a pair of C-shaped side rails 118 connected by a central bight portion 152. The side rails 118 are shaped to conform to the exterior surface of the side walls 136 to securely hold the abrasive material 114 in proper operating position with the upper working surface of the abrasive material 114 being curved as is shown in FIG. 9. A pair of end members 154 are provided for holding the sleeve member 150 in position upon the frame 112 through the use of internally threaded nuts 156 and threaded studs 158. Frame 112 has a bottom or exterior surface 140 preferably formed to include a plurality of longitudinally extending ribs 142 which define a curved surface in profile or transverse section. A comparison of FIGS. 9 and 10 will show that sleeve member 150 is reversible such that an upper curved surface of abrasive material 114 is exposed (FIG. 9) or a portion of abrasive material 114 can be exposed in connection with the curved bottom surface 140 (FIG. 10). It should also be noted that the sheet of abrasive material 114 is in the form of an abrasive belt such that the abrasive material 114 can be sequentially positioned about the frame 112 in order to efficiently use the total abrasive surface thereof.
FIGS. 11 and 12 illustrate a third embodiment of apparatus useful with the present invention. In this embodiment, a box frame 212 includes a base 234, a pair of upstanding side walls 236, and a pair of end walls 238 each of which is provided with a curved upper surface 244. A series of side rails 218 are provided to cooperate with side walls 236 for holding coated abrasive material 214 (or polishing cloths 16) in position upon frame 212. The side rails 218 are preferably provided with V-shaped ribs 219 which extend into hollow portions 221 of the side walls 236 for securely holding the abrasive material 214 in position. A series of screw members or threaded studs 158 are located within extensions of the side walls 236 and cooperate with a plurality of cap screws 260 for securely fastening the side rails 236 and abrasive material 214 in operative position.
FIGS. 13-15 illustrate a fourth embodiment of appartus for use with the present invention. A box frame 312 includes a base 334, a pair of spaced side walls 336 and a pair of end walls 338 each of which is provided with a curved upper surface 344. A pair of side rails 318 and a pair of C-shaped sleeves 350 cooperate to hold abrasive material 314 in operative position either across the hollow portion of frame 312 (FIG. 14) or across the curved bottom or exterior surface 340 (FIG. 15).
FIGS. 16 and 17 illustrate a fifth embodiment of apparatus for use with the present invention. A box frame 412 is preferably integrally molded from plastic material and the like to provide a base 434, a pair of spaced upstanding side walls 436 and a pair of end walls 438 each of which is provided with a curved upper surface 444. A pair of flat side rails 418 cooperate with threaded studs 458 and nuts 460 to securely fasten abrasive material 414 in operative position about frame 412. Preferably, the sheet of abrasive material 414 is in the form of an endless belt so that full utilization of the working surface thereof can be made. It should be noted that the upper surface of side wall 436 are provided with hollow portions 448 for use in a manner which will be more particularly described in connection with the operation of the various embodiments.
USE OF THE INVENTION
The process of forming gemstones requires grinding and sanding a stone, such as preform stone 29, from a rough shape with a rough surface to a delicate, precise shape with a high polish and lustre. In the process, portions of the stone are removed in the form of very fine, almost invisible, dust. Inhaling the dust or getting it into the pores of skin can be irritating. Thus, the abrasive material, shaping stone, file board and preform stones should always be used under wet conditions and are designed to work best in this manner.
First, a coarse screen abrasive 14 is assembled about a frame 12, 112, 212, 312 or 412 and secured thereto by the side rails 18, etc., as described above, according to the respective embodiment of the invention.
Second, a dop stick 27 or 28 that best fits a particular preform stone 29 is chosen. The dop stick is then adhered to the preform stone 29 by using dop tape 30.
Third, the shaping stone 24 is used to break the top edge of the stone 29 and to quickly round-off excess side material. Using the shaping stone 24 greatly reduces the time spent in initial gemstone shaping. The shaping stone 24 is used "wet" as in all of the grinding and sanding operations. The stone 24 and preform stone 29 should be thoroughly soaked in water prior to and during use. The bottom or exterior surface 40, etc., may be used as a convenient place to rest the shaping stone 24 or it can be placed on some folded paper towels or any convenient surface that would not be marred by the wet stone. Assuming that the desired final shape is to be a full dome top surface, the sharp upper edge of the stone 29 is rounded off along with some of the excess side material by the use of relatively short back and forth strokes of the stone 29 against the shaping stone 24. The upper edge is rounded off on the shaping stone 24 to prevent the preform stone 29 from digging or catching in the coarse abrasive material 14 which, as previously pointed out, is preferably an abrasive coated screen material. This material is available from The Carborundum Company, Niagara Falls, New York under the trademark Sandscreen.
Fourth, after the approximately final shape is achieved through use of the shaping stone 24, final shaping is done on the coarse abrasive material 14. Initial use of that portion of abrasive screen material overlying side walls 36 or 436 will avoid inadvertent cutting of the screen by sharp edges on the preform stone 29; hollow portions 48 and 448 will collect dust and grit. There are many ways to "stroke" the gemstone 29 to achieve its final shape. Following is one method. Align the long axis of the stone 29 with the long axis of the frame 12, etc., and move the stone 29 longitudinally of the frame 12, rotating the stone 29 ninety degrees after every 15 to 30 strokes. This will gradually form the desired dome top surface. The sides and ends of the preform stone 29 will gradually become rounded and the original top flat oval portion will gradually shrink. By keeping the top flat oval centered, until it finally shrinks away, you will end up with a fully domed top shape. When the preform stone 29 has been domed, the next step is to sand out the scratches put on the surface during shaping. The coarse abrasive material 14 is removed and the frame 12, side rails 18, etc., should be cleaned of all dust and grit.
Fifth, install a "medium grit" abrasive material 14 to the frame 12, 112, etc., and keeping the stone 29 and abrasive material 14 "wet", use long sweeping strokes and circular or oval strokes to remove all deep scratches in the surface of the stone 29. Then, replace the "medium grit" abrasive material 14 with "fine grit" abrasive material 14 and proceed as before until the preform stone is really smooth.
Sixth, the smooth stone 29 is then polished. Polishing cloths 16 are, sequentially, used with the pre-polish and polish material 31 and 31'. The polish materials are in the form of powder which is to be mixed with a small amount of water to obtain a cream-like consistency. Polishing is accomplished by the use of short, very rapid strokes. It is not necessary to keep the polishing compound very damp during final polishing. In fact, the final shine will appear when the polishing compound is almost dry. There is little danger of noxious dusts at this time as virtually no gemstone material is being removed. The final polish achieved will rival that achieved on the most expensive cabochonning machines available and the process is performed manually in not much more time.
Lastly, care should be taken in removing the gemstone from the dop stick. The stone should be removed by using a sharp, thin knife; "popping off" soft stones by using thumb pressure may cause breaking of the stone.
If desired, the gemstone may be fixed to various types of jewelery mountings which are available from lapidary companies, dealers, retail outlets, hobby shops, etc. The most common mountings are glue-on pads, prong or claw mounts, and bezel mounts which may be solid, either full or partial, or various lace and prong designs.
While various embodiments of the invention have been specifically illustrated and described herein, it is to be understood that minor variations may be made in the disclosed kit and frames 12, 112, etc., without departing from the spirit and scope of the invention, as defined by the appended claims.
|
Apparatus, including a kit and elements thereof, for manually producing cabochons from various types of rocks and gemstones such as onyx, agate, opal, jade, etc. The kit contains all necessary equipment for hobbyists and craftsman to shape and polish gemstones from preform pieces of rock or stone. Also disclosed are various novel embodiments of base frames and attachment means for fixedly securing abrasive and polishing media to the base frame.
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates to a method of producing a smooth, cold-drawn, multifilament yarn from polyester POY (partially oriented yarn) and to a yarn produced by this process.
A smooth multifilament yarn is to be understood as meaning an untextured multifilament yarn which retains its uncrimped flat shape even on boiling in water.
Polyester is to be understood as meaning a thermoplastic material prepared from at least 85% by weight of terephthalic acid and ethylene glycol.
Polyester POY refers to a polyester yarn which has a linear density of about 50 to 1,200 dtex and was melt-spun at a speed of about 2,800 to 4,000 m/min.
In the present invention, cold drawing refers to drawing at yarn temperatures which are significantly below the glass transition temperature of the polyester, i.e. appreciably below 85° C. For example, a delivery roller for the drawing can be unheated or be at a temperature of up to 70° C. The drawing can take place with or without the use of a drawing peg.
Homogeneous cold drawing is to be understood as meaning that the draw ratio has to be chosen sufficiently high to ensure that, in the drawn yarn, there are no undrawn areas or areas drawn to less than the draw ratio, which is discernable for example in the Uster %, which in general should be <1.5. For POY from the stated speed range, this means that the draw ratio shall be at least 1.6, depending on a spin speed.
For the purposes of the present invention, hot relaxation is a treatment which causes a decrease in the length of the yarn by heat treatment at temperatures above the glass transition temperature. The extent of the decrease in length is determined by the overfeed VE: ##EQU1## V L =speed of delivery system V A =speed of take-off system
The production of a cold-drawn polyester yarn from POY spun at more than 4,000 m/min is known from (JP-A-53-143,728).
DE-A-2,839,672 discloses a polyester replacement yarn for cellulose acetate, having a boil shrinkage of 2 to 6% and obtainable by direct high-speed spinning at about 4,000 m/min without the use of a drawing system or any heat treatment. In this publication, a boil shrinkage of less than 2% is referred to as extremely low and as very difficult to obtain directly.
The main disadvantage of the known yarn consists in that its shrinkage is still too high. In addition, such a yarn has to be shrunk before package dyeing and be rewound onto perforated dyeing centers.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process whereby it is possible to prepare a yarn which has an extremely low shrinkage while resembling a cellulose acetate or viscose yarn in-its other properties.
This object is achieved according to the invention by a method of producing a polyester yarn which is characterized in that the polyester POY, in a first process step, is homogeneously cold-drawn to a draw ratio of at least 1.6 and, in a second process step, is hot-relaxed under an overfeed of 10 to 20%.
In the range from 10 to 20% overfeed, preferably from 12 to 18% overfeed, with simultaneous heat treatment, the product is surprisingly a virtually shrinkage-free yarn which produces a full-bodied, soft sheetlike structure which has good drape and a silky lustre in the case of undelustred polymer.
The resulting yarn is highly suitable for use as a replacement material for cellulose acetate in smooth sheetlike structures and exhibits high utility for napping.
If the overfeed is less than 10%, the result is a yarn having an excessively high shrinkage; an overfeed of more than about 20% gives rise to a form of crimping which is undesirable for the intered use as a smooth yarn.
It is expedient to carry out the dry heat treatment at 140° to 250° C., preferably at 200° to 230° C., in particular at 225° C., combined with a heater length of at least 200 mm.
However, it is also possible to carry out the heat treatment in a fluid, advantageously in water/steam, at 70° to 140° C.
It is expedient to carry out the relaxation at a take-off speed of 100 to 1,000 m/min, preferably at 300 to 700 m/min.
The yarn produced by the process according to the invention is characterized by its stress-strain diagram. Reproducing the complete stress-strain diagram is very revealing of the mechanicaL properties of the yarn under test. In addition, the parameters initial modulus, reversibility limit, tensile strength and elongation at break are determined therefrom in a conventional manner, for example the initial modulus on the linear slope at the start of the diagram, while the reversibility limit corresponds to that strength at which the diagram deviates from the linear curve.
Customarily, yarns of this type are also described by means of a number of thermomechanical parameters which refer to the later processing conditions or performance characteristics. These are the shrinkages (=length changes) or shrinkage forces resulting at defined temperatures and pretensioning forces in water or hot air (see explanations with table).
The yarn according to the invention shall in detail meet the following conditions at one and the same time. It shall have an initial modulus of 200 to 800 cN/tex, in particular 350 to 500 cN/tex, a reversibility limit of 4 to 12 cN/tex, in particular 6 to 12 cN/tex, a boil shrinkage of 0 to 2.8%, in particular 0 to 2%, and intrinsic viscosity of 0.60 to 0.75 dl/g, in particular 0.62 to 0.66 dl/g, measured at 25° C. in a 1:1 mixture of phenol/ tetrachloroethane, a thermoshrinkage of <2% at 160° C. and a pretensioning force of 0.1 cN/tex, and a shrinkage force, measured under the same temperature and pretensioning force conditions, of 0.1 cN/tex.
The substantially relaxed yarn has the advantage that, in the event of a package dyeing, it can be twisted directly without steaming or rewinding onto a perforated dyeing center.
The invention will be illustrated in more detail by reference to examples.
The starting material in both examples is a polyester POY having an intrinsic viscosity of 0.62 dl/g.
Example 1 (continuous process)
A 100-dtex 36-filament polyester POY, produced at a spin speed of 3,100 m/min, is cold-drawn in the 1st stage on a two-stage draw-twist machine at room temperature in a ratio of 1:1.8 without drawing peg and then, in the 2nd stage, is guided under 10% overfeed over a plate-type heater having a length of 48 cm and a heater temperature of 225° C. The tensile force exerted on the yarn during processing in the 2nd stage results from the process-induced stress of relaxation. This is immediately followed by the intermingling at about 25 knots/meter and winding up at 420 m/min.
Example 2 (batch process)
A 100-dtex 36-filament polyester POY spun at 3,100 m/min is drawn at room temperature with a take-off speed of 530 m/min and a draw ratio of 1:1.8 without drawing peg and immediately intermingled after the drawing zone at about 15 knots/meter. In a second operation, the yarn is fed under a 20% overfeed through a closed radiator heater having a langth of 70 cm and a heater temperature of 225° C. In this case too the tensile force exerted on the yarn during processing corresponds to the process-induced stress of relaxation. The take-off speed is 110 m/min.
The polyester yarns according to the invention are represented by their characteristic curves in FIGS. 2-4. In these figures, the curves obtained from the continuous and the batchwise process of manufacture are virtually identical.
DESCRIPTION OF THE DRAWINGS
The invention will be best understood from the following description with reference to appended drawings wherein:
FIG. 1 shows a schematic block-diagram of the process according to the invention,
FIG. 2 shows stress-strain curves of polyester yarns according to the present invention;
FIG. 3 shows thermoshrinkage curves of unloaded polyester yarns according the the present invention; and
FIG. 4 shows thermoshrinkage curves of polyester yarns according to the present invention under a load of 0.1 cN/tex.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the reference numeral 1 designates a first delivery system 1. Delivery system 1 is followed by a second delivery system 2 with a separating roller 2'. A heater 3 is arranged between the delivery system 2 and a take-off system 4 with a separating roller 4' which is followed by a winding unit. An undrawn polyester POY 5a is taken up by the delivery system 1 and is cold-drawn by delivery system 2 in a drawing zone 5b. The take-off system 4 runs at a lower speed than the delivery system 2, as a result of which the drawn yarn passes under an adjustable overfeed preferably heater 3 in a relaxation zone 5c. The result is a hot-relaxed yarn having the properties according to the invention.
It is easy to see the marked relaxation-induced shoulders in the curves of the yarns according to the invention in FIG. 2 show stress-strain curves representing dependence of stretching on the tensile strength of a yarn. The first curve "a" represents a stress-strain curve of an unshrunk polyester (PES) yarn which consists of thirty-six (36) single fibrels (f) wound on a yarn carrier cop and which has a total denier of 84 dtex, where dtex is an international measurement unit characterizing a fineness or denier of a yarn. For convenience, such a yarn is designed as a PES dtex 84 f 36 which is an internationally accepted abbreviation.
The second curve "b" represents a stress-strain curve of a PES dtex 66 f 36 relaxed yarn with a 10% overfeed, and a curve "c" represents a stress-strain curve of a PES dtex 74 f 36 relaxed yarn with a 20% overfeed. Generally, all polyester yarn produced according to the present invention would have stress strain curves lying in the region between curves "b" and "c".
FIG. 3 shows thermoshrinkage values over the entire temperature range of the same polyester yarns shown in FIG. 2. As it is clearly shown in FIG. 3, the shrunk yarns have a much lower value than the unshrunk yarn.
In addition, FIG. 4 shows the pronounced effect of the pretensioning force on the shrinkage with respect to the same yarns as in FIGS. 2 and 3.
For convenience, the results are summarized in the following table:
______________________________________ Standard Example Example yarn A B on cops 10% VE 20% VE______________________________________Intrinsic viscosity dl/g 0.62 0.62 0.62Linear density dtex 71.7 65.6 74.4Strength cN/tex 41.0 37.5 32.0Elongation at break % 21.0 29.0 41.0Reversibility limit cN/tex 18.0 8.4 6.0based on linear densityInitial modulus.sup.4 cN/tex 900 650 330based on linear densityBoil shrinkage.sup.1 % 10.3 1.9 1.2Thermoshrinkage.sup.1 % 12.8 2.5 1.0permanentShrinkage.sup.2 % 10.7 1.0 1.1*effectiveShrinkage force.sup.3 cN/tex 3.2 0.6 0.01**based on linear densityThermoshrinkage.sup.5 cN/tex 30.0 25.0 1.0modulusYarn non-uniformity Uster % 0.9 0.9 1.2Birefringence Δn · 10.sup.-3 180.0 145.0 123.0______________________________________ .sup.1 Permanent change in length after shrinkage process carried out without tension (in hot air about 160° C., 15 min. or in hot water at 98° C., 15 min.) .sup.2 Change in length of yarn under a load of 0.1 cN/tex when heated (160° C., 15 min.) .sup.3 Specific change in force of yarn under a load of 0.1 cN/tex when heated (160° C., 15 min.) .sup.4 Specific force for 100% theoretical extension .sup.5 The effective shrinkage modulus (Sm.sub.e) takes into account the three components linear density (T), effective shrinkage (Se) and the effective shrinkage force Sk.sub.e and is calculated as follows: ##STR1## *Yarn becomes longer **Relative to the pretensioning force, the action of heat brings about a force reduction
The yarn according to the invention is suitable for woven material, knitted material and in particular for pile material such as velvet, velour and the like. The improved tactile properties are very similar to those of cellulose acetate and viscose.
|
A method of producing a smooth, cold-drawn multifilament yarn from a polyester POY comprising cold-drawing of the polyester POY to a draw ratio of at least 1.6 and subsequent hot-relaxing the polyester POY under an over-feed of 10 to 20%, and a polyester yarn produced by this method.
| 3
|
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application No. 61/180,700, filed May 22, 2009 which is incorporated herein by reference in its entirety.
[0002] This application is also related to U.S. application Ser. No. ______ entitled “Safety Features For Integrated Insulin Delivery System,” (U.S. Provisional Application No. 61/180,627, filed May 22, 2009); U.S. application Ser. No. ______ entitled “Usability Features For Integrated Insulin Delivery System,” (U.S. Provisional Application No. 61/180,649, filed May 22, 2009); U.S. application Ser. No. ______ entitled “Safety Layer For Integrated Insulin Delivery System,” (U.S. Provisional Application No. 61/180,774, filed May 22, 2009); and U.S. application Ser. No. ______ entitled “Adaptive Insulin Delivery System,” (U.S. Provisional Application No. 61/180,767, filed May 22, 2009).
BACKGROUND
[0003] Diabetes is a metabolic disorder that afflicts tens of millions of people throughout the world. Diabetes results from the inability of the body to properly utilize and metabolize carbohydrates, particularly glucose. Normally, the finely tuned balance between glucose in the blood and glucose in bodily tissue cells is maintained by insulin, a hormone produced by the pancreas which controls, among other things, the transfer of glucose from blood into body tissue cells. Upsetting this balance causes many complications and pathologies including heart disease, coronary and peripheral artery sclerosis, peripheral neuropathies, retinal damage, cataracts, hypertension, coma, and death from hypoglycemic shock.
[0004] In persons with insulin-dependent diabetes, the symptoms of the disease can be controlled by administering additional insulin (or other agents that have similar effects) by injection or by external or implantable insulin pumps. The “correct” insulin dosage is a function of the level of glucose in the blood. Ideally, insulin administration should be continuously readjusted in response to changes in glucose level.
[0005] Presently, systems are available for continuously monitoring a person's glucose levels by implanting a glucose sensitive probe into the person. Such probes measure various properties of blood or other tissues, including optical absorption, electrochemical potential and enzymatic products. The output of such sensors can be communicated to a hand held device or controller that is used to calculate an appropriate dosage of insulin to be delivered to the user of the continuous glucose monitor (CGM) in view of several factors, such as the user's present glucose level, insulin usage rate, carbohydrates consumed or to be consumed and exercise, among others. These calculations can then be used to control a pump that delivers the insulin, either at a controlled “basal” rate, or as a “bolus” into the user. When provided as an integrated system, the continuous glucose monitor, controller and pump work together to provide continuous glucose monitoring and insulin pump control.
[0006] Such systems can be closed loop systems, where the amount of insulin being delivered is completely controlled by the controller and pump in conjunction with glucose level data received from the CGM device. Alternatively, such systems may be open loop systems, where the user evaluates the glucose level information from a glucose monitoring device and then instructs the pump accordingly, or the system may be a semi-closed loop system that combines various aspects of a closed loop and open loop system.
[0007] Typically, present systems may be considered to be open or semi-closed loop in that they require intervention by a user to calculate and control the amount of insulin to be delivered. However, there may be periods when the user is not able to adjust insulin delivery. For example, when the user is sleeping, he or she cannot intervene in the delivery of insulin, yet control of a patient's glucose level is still necessary. A system capable of integrating and automating the functions of glucose monitoring and controlled insulin delivery into a closed loop system would be useful in assisting users in maintaining their glucose levels, especially during periods of the day when they are unable or unwilling to the required calculations to adjust insulin deliver to control their glucose level.
[0008] What has been needed, and heretofore unavailable, is an integrated, automated system combining continuous glucose monitoring and controlled insulin delivery. Such a system would include various features to insure the accuracy of the glucose monitor and to protect the user from either under- or over-dosage of insulin. The system would include various functions for improving the usability, control, and safety of the system, including a variety of alarms which could be set by a user or a technician to avoid false alarms while ensuring adequate sensitivity to protect the user. The present invention satisfies these and other needs.
SUMMARY OF THE INVENTION
[0009] Briefly, and in general terms, the invention is directed to new and improved systems and methods for management of glucose level management, including systems and methods for improving the usability and safety of systems including continuous glucose monitors and a drug delivery pumps.
[0010] In one aspect, the invention includes programming a processor to be responsive to an input to determine whether an alarm should be presented to a user indicating that a hypoglycemic condition exists, and if so, determine when to present the alarm to the user.
[0011] In another aspect, the state machine comprises a CGM based subsystem that is described in terms of a state machine governing the behavior of the assertion of a CGM based hypoglycemia detection and alarm mechanism and a glucose level based subsystem that is described in terms of a state machine that governs how and when confirmatory glucose level measurements should be taken, how and when rescue carbohydrates should be administered, and when to de-assert the CGM based hypoglycemia detector.
[0012] In still another aspect, the system also uses historical information, such as, for example, previous glucose measurements and insulin delivery history to set a variable delay dependent on a future prediction of glucose level before sounding an alarm. In an alternative embodiment, a look up table may be used to modify the duration of the timer.
[0013] In yet another aspect, the present invention includes a system for monitoring the glucose level of a user, comprising: a continuous glucose monitor; a processor configured to receive signals from the continuous glucose monitor and also adapted to analyze those signals in accordance with software commands, the software commands including commands to program at least a portion of the processor to operate as a state machine, the state machine having a first state when the signals from the continuous glucose monitor indicate a not hypoglycemic state and a second state when the signals indicate that a glucose value is below a selected threshold value.
[0014] In an alternative aspect, the second state includes starting a timer to delay presentation of an alarm to the user, the delay determined by the glucose value; and in still another alternative aspect, the second state includes presenting an alarm to the user and requesting a confirmation measurement of glucose level when the glucose value is below a second selected threshold value that is lower than the first threshold value. In still a further aspect, the second state includes recommending administration of rescue carbohydrates if the confirmation measurement glucose value is below a selected threshold. In yet another aspect, the present invention, an alarm is presented to the user at the expiration of the delay if the signal from the continuous glucose monitor indicates that the glucose value is still below the threshold value.
[0015] In still another aspect, the present invention includes a method for determining when to present a hypoglycemic alarm to a user of a continuous glucose monitor, comprising: providing a controller programmed to operate as a state machine; providing signals from a continuous glucose monitor as input to the state machine; wherein the state machine operates in accordance with the programming and the input to determine if an alarm is to be presented to the user indicating that an actual hypoglycemic condition exists.
[0016] In yet another aspect, the present invention includes a system for monitoring the glucose level of a user, comprising: a continuous glucose monitor configured to transmit signals representative of a glucose value; a processor configured to receive signals from the continuous glucose monitor and also adapted to analyze those signals in accordance with software commands, the software commands including commands to program at least a portion of the processor to operate as an alarm specificity optimizing system, the alarm specificity system having a first subsystem where temporal behavior of the signals from the continuous glucose monitor is used to maximize the specificity of a hypoglycemic event detection and assert a hypoglycemic alarm, and a second subsystem where one or more glucose level measurements is used to ensure whether or not the hypoglycemic event has been resolved.
[0017] In an alternative aspect, optimization of the alarm specificity includes having the first subsystem starting one or more timers to delay presentation of an alarm to the user, wherein the delay for each timer is a function of the level of hypoglycemia indicated by signals received from the continuous glucose monitor. In another alternative aspect, the second subsystem includes requesting a confirmation measurement of glucose level when the first subsystem presents an alarm or when a value of a previous glucose level measurement is below a selected threshold value. In still another alternative aspect, the second subsystem includes recommending administration of rescue carbohydrates if the confirmation measurement glucose value is below a selected threshold.
[0018] In still another alternative aspect, the second subsystem utilizes temporal glucose information and other relevant information to aid in minimizing false alarms by determining the appropriate amount of delay since the latest glucose level measurement that confirms a non-hypoglycemic event before the first subsystem can start detecting hypoglycemic events again. In yet another alternative aspect, an alarm is presented to the user at the expiration of the delay if the signal from the continuous glucose monitor indicates that the glucose value is still below the threshold value; and in a further alternative aspect, the delay can be zero if the glucose measurement is below a low glucose threshold value.
[0019] In still another aspect, the present invention includes a method for determining when to present a hypoglycemic alarm to a user of a continuous glucose monitor, comprising: providing at least one timer to track the amount of time since one or more low glucose value thresholds have been passed; providing signals from a continuous glucose monitor as an input to a processor controlling the operation of the at least one timer; presenting a hypoglycemic alarm when the at least one timer has elapsed; requesting a glucose level measurement to verify a hypoglycemic event; utilizing glucose level measurements to determine whether the at least one timer should reset and start over; utilizing continuous glucose measurements, knowledge of a meal, knowledge of insulin delivery, and other physiologically relevant information in order to determine the amount of time before the at least one timer can be reset and start detecting hypoglycemic events again since the last time a glucose level measurement confirms that the patient is no longer in a hypoglycemic state; utilizing glucose level measurements to suggest corrective action such as taking rescue carbohydrates when the latest glucose level measurement confirms that the patient is in a hypoglycemic state; and wherein the processor operates in accordance with suitable programming and the input to determine if an alarm is to be presented to the user indicating that an actual hypoglycemic condition exists.
[0020] In another aspect, the present invention includes a method for determining when to present a hypoglycemic alarm to a user of a continuous glucose monitor, comprising: providing a plurality timers to track the amount of time since one or more low glucose value thresholds have been passed; providing signals from a continuous glucose monitor as a primary input to the system; presenting a hypoglycemic alarm when any one of the plurality of timers has elapsed past its corresponding limit; requesting a glucose level measurement to verify the hypoglycemic event; utilizing glucose level measurements to confirm the predicted hypoglycemic event; utilizing continuous glucose measurements, knowledge of a meal, knowledge of insulin delivery, and other physiologically relevant information in order to determine the amount of time before the plurality of timers can reset and start detecting hypoglycemic events again since the last time a glucose level measurement confirms that the patient is no longer in a hypoglycemic state; wherein the system operates in accordance with suitable programming and the input to determine if an alarm is to be presented to the user indicating that an actual hypoglycemic condition exists.
[0021] In yet another aspect, the present invention includes a system for monitoring the glucose level of a user, comprising: a continuous glucose monitor; a processor configured to receive signals from the continuous glucose monitor and also adapted to analyze those signals in accordance with software commands, the software commands including commands to program at least a portion of the processor to operate as a state machine, the state machine having a first state when the signals from the continuous glucose monitor are used to predict threshold detection with minimal annunciation of a false alarm with respect to signal artifacts and a second state when the signals confirm the event prediction. In an alternative aspect, the second state includes minimizing the false alarm with respect to signal artifacts by starting a timer to delay presentation of an alarm to the user, the delay determined by the glucose value.
[0022] Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic diagram illustrating an exemplary embodiment of a controller and its various components in operable communication with one or more medical devices, such as a glucose monitor or drug delivery pump, and optionally, in operable communication with a remote controller device.
[0024] FIG. 2 is a graphical representation of a glucose profile showing glucose level measured using a CGM sensor as a function of time, and also showing the variation of the glucose level as function of carbohydrate intake and insulin administration.
[0025] FIG. 3 is a schematic diagram of a continuous glucose monitor based subsystem, illustrated in terms of a state machine.
[0026] FIG. 4 is a schematic diagram of a glucose level based subsystem illustrated in terms of a state machine coupled to the continuous glucose monitor subsystem of FIG. 3 .
[0027] FIG. 5 is a schematic diagram of an embodiment of the invention wherein the continuous glucose monitor and glucose level state machines are coupled to a stronger degree than the embodiments shown in FIGS. 3 and 4 , and also showing an additional delay timer asserted after glucose level confirmation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to a number of illustrative embodiments shown in the attached drawings and specific language will be used to describe the same. It will be understood that throughout this document, the terms “user” and “patient” are used interchangeably.
[0029] Referring now to FIG. 1 , a block diagram of one illustrative embodiment of a system 10 for determining drug administration information is shown. In the illustrated embodiment, the system 10 includes an electronic device 12 , which may be handheld, having a processor 14 in data communication with a memory unit 16 , an input device 18 , a display 20 , and a communication input/output unit 24 . The electronic device 12 may be provided in the form of a general purpose computer, central server, personal computer (PC), lap top or notebook computer, personal data assistant (PDA), programmable telephone or cellular phone or other hand-held device, external infusion pump, glucose level meter, analyte sensing system, or the like. The electronic device 12 may be configured to operate in accordance with one or more conventional operating systems including for example, but not limited to, the Windows® operating system (distributed by Microsoft Corporation), the Linux operating system, the Mac OS® (distributed by Apple, Inc.) and embedded operating systems such as the QNX® operating system (distributed by QNX Software Systems), the eCOS® operating system (distributed by eCosCentric Limited), Windows CEO (distributed by Microsoft Corporation) and the Palm® operating system (distributed by Palm Inc.), and may be configured to process data according to one or more conventional internet protocols for example, but not limited to, NetBios, TCP/IP and AppleTalk® (Apple, Inc.). In any case, the electronic device 12 forms part of a fully closed-loop, semi closed-loop, or open loop diabetes control system.
[0030] The processor 14 is microprocessor-based, although processor 14 may alternatively be formed of one or more general purpose and/or application specific circuits and operable as described hereinafter. The processor 14 is programmed using appropriate software commands that may be stored in the memory or communicated to the processor 14 as needed. The memory unit 16 includes sufficient capacity to store data, one or more software algorithms executable by the processor 14 and other data. The memory unit 16 may include one or more conventional memory or other data storage devices. Electronic device 12 may also include an integrated glucose level meter for use in calibrating a continuous glucose monitor (CGM) or for calculating insulin amounts for bolus delivery.
[0031] The input device 18 may be used in a conventional manner to input and/or modify data. The display 20 is also included for viewing information relating to operation of the device 12 and/or system 10 . Such a display may be a conventional display device including for example, but not limited to, a light emitting diode (LED) display, a liquid crystal display (LCD), a cathode ray tube (CRT) display, or the like. Alternatively or additionally, the display 20 may be or include an audible display configured to communicate information to a user, another person, or another electronic system having audio recognition capabilities via one or more coded patterns, vibrations, synthesized voice responses, or the like. Alternatively or additionally, the display 20 may be or include one or more tactile indicators configured to display or annunciate tactile information that may be discerned by the user or another person.
[0032] The input device 18 may be or include a conventional keyboard or keypad for entering alphanumeric data into the processor 14 . Such a keyboard or keypad may include one or more keys or buttons configured with one or more tactile indicators to allow users with poor eyesight to find and select an appropriate one or more of the keys, and/or to allow users to find and select an appropriate one or more of the keys in poor lighting conditions. Alternatively or additionally, the input device 18 may be or include a conventional mouse or other conventional point and click device for selecting information presented on the display 20 . Alternatively or additionally, the input device 18 may include the display 20 configured as a graphical user interface (GUI). In this embodiment, the display 20 may include one or more selectable inputs that a user may select by touching an appropriate portion of the display 20 using an appropriate implement. Alternatively, the display 20 may be configured as a touch-screen capable of responding to user activation to, for example, enter data or select device functions.
[0033] Alternatively, the input device 18 may also include a number of switches or buttons that may be activated by a user to select corresponding operational features of the device 12 and/or system 10 . Input device 18 may also be or include voice-activated circuitry responsive to voice commands to provide corresponding input data to the processor 14 . In any case, the input device 18 and/or display 20 may be included with or separate from the electronic device 12 .
[0034] System 10 may also include a number of medical devices which carry out various functions, for example, but not limited to, monitoring, sensing, diagnostic, communication and treatment functions. In such embodiments, any of the one or more of the medical devices may be implanted within the user's body, coupled externally to the user's body (e.g., such as an infusion pump), or separate from the user's body. Alternatively or additionally, one or more of the medical devices may be mounted to and/or form part of the electronic device 12 . Typically, the medical devices are each configured to communicate wirelessly with the communication I/O unit 24 of the electronic device 12 via one of a corresponding number of wireless communication links.
[0035] The wireless communications between the various components of the system 10 may be one-way or two-way. The form of wireless communication used may include, but is not limited to, radio frequency (RF) communication, infrared (IR) communication, Wi-Fi, RFID (inductive coupling) communication, acoustic communication, capacitive signaling (through a conductive body), galvanic signaling (through a conductive body), or the like. In any such case, the electronic device 12 and each of the medical devices include conventional circuitry for conducting such wireless communications circuit. Alternatively, one or more of the medical devices may be configured to communicate with the electronic device 12 via one or more conventional serial or parallel configured hardwire connections therebetween.
[0036] Each of the one or more medical devices 26 may include one or more of a conventional processing unit 52 , conventional input/output circuitry and/or devices 56 , 58 communication ports 60 and one or more suitable data and/or program storage devices 58 . It will be understood that not all medical devices 26 will have the same componentry, but rather will only have the components necessary to carry out the designed function of the medical device. For example, in one embodiment, a medical device 26 may be capable of integration with electronic device 12 and remote device 30 . In another embodiment, medical device may also be capable of stand-alone operation, should communication with electronic device 12 or remote device 30 be interrupted. In another embodiment, medical device 26 may include processor, memory and communication capability, but does not have a display 58 or input 56 . In still another embodiment, the medical device 26 may include an input 56 , but lack a display 58 .
[0037] In some embodiments, the system 10 may alternatively or additionally include a remote device 30 . The remote device 30 may include a processor 32 , which may be identical or similar to the processor 14 , a memory or other data storage unit 34 , an input device 36 , which may be or include any one or more of the input devices described hereinabove with respect to the input device 18 , a display unit 38 , which may be or include any one or more of the display units described hereinabove with respect to the display unit 20 , and communication I/O circuitry 40 . The remote device 30 may be configured to communicate with the electronic device 12 or medical devices(s) 26 via any wired or wireless communication interface 42 , which may be or include any of the communication interfaces or links described hereinabove. Although not shown, remote device 30 may also be configured to communicate directly with one or more medical devices 26 , instead of communicating with the medical device 26 through electronic device 12 .
[0038] The system 10 illustrated in FIG. 1 is, or forms part of, a fully closed-loop, semi closed-loop, or open loop diabetes control arrangement. In this regard, the system 10 requires user input of some amount of information from which the system 10 determines, at least in part, insulin bolus administration information. Such insulin bolus administration information may be or include, for example, insulin bolus quantity or quantities, bolus type, insulin bolus delivery time, times or intervals (e.g., single delivery, multiple discrete deliveries, continuous delivery, etc.), and the like. Examples of user supplied information may be, for example but not limited to, user glucose level concentration, interstitial glucose level information, information relating to a meal or snack that has been ingested, is being ingested, or is to be ingested sometime in the future, user exercise information, user stress information, user illness information, information relating to the user's menstrual cycle, and the like. In any case, the system 10 includes a delivery mechanism for delivering controlled amounts of a drug; such as, for example, insulin, glucagon, incretin, or the like, and/or offering an alternatively actionable therapy recommendation to the user via the display 20 , such as, for example, directions or instructions related to ingesting carbohydrates, exercising, and the like.
[0039] The system 10 may be provided in any of a variety of configurations, and examples of some such configurations will now be described. It will be understood, however, that the following examples are provided merely for illustrative purposes, and should not be considered limiting in any way. Those skilled in the art may recognize other possible implementations of a fully closed-loop, semi closed-loop, or open loop diabetes control arrangement, and any such other implementations are contemplated by this disclosure.
[0040] In a first exemplary implementation of the system 10 , the electronic device 12 is provided in the form of an insulin pump configured to be worn externally to the user's body and also configured to controllably deliver insulin to the user's body. In this example, the medical devices 26 may include one or more implanted sensors and/or sensor techniques for providing information relating to the physiological condition of the user. Examples of such implanted sensors may include, but should not be limited to, a glucose sensor, a body temperature sensor, a blood pressure sensor, a heart rate sensor, one or more bio-markers configured to capture one or more physiological states of the body, such as, for example, HBA1C, or the like.
[0041] In implementations that include an implanted glucose sensor, the system 10 may be a fully closed-loop system operable in a conventional manner to automatically monitor glucose level and deliver insulin, as appropriate, to maintain glucose at desired levels. The various medical devices may alternatively or additionally include one or more sensors or sensing systems that are external to the user's body and/or sensor techniques for providing information relating to the physiological condition of the user. Examples of such sensors or sensing systems may include, but should not be limited to, a glucose strip sensor/meter, a body temperature sensor, a blood pressure sensor, a heart rate sensor, one or more bio-markers configured to capture one or more physiological states of the body, such as, for example, HBA1C, or the like.
[0042] In implementations that include an external glucose sensor, the system 10 may be a closed-loop, semi closed-loop, or open loop system operable in a conventional manner to deliver insulin, as appropriate, based on glucose information provided thereto by the user. Information provided by any such sensors and/or sensor techniques may be communicated to the system 10 using any one or more conventional wired or wireless communication techniques. In this exemplary implementation, the remote device 30 may also be included in the form of a handheld or otherwise portable electronic device configured to communicate information to and/or from the electronic device 12 .
[0043] In a second exemplary implementation of the system 10 , the electronic device 12 is provided in the form of a handheld remote device, such as a PDA, programmable cellular phone, or other handheld device. In this example, the medical devices 26 include at least one conventional implantable or externally worn drug pump. In one embodiment of this example, an insulin pump is configured to controllably deliver insulin to the user's body. In this embodiment, the insulin pump is configured to wirelessly transmit information relating to insulin delivery to the handheld device 12 . The handheld device 12 is configured to monitor insulin delivery by the pump, and may further be configured to determine and recommend insulin bolus amounts, carbohydrate intake, exercise, and the like. The system 10 may or may not be configured in this embodiment to provide for transmission of wireless information from the handheld device 12 to the insulin pump.
[0044] In an alternate embodiment of this example, the handheld device 12 is configured to control insulin delivery to the user by determining insulin delivery commands and transmitting such commands to the insulin pump. The insulin pump, in turn, is configured to receive the insulin delivery commands from the handheld device 12 , and to deliver insulin to the user according to the commands. The insulin pump, in this embodiment, may or may not further process the insulin pump commands provided by the handheld unit 12 . In any case, the system 10 will typically be configured in this embodiment to provide for transmission of wireless information from the insulin pump back to the handheld device 12 to thereby allow for monitoring of pump operation. In either embodiment of this example, the system 10 may further include one or more implanted and/or external sensors of the type described in the previous example. In this exemplary implementation, a remote device 30 may also be included in the form of, for example, a PC, PDA, programmable cellular phone, laptop or notebook computer configured to communicate information to and/or from the electronic device 12 .
[0045] Those skilled in the art will recognize other possible implementations of a fully closed-loop, semi closed-loop, or open loop diabetes control arrangement using at least some of the components of the system 10 illustrated in FIG. 1 . For example, the electronic device 12 in one or more of the above examples may be provided in the form of a PDA, programmable cellular phone, laptop, notebook or personal computer configured to communicate with one or more of the medical devices 26 , at least one of which is an insulin delivery system, to monitor and/or control the delivery of insulin to the user. As another example, the remote device 30 may be configured to communicate with the electronic device 12 and/or one or more of the medical devices 26 , to control and/or monitor insulin delivery to the patient, and/or to transfer one or more software programs and/or data to the electronic device 12 . The remote device 30 may reside in a caregiver's office or other remote location, and communication between the remote device and any component of the system 10 may be accomplished via an intranet, internet (such as, for example, through the world-wide-web), cellular, telephone modem, RF, or other communication link. Any one or more conventional internet protocols may be used in such communications. Alternatively or additionally, any conventional mobile content delivery system; such as, for example, Wi-Fi, WiMAX, short message system (SMS), or other conventional message scheme may be used to provide for communication between devices comprising the system 10 .
[0046] Generally, the concentration of glucose in a person changes as a result of one or more external influences such as meals and exercise, and also changes resulting from various physiological mechanisms such as stress, illness, menstrual cycle and the like. In a person with diabetes, such changes can necessitate monitoring the person's glucose level and administering insulin or other glucose level altering drug, such as, for example, a glucose lowering or raising drug, as needed to maintain the person's glucose level within a desired range. In any of the above examples, the system 10 is thus configured to determine, based on some amount of patient-specific information, an appropriate amount, type and/or timing of insulin or other glucose level altering drug to administer in order to maintain normal glucose levels without causing hypoglycemia or hyperglycemia. In some embodiments, the system 10 is configured to control one or more external insulin pumps, such as, for example, subcutaneous, transcutaneous or transdermal pumps, and/or implanted insulin pumps to automatically infuse or otherwise supply the appropriate amount and type of insulin to the user's body in the form of one or more insulin boluses.
[0047] In other embodiments, the system 10 is configured to display or otherwise notify the user of the appropriate amount, type, and/or timing of insulin in the form of an insulin delivery or administration recommendation or instruction. In such embodiments, the hardware and/or software forming system 10 allows the user to accept the recommended insulin amount, type, and/or timing, or to reject it. If the recommendation is accepted by the user, the system 10 , in one embodiment, automatically infuses or otherwise provides the appropriate amount and type of insulin to the user's body in the form of one or more insulin boluses. If, on the other hand, the user rejects the insulin recommendation, the hardware and/or software forming system 10 allows the user to override the system 10 and manually enter values for insulin bolus quantity, type, and/or timing in the system. The system 10 is thus configured by the user to automatically infuse or otherwise provide the user specified amount, type, and/or timing of insulin to the user's body in the form of one or more insulin boluses.
[0048] Alternatively, the appropriate amount and type of insulin corresponding to the insulin recommendation displayed by the system 10 may be manually injected into, or otherwise administered to, the user's body. It will be understood, however, that the system 10 may alternatively or additionally be configured in like manner to determine, recommend, and/or deliver other types of medication to a patient.
[0049] The system 10 is operable, as just described, to determine and either recommend or administer an appropriate amount of insulin or other glucose level lowering drug to the patient in the form of one or more insulin boluses. In order to determine appropriate amounts of insulin to be delivered or administered to the user to bring the user's glucose level within an acceptable range, the system 10 requires at least some information relating to one or more external influences and/or various physiological mechanisms associated with the user. For example, if the user is about to ingest, is ingesting, or has recently ingested, a meal or snack, the system 10 generally requires some information relating to the meal or snack to determine an appropriate amount, type and/or timing of one or more meal compensation boluses of insulin. When a person ingests food in the form of a meal or snack, the person's body reacts by absorbing glucose from the meal or snack over time. For purposes of this document, any ingesting of food may be referred to hereinafter as a “meal,” and the term “meal” therefore encompasses traditional meals, such as, for example, breakfast, lunch and dinner, as well as intermediate snacks, drinks, and the like.
[0050] FIG. 2 depicts a typical glucose absorption profile 200 for a user measured using a CGM sensor. The graph 205 plots the measured glucose level as a function of time. This profile shows the effect on glucose level of various actions, such as carbohydrate intake 210 , and the delivery of rapid acting insulin 210 and long acting insulin 230 .
[0051] The general shape of a glucose absorption profile for any person rises following ingestion of the meal, peaks at some measurable time following the meal, and then decreases thereafter. The speed, that is, the rate from beginning to completion, of any one glucose absorption profile typically varies for a person by meal composition, meal type or time (such as, for example, breakfast, lunch, dinner, or snack) and/or according to one or more other factors, and may also vary from day-to-day under otherwise identical meal circumstances. Generally, the information relating to such meal intake information supplied by the user to the system 10 should contain, either explicitly or implicitly, an estimate of the carbohydrate content of the meal or snack, corresponding to the amount of carbohydrates that the user is about to ingest, is ingesting, or has recently ingested, as well as an estimate of the speed of overall glucose absorption from the meal by the user.
[0052] The estimate of the amount of carbohydrates that the patient is about to ingest, is ingesting, or has recently ingested, may be provided by the user in any of various forms. Examples include, but are not limited to, a direct estimate of carbohydrate weight (such as, for example, in units of grams or other convenient weight measure), an amount of carbohydrates relative to a reference amount (such as, for example, dimensionless), an estimate of meal or snack size (such as, for example, dimensionless), and an estimate of meal or snack size relative to a reference meal or snack size (such as, for example, dimensionless). Other forms of providing for user input of carbohydrate content of a meal or snack will occur to those skilled in the art, and any such other forms are contemplated by this disclosure.
[0053] The estimate of the speed of overall glucose absorption from the meal by the user may likewise be provided by the user in any of various forms. For example, for a specified value of the expected speed of overall glucose absorption, the glucose absorption profile captures the speed of absorption of the meal taken by the user. As another example, the speed of overall glucose absorption from the meal by the user also includes time duration between ingesting of the meal by a user and the peak glucose absorption of the meal by that user, which captures the duration of the meal taken by the user. The speed of overall glucose absorption may thus be expressed in the form of meal speed or duration. Examples of the expected speed of overall glucose absorption parameter in this case may include, but are not limited to, a compound parameter corresponding to an estimate of the meal speed or duration (such as, for example, units of time), a compound parameter corresponding to meal speed or duration relative to a reference meal speed or duration (such as, for example, dimensionless), or the like.
[0054] As another example of providing the estimate of the expected speed of overall glucose absorption parameter, the shape and duration of the glucose absorption profile may be mapped to the composition of the meal. Examples of the expected speed of overall glucose absorption parameter in this case may include, but are not limited to, an estimate of fat amount, protein amount and carbohydrate amount (such as, for example, in units of grams) in conjunction with a carbohydrate content estimate in the form of meal size or relative meal size, an estimate of fat amount, protein amount and carbohydrate amount relative to reference fat, protein and carbohydrate amounts in conjunction with a carbohydrate content estimate in the form of meal size or relative meal size, and an estimate of a total glycemic index of the meal or snack (such as, for example, dimensionless), wherein the term “total glycemic index” is defined for purposes of this document as a parameter that ranks meals and snacks by the speed at which the meals or snacks cause the user's glucose level to rise. Thus, for example, a meal or snack having a low glycemic index produces a gradual rise in glucose level whereas a meal or snack having a high glycemic index produces a fast rise in glucose level. One exemplary measure of total glycemic index may be, but is not limited to, the ratio of carbohydrates absorbed from the meal and a reference value, such as, for example, derived from pure sugar or white bread, over a specified time period, such as, for example, 2 hours. Other forms of providing for user input of the expected overall speed of glucose absorption from the meal by the patient, and/or for providing for user input of the expected shape and duration of the glucose absorption profile generally will occur to those skilled in the art, and any such other forms are contemplated by this disclosure.
[0055] Generally, the concentration of glucose in a person with diabetes changes as a result of one or more external influences such as meals and/or exercise, and may also change resulting from various physiological mechanisms such as stress, menstrual cycle and/or illness. In any of the above examples, the system 10 responds to the measured glucose by determining the appropriate amount of insulin to administer in order to maintain normal glucose levels without causing hypoglycemia. In some embodiments, the system 10 is implemented as a discrete system with an appropriate sampling rate, which may be periodic, aperiodic or triggered, although other continuous systems or hybrid systems may alternatively be implemented as described above.
[0056] As one example of a conventional diabetes control system, one or more software algorithms may include a collection of rule sets which use (1) glucose information, (2) insulin delivery information, and/or (3) user inputs such as meal intake, exercise, stress, illness and/or other physiological properties to provide therapy, and the like, to manage the user's glucose level. The rule sets are generally based on observations and clinical practices as well as mathematical models derived through or based on analysis of physiological mechanisms obtained from clinical studies. In the exemplary system, models of insulin pharmacokinetics and pharmacodynamics, glucose pharmacodynamics, meal absorption and exercise responses of individual patients are used to determine the timing and the amount of insulin to be delivered. A learning module may be provided to allow adjustment of the model parameters when the patient's overall performance metric degrades such as, for example, adaptive algorithms, using Bayesian estimates, may be implemented. An analysis model may also be incorporated which oversees the learning to accept or reject learning. Adjustments are achieved utilizing heuristics, rules, formulae, minimization of cost function(s) or tables (such as, for example, gain scheduling).
[0057] Predictive models can be programmed into the processor(s) of the system using appropriate embedded or inputted software to predict the outcome of adding a controlled amount of insulin or other drug to a user in terms of the an expected glucose value. The structures and parameters of the models define the anticipated behavior.
[0058] Any of a variety of conventional controller design methodologies, such as PID systems, full state feedback systems with state estimators, output feedback systems, LQG (Linear-Quadratic-Gaussian) controllers, LQR (Linear-Quadratic-Regulator) controllers, eigenvalue/eigenstructure controller systems, and the like, could be used to design algorithms to perform physiological control. They typically function by using information derived from physiological measurements and/or user inputs to determine the appropriate control action to use. While the simpler forms of such controllers use fixed parameters (and therefore rules) for computing the magnitude of control action, the parameters in more sophisticated forms of such controllers may use one or more dynamic parameters. The one or more dynamic parameters could, for example, take the form of one or more continuously or discretely adjustable gain values. Specific rules for adjusting such gains could, for example, be defined either on an individual basis or on the basis of a user population, and in either case will typically be derived according to one or more mathematical models. Such gains are typically scheduled according to one or more rule sets designed to cover the expected operating ranges in which operation is typically nonlinear and variable, thereby reducing sources of error.
[0059] Model based control systems, such as those utilizing model predictive control algorithms, can be constructed as a black box wherein equations and parameters have no strict analogs in physiology. Rather, such models may instead be representations that are adequate for the purpose of physiological control. The parameters are typically determined from measurements of physiological parameters such as glucose level, insulin concentration, and the like, and from physiological inputs such as food intake, alcohol intake, insulin doses, and the like, and also from physiological states such as stress level, exercise intensity and duration, menstrual cycle phase, and the like. These models are used to estimate current glucose level or to predict future glucose levels. Such models may also take into account unused insulin remaining in the user after a bolus of insulin is given, for example, in anticipation of a meal. Such unused insulin will be variously described as unused, remaining, or “insulin on board.”
[0060] Insulin therapy is derived by the system based on the model's ability to predict glucose levels for various inputs. Other conventional modeling techniques may be additionally or alternatively used to predict glucose levels, including for example, but not limited to, building models from first principles.
[0061] In a system as described above, the controller is typically programmed to provide a “basal rate” of insulin delivery or administration. Such a basal rate is the rate of continuous supply of insulin by an insulin delivery device such as a pump that is used to maintain a desired glucose level in the user. Periodically, due to various events that affect the metabolism of a user, such as eating a meal or engaging in exercise, a “bolus” delivery of insulin is required. A “bolus” is defined as a specific amount of insulin that is required to raise the blood concentration of insulin to an effective level to counteract the affects of the ingestion of carbohydrates during a meal and also takes into account the affects of exercise on the glucose level of the user.
[0062] As described above, an analyte monitor may be used to continuously monitor the glucose level of a user. The controller is programmed with appropriate software and uses models as described above to predict the affect of carbohydrate ingestion and exercise, among other factors, on the predicted level of glucose of the user at a selected time. Such a model must also take into account the amount of insulin remaining in the blood stream from a previous bolus or basal rate infusion of insulin when determining whether or not to provide a bolus of insulin to the user.
[0063] Continuous glucose monitoring (CGM) systems occasionally exhibit non-zero-mean signal artifacts commonly called “dropout,” where the sensor signal output is momentarily lower than it should be given an interstitial glucose value. From a closed-loop control perspective, this measurement error poses an annoyance in that the falsely lower signal could trigger a momentary reduction or cessation of insulin delivery commands due to the perceived hypoglycemia event. This can result in a false alarm based either on a perceived current glucose level or a computed future glucose level.
[0064] In an embodiment of the invention, a means for reducing false hypoglycemic alarms due to a combination of a user's glucose range being mostly euglycemia (normal) and CGM system signal artifacts such as dropouts which tend to negatively bias the glucose display is presented. In such an embodiment, the threshold for detecting a hypoglycemic threshold is modified by introducing a conditional time delay such that most dropouts are shorter in duration than the time delay so that the dropouts do not trigger an alarm. Additionally, the threshold is modified appropriately so that detection of true hypoglycemic events are not delayed beyond what has been determined to be clinically safe.
[0065] It is possible, using clinical data and insulin delivery information, to tune a CGM system to provide a balance between hypoglycemic detection sensitivity and reasonable specificity that minimizes false alarms under a wide range of glucose profiles. With good glycemic control, the proportion of true-hypoglycemia may be reduced significantly enough that signal artifacts of the CGM system become an important factor in causing false alarm rates.
[0066] In one embodiment of the invention, a combination of glucose level measurements, known CGM signal artifact characteristics, and the best estimate of relevant physiological states, such as, \or example, plasma glucose, interstitial glucose, insulin onboard, and effective insulin, are used to delay the enunciation of a CGM-based hypoglycemic alarm and determine whether or not the alarm should persist. In this embodiment, instead of using an artifact detector which relies on a mechanism that is sensitive to the artifacts in the signal, the alarm instead is tuned to be insensitive to the artifacts, yet at the same time maintain a safe level of sensitivity to hypoglycemic events.
[0067] The CGM based hypoglycemic alarm of one embodiment of the invention comprises several hypoglycemic thresholds. For each threshold, there exists a timer that may potentially enunciate a hypoglycemic alarm. The lower the threshold, the shorter the amount of delay between the time the CGM measurement value is obtained and when the alarm is sounded. The amount of delay depends primarily on the level of risk associated with the delayed response to a true hypoglycemic event at a given glucose level as well as the probability of the duration of false alarms due to the presence of CGM signal artifacts at a given glucose level.
[0068] The CGM-based hypoglycemic alarm may result in the system recommending that a finger stick glucose level measurement request. If the glucose level measurement resulting from the finger stick indicates that the CGM measured hypoglycemia does not exist, the system can turn off the alarm. Alternatively, if the finger stick glucose level measurement confirms the presence of hypoglycemia, then the controller may indicate to the user that certain actions, such as taking rescue carbohydrates and/or checking glucose level frequently thereafter until the condition has been resolved, may be required.
[0069] A user with a well-controlled glucose level, using either a fully automatic closed loop system, a partial closed loop system or intensive open loop treatment, may have a glucose profile and distribution that is altered enough that the amount of false hypoglycemic alarms from the system is significantly larger than found in the general population of clinical date used to tune and confirm the hypoglycemic alarm response. The primary reason for this is that in the lower glucose range, the effect of signal artifacts from the CGM device become more dominant.
[0070] The CGM signal artifacts that reduce the effectiveness of the CGM-based hypoglycemic alarm have been found to have an a-priori distribution of severity, duration and trajectory profile. Given a user's history of glucose levels, insulin delivery, and other relevant physiological information, a particular level of hypoglycemia carries a particular level of risk in terms of the maximum delay allowed before treatment should begin to avoid the affects of severe hypoglycemia. Delaying a hypoglycemic alarm to the extent that it is still clinically safe and yet as long as possible can reduce the false alarms due to the CGM signal artifacts.
[0071] Given a glucose level confirmation and possibly a corrective action such as administering rescue carbohydrates, glucose can be estimated with sufficient confidence such that for a finite horizon in the future, there is no need to activate the CGM-based hypoglycemic alarm. This further decreases the likelihood of false alarms.
[0072] In one embodiment of the invention, the controller is programmed using appropriate software so as to set up two separate subsystems for decision making While these subsystems will be described in terms of one or more state machines, those skilled in the art will understand that the scope of the invention is not so limited. The concept of state machines is well known to those skilled in the art of control theory and engineering. Thus, skilled artisans will understand how to program the processor to implement such a state machine.
[0073] FIG. 3 illustrates a state machine which governs the behavior of the assertion of the CGM-based hypoglycemic detector. FIG. 3 illustrates a state machine which governs how and when confirmatory glucose level measurements, such as by a finger stick, should be taken, how and when rescue carbohydrates should be administered, and when to de-assert the CGM based hypoglycemic detector.
[0074] Referring now to FIG. 3 , the purpose of the CGM state machine is to determine when a hypoglycemic alarm should be asserted relative to a CGM threshold reading. The CGM state machine begins at 105 . The moment CGM measurements start to become available, the state machine enters the “no hypoglycemia confirmed” state 110 . Within this state, the controller obtains a current CGM value, and, depending on the value of the measurement, controls the analysis along one of several paths. For example, if the latest CGM value (at the CGM check 115 ) is less than or equal to 3.5 mMol/L (63 mg/dL) but greater than 3.0 mMol/L (54 mg/dL), a delay timer of 40 minutes is implemented at state 120 . If the CGM value is greater than 2.5 mMol/L (45 mg/dL) but less than or equal to 3.0 mMol/L (54 mg/dL), a delay of 30 minutes is implemented at state 125 . Similarly, if the CGM value is greater than 2.0 mMol/L (36 mg/dL) but less than or equal to 2.5 mMol/L (45 mg/dL), a delay of 20 minutes is implemented at state 130 .
[0075] When any of the timers set at states 120 , 125 or 130 expire, and the latest CGM value is still no higher than the corresponding upper limits for the delayed timer module states 120 , 125 or 130 , the state changes to “confirm intermediate hypoglycemia” at state 140 . In this state, the controller resets all of the timers of states 120 , 125 and 130 , and sets the hypoglycemia alarm to on. This state prevents the alarm from sounding unnecessarily when a user's glucose level is still within a range where the annoyance of an alarm outweighs the risk that the user is actually in a hypoglycemic condition that requires immediate attention. Once the alarm is sounded, the CGM state machine returns to the “no confirmed hypoglycemic state” 110 .
[0076] Where the CGM value is less than or equal to 2.0 mMol/L (36 mg/dL), which is indicative of severe hypoglycemia, no delay is implemented, and the machine exits from the “no confirmed hypoglycemia” state 110 directly to the “confirm severe hypoglycemia” state 145 . In this state, all of the timers of states 120 , 125 and 130 are reset, the hypoglycemia alarm is set to on, thus sounding an alarm, and the controller continues to check the current CGM value. In this state the system cannot return to the “no confirmed hypoglycemia” state 110 until the latest CGM value rises above 3.5 mMol/L (63 mg/dL). Note that the hypoglycemia alarm, which was already activated, is related to the glucose level subsystem. The fact that the CGM subsystem state machine returns to “no confirmed hypoglycemia” 110 whether or not the latest alarm has been confirmed by a separate glucose level reading means that any time the CGM reads low values again, the potential for another false hypoglycemia alarm can be prevented.
[0077] Referring now to FIG. 4 , the controller is programmed to set up a separate glucose level (BG) subsystem, which will be described in terms of a state machine. This state machine de-asserts the hypoglycemic alarm upon non-hypoglycemic confirmation using glucose level at a fixed threshold, such as when the glucose level is equal to 3.5 mMol/L (63 mg/dL). When the system starts, the BG state machine initializes into state 205 . In this state, no glucose level check is needed, and the hypoglycemia alarm is set to off.
[0078] When the CGM state machine asserts the hypoglycemic alarm at states 140 or 145 , the BG state machine performs a transition 207 , where the BG state machine enters a “BG check needed” state 210 . In this state, the system requests and waits for a finger stick glucose level measurement at 215 , and, if a “BG equals hypoglycemia” confirmation results from the finger stick, the controller alerts the user at state 220 . The hypoglycemia confirmation based on the BG finger stick may be set at the uppermost limit of the CGM state machine's limits, which may be equal to 3.5 mMol/L (63 mg/dL) as depicted in FIG. 2 , or any other suitable value. The user may then address the low glucose level measurement by taking rescue carbohydrates at state 220 . This action may be recommended by the controller. The controller also requests that another glucose level be measured in 15 minutes. This process continues until the latest glucose level indicates that the user is no longer in a hypoglycemic state.
[0079] The previous embodiments illustrated in FIGS. 3 and 4 may be generalized further by removing the actions “confirm intermediate hypoglycemia” ( FIG. 3 , reference number 140 ) and “confirm severe hypoglycemia” ( FIG. 3 , reference number 145 ) from the CGM state machine. In this embodiment, no CGM hypoglycemia timers are reset until the timers expire and the hypoglycemic alarm is enunciated. This is allows for several alarm mechanisms occurring simultaneously.
[0080] In an alternative embodiment, if the current CGM glucose value rises above 3.5 mM at any time while the CGM state machine is in the “no confirmed hypoglycemia” state 110 , the alarm may be reset and the controller returns to processing incoming CGM data as before. In this case, no alarm will be sounded.
[0081] Referring now to FIG. 5 , another embodiment of the invention utilizes prior knowledge of various factors such as glucose level, CGM value, insulin on board, and the like, to further minimize false alarms by adding another delayed timer. As in the embodiment of the invention depicted in FIG. 3 , the CGM state machine asserts the hypoglycemic alarm, and the BG state machine de-asserts the alarm. However, the two state machines are coupled even further with the assumption that while system is at a “hypoglycemia suspected” state 340 , no CGM based hypoglycemic threshold shall matter. In addition, depending on the control model and the value from the latest finger stick glucose level check, a variable time can be added to delay the return into the periodic CGM-based hypoglycemic detection “no hypoglycemia suspected” state 310 .
[0082] For example, if the latest finger stick BG value is 4.0 mMol/L (72 mg/dL), and the control model predicts a rapidly rising glucose level, then a relatively long delay timer might be activated before the system transitions from “hypoglycemia suspected” state 340 to the “no hypoglycemia suspected” state 310 . On the other hand, if the latest finger stick BG check indicates a glucose level value of 4.0 mMol/L (72 mg/dL) and the control model programmed into the controller predicts a rapidly dropping glucose level profile, then the system immediately transitions from the “hypoglycemia suspected” state 340 to “no hypoglycemia suspected” state 310 , but the CGM based hypoglycemia detector will be given the fastest opportunity to trigger. Using the control model and relative value of the latest finger stick BG check allows the system to apply a state transition rule that is decoupled from which CGM based hypoglycemic detector triggered the state transition
[0083] A simple kinetic example can be used to illustrate the processes described above. In this example, the value of time-to-return to hypoglycemia detection parameter Tr is calculated using only the latest BG value and the latest CGM rate:
[0000] Tr =(( BG−BG — t )/ K — t )+( BG — r/K — r )if BG>BG — t and BG — r> 0,
[0000] Tr=0 if BG≦BG_t, and
[0000] Tr =(( BG−BG — t )/ K — t ) if BG>BG — t and BG — r≦ 0; where BG is the latest BG value, BG_t is a hypoglycemic threshold, BG_r is a model based BG rate, and K_t and K_r are predetermined constants.
[0088] Using this approach, and assuming BG_t=4 mMol/L, K_t is 0.1 mMol/L/min, and K_r is 0.05 mMol/L/min 2 , there are 3 distinct cases. The first case is when the latest BG while the system is in state 350 is less than or equal to BG_t (4 mMol/L). The delay is determined as Tr=0, which means that the system immediately transitions back to the “no hypoglycemia suspected” state 310 , where hypoglycemic checking using CGM is active again.
[0089] The second case occurs when the latest BG while the system is in the “hypoglycemia suspected” state 350 is more than BG_t, and the estimated BG rate BG_r is negative. For this example, assume that BG=4.2 mMol/L. Then, Tr=(4.2−4.0)/0.1=2 minutes, which means that the system will transition back to the “no hypoglycemia suspected” state 310 two minutes after this latest BG measurement.
[0090] The third case occurs when the latest BG while the system is in the “hypoglycemia suspected” state 350 is more than BG_t, and BG_r is positive. For this case, assume that BG=4.2 mMol/L, and BG_r=0.5 mMol/L/min. Under this assumption, Tr=12 minutes, and the system will wait 12 minutes since the latest BG measurement before allowing hypoglycemic checking using the CGM sensor to resume. The above example uses BG measurement, a simple kinetic assumption, and a model that attempts to track the rate of the glucose level BG_r using any available information such as CGM measurements, past BG measurements, meal, and insulin history. The formation of the necessary state observer to estimate BG_r will be immediately understood by those skilled in the art.
[0091] Returning to FIG. 5 , when the “hypoglycemia suspected” state 340 is entered, a finger stick BG value is requested at state 345 . Depending on the glucose level profile of the user, that is, the profile due to prior insulin deliveries, insulin sensitivity, exercise and the like, the controller may enter either state 355 , where rescue carbohydrates are administered and the finger stick BG is again measured after fifteen minutes, or state 350 , where a timer indicating when the next finger stick BG confirmation is to be performed is started. The duration of this timer is dependent upon a determination of the likelihood of glucose value changes based on the future glucose level profile determined by the control model being used by the controller and the latest finger stick glucose level value.
[0092] In yet another embodiment, the processor is programmed using appropriate software or hardware commands to implement the following exemplary pseudo code, where glucose related parameters are specified in units of mg/dL, and time related parameters are specified in units of minutes:
[0000]
Th = 60 mg/dL % equiv of hypo alarm threshold
Ta = time until alarm will sound
% repeat every minute...
if Glu >= Th, then Ta = 60 min
Tnew = (Glu-40 mg/dL) * 3 min/(mg/dL)
If Tnew < Ta, then Ta = Tnew
If Ta <= 0 min, the soundalarm( )
end
[0093] In this embodiment, the system checks the CGM value at every sample time, instead of using four or more distinct hypoglycemia thresholds with specific time delay amounts, and continues to count-down the timer until is it is larger than a latest-glucose-dependent timer.
[0094] In still another embodiment, a table of delay values as a function of glucose level is used by the processor to modify the timer delay, where crossing a lower glucose value (Glu) results in a shorter time duration (Ta). An alarm will be enunciated whenever any timer expires. An example of such a table is set forth below:
[0000]
Glu (mg/dl)
Ta (minute)
60
60
55
45
50
30
45
15
40
0
[0095] For example, when the user's glucose level is above 60 mg/dL, the alarm will not annunciate for 60 minutes. When the user's glucose level falls below 60 mg/dL, but is above 55 mg/dL, the alarm will be delayed only 45 minutes. If the user's glucose level falls below 40 mg/dL, then the alarm annunciates immediately.
[0096] The embodiments described above are particularly useful in reducing or eliminating unacceptably large number of false hypoglycemic alarms that can desensitize a user from responding to true alarms. Such desensitization may result in harm to a user because required actions to alleviate a hypoglycemic condition would not be taken in a timely manner.
[0097] While several specific embodiments of the invention have been illustrated an described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
|
A system and method for reducing the number of hypoglycemic alarms presented to a user is presented. The system and methods include use of model based state estimation and variable-delayed threshold values to balance the risk of not presenting an alarm caused by an actual hypoglycemic state with the presentation of alarms caused by artifacts in the signals produced by a continuous glucose monitor.
| 6
|
CONTRACTUAL ORIGIN OF THE INVENTION
The invention described herein was made in the course of, or under, a contract with the UNITED STATES DEPARTMENT OF ENERGY.
BACKGROUND OF THE INVENTION
This invention relates to a method and means for measuring the level of a liquid in a container. More particularly, a coaxial cavity having a perforated tubular outer conductor is partially submerged in the liquid in the container so that liquid enters and terminates a portion of the annular region of the coaxial cavity. The fundamental resonant frequency of the portion of the coaxial cavity which does not contain liquid is determined experimentally and is used to calculate the length of the liquid-free portion of the coaxial cavity, and thereby the level of the liquid in the container.
It is extremely important from a safety standpoint to have accurate measuring devices for monitoring the level of liquid radioactive waste in large storage containers. Due to the highly radioactive nature of the liquid being stored a reliable measuring device is needed to insure against leaks or theft of the tanks' potentially dangerous contents.
One type of measuring device typically used to measure the level of liquid in a container which is well known to those skilled in the art is floats suspended within the liquid in the container. These floats can be connected to the outside of the container by mechanical linkage.
Another type of measuring device typically used in chemical processing plants is pneumatic bubble probes. These bubble probes can be connected to a pair of differential pressure transducers which give the data necessary to derive the level of the fluid in the container. In most applications this is a reliable approach, difficulty being encountered only in the case of solution near saturation which can cause the pneumatic bubble probes to clog.
One particular processing plant which uses pneumatic bubble probes as described above is the Idaho Chemical Processing Plant which is part of the Idaho National Energy Laboratory owned by the Department of Energy and located 50 miles west of of Idaho Falls, Idaho. The processing plant has a tank farm which contains several underground liquid-waste-storage containers. The containers are used to store a highly radio-active acidic solution which is in an intermediate step of reprocessing. It has been determined that a second independent measuring system is needed for monitoring the level of liquid in the storage containers. Safety considerations, in addition to the possibility of the loss of tank level information due to probe clogging, make it desirable that the second system not use pneumatic bubble probes.
SUMMARY OF THE INVENTION
This invention is directed to a method and means for measuring the level of a liquid in a container. A coaxial cavity having a perforated tubular outer conductor is partially submerged in the liquid in the container so that the liquid enters and terminates a portion of the annular region of the coaxial cavity. Energy from a variable-frequency RF source is injected into the liquid-free portion of the annular region of the coaxial cavity. The output-power of the cavity is monitored while the frequency of the RF power source is varied to determine several frequencies at which maximum or minimum output-power levels occur. These frequencies are used to calculate the fundamental resonant frequency of the cavity. The fundamental resonant frequency is used to calculate the length of the portions of the cavity which do not contain liquid and from this length the level of the liquid within the container is calculated.
It is therefore an object of the present invention to provide an accurate and reliable device and method for measuring the level of a liquid in a container.
It is a further object of the invention to provide a device and method for constantly monitoring the level of liquid in the container.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a partial sectional side view of a coaxial cavity.
FIG. 2 is a partial sectional side view of the bottom portion of the coaxial cavity.
FIG. 3 is a partial sectional side view of the top portion of the coaxial cavity.
FIG. 4 is a schematic diagram of a device for measuring the level of liquid in a container.
DETAILED DESCRIPTION OF THE INVENTION
A device for measuring the level of liquid in the liquid waste storage containers of the Idaho Chemical Processing Plant will be used to illustrate a preferred embodiment of the invention.
FIG. 1 illustrates coaxial cavity 10 which has a tubular right-circular-cylindrical inner conductor 12 surrounded by a coaxial tubular right-circular-cylindrical outer conductor 14. Inner conductor 12 is approximately 20 feet in length and has an outside diameter of one inch. Outer conductor 14 is also approximately 20 feet in length and has an inside diameter of four inches. Slots 16, 18, 20 and 22 extend through outer conductor 14, run vertically down outer conductor 14, are each approximately five feet in length, and are uniformly located 90 degrees about and at different locations along the length of outer conductor 14. The slots allow fluid located in the area surrounding coaxial cavity 10 to enter and terminate a portion of annular region 24 which is located between outer conductor 14 and inner conductor 12.
FIG. 2 illustrates the bottom portion of coaxial cavity 10. Inner conductor 12 is centered within outer conductor 14 at the bottom of coaxial cavity 10 as follows. End plate 26 which is a circular disk is affixed by means such as welding to the bottom edge of outer conductor 14. Hole 28 is located in the center of end plate 26. Retention rod 30 extends through hole 28 and is secured to end plate 26 by nut 32. The distal portion 33 of retention rod 30 extends along the center of outer conductor 14, and is seated in the center of inner conductor 12. Distal portion 33 is soldered to inner conductor 12, thereby centering inner conductor 12 within outer conductor 14. End plate 26 also contains holes 34 located about hole 28 which allow liquid to enter annular region 24.
FIG. 3 illustrates the top portion of coaxial cavity 10. Disc-like upper flange 36 is mounted coaxial with and on top of disc-like lower flange 38. Lower flange 38 has a larger diameter than upper flange 36. The flanges are bolted together by four evenly spaced bolts 40 of which only three are visible in FIG. 3. Lift rings 42 (see FIG. 1) extend perpendicularly from and are attached to the top face of lower flange 38. Lift rings 42 are located diametrically about the center of lower flange 38 and are provided for handling coaxial cavity 10.
Turning once again to FIG. 3, inner conductor 12 and outer conductor 14 are connected to upper flange 36 and lower flange 38 as follows. Circular hole 44, located in the center of lower flange 38, has a diameter which is equal to the outer diameter of outer conductor 14. The top portion of outer conductor 14 is seated in hole 44, butts against the bottom face of upper flange 36, and is welded in place. Circular hole 46 which is located in the center of upper flange 36 is coaxial with hole 44 and has a diameter which is equal to the outer diameter of inner conductor 12. The top portion of inner conductor 12 is seated in hole 46, the top edge of inner conductor 12 is flush with the upper face of upper flange 36, and inner conductor 12 is welded in place.
Attached to upper flange 36 are 50-Ohm connectors 48 and 49 which are standard coaxial connectors well known in the art. Connectors 48 and 49 are seated respectively within holes 52 and 54. Holes 52 and 54 are located at diametrically opposite points about the center of outer conductor 14 and extend through upper flange 36 into annular region 24. Connector 48 is soldered into hole 52 as follows. Hole 52 has a right-circular-cylindrical upper portion 56 and coaxial right-circular-cylindrical lower portion 58. Upper portion 56 has a larger diameter than lower portion 58. The end of the connector 48 is seated within upper portion 56 and butts against the edge of lower portion 58. Connector 48 is soldered into hole 24 as follows. Hole 54 has an upper portion 60 and a lower portion 62 which have the same dimensions as upper portion 56 and lower portion 58. The end of connector 49 is seated within upper portion 60 and butts against the lower edge of lower portion 62.
Coupling loops 64 and 66 are connected to connectors 48 and 49 and extend down into annular region 24 as follows. Connector 48 has a main body 68 and a center conductor 70. Coupling loop 64 forms a square loop which extends into annular region 24 and is connected at one end to center conductor 70 and at the other end is soldered against the inner wall of the main body 68. Similarly, connector 49 has a main body 72 and a center conductor 74. Coupling loop 66 also forms a square loop which extends into annular region 24 diametrically opposite coupling loop 64 and is connected at one end to center conductor 74 and at the other end is soldered against the inner wall of main body 72. Coupling loop 64 is used as an antenna to couple RF energy into annular region 24 and coupling loop 66 is used as a current-sensing loop to detect the intensity of the RF magnetic field at the top portion of coaxial cavity 10.
FIG. 4 shows a schematic diagram of the device for measuring the level of liquid in a container. RF power supply 76 and RF power detector 78 are connected to coaxial cavity 10 as follows. The output of RF power supply 76 is connected by line 80 to impedance-matching network 82, which is connected by line 84 to connector 48 of coaxial cavity 10. Impedance-matching network 82 is provided to match the load of RF power supply 76 to the load of connector 48. The input of RF power detector 78 is connected by line 86 to impedance-matching network 88, which is connected by line 90 to connector 49 of coaxial cavity 10. Impedance-matching network 88 is provided to match the load of RF power detector 84 to the load of connector 49. It is noted that lines 80, 84, 86, and 90 are all coaxial cables.
As noted before, the device described above was designed for monitoring the level of liquid in the liquid-waste-storage-containers of the Idaho Chemical Processing Plant. Although the storage containers are not shown in the figures, each storage container has a circular hole in its top. The diameter of these holes is slightly larger than the outside diameter of outer conductor 15. Coaxial cavity 10 is connected to a storage container in the following manner. Lift rings 42 are used to lift coaxial cavity 10, which is inserted vertically into the interior of the storage container through the hole in the top of the storage container until the bottom of lower flange 38 rests on the top of the storage container about the hole. As noted the length of coaxial cavity 10 is chosen so that at least a portion of the end of coaxial cavity 10 will be submerged when the storage container contains the lowest level of liquid that is desired to be monitored. The reason for this is that a measurement of the height of fluid in the storage tank can only be made when at least a portion of coaxial cavity 10 is submerged.
The following steps are peformed to determine the level of liquid in a storage container. RF power source 28 is activated, thus injecting RF energy into annular region 26 through coupling loop 64. The RF energy propagates down annular region 24 until the liquid-air junction, where a portion of the RF energy is transmitted through the surface of the liquid. A majority of the RF energy, however is reflected back up annular region 24 thus creating a standing-wave pattern in annular region 24. The standing-wave pattern has a magnetic and an electric field component which are 180° out of the phase. In the preferred embodiment only the magnetic-field compnent is measured.
With a constant power output the frequency of RF power source 28 is varied while the power output of coaxial cavity 10, which is the standing-wave pattern, is monitored on RF power detector 32. RF power detector 32 measures the magnetic-field field strength at the top portion of coaxial cavity 10 as detected by coupling loop 66. At maximum or minimum magnetic-field output levels as measured on RF power detector 32, the input frequency of RF power source 28 is to a good approximation equal to an n th -harmonic resonant frequency of the liquid-free portion of coaxial cavity 10. The n th -harmonic frequencies are equal to n times the fundamental resonant frequency of the liquid-free portion of coaxial cavity 10, where n is an integer. The fundamental resonant frequency is the lowest frequency at which resonance occurs in the cavity. Several different n th -harmonic resonant frequencies are determined and statistical analysis, which is well known in the art, is applied to these values to approximate the fundamental resonant frequency of the cavity. To a good approximation the length of the liquid-free portion of coaxial cavity 10 is equal to the velocity of light divided by the fundamental resonant frequency. To determine the height of liquid in the liquid container, the length of the liquid-free portion of coaxial cavity is subtracted from the distance between the top annular region 24 of coaxial cavity 10 and the bottom of the container vessel. This value can be used to calculate the amount of liquid in the storage container.
The calculations for determining the level of liquid in the storage container can be done manually as described above. However, in practice a computer is connected to and operates RF power supply 28 and RF power detector 32. The computer is programmed to vary automatically the frequency of RF power supply 28 while monitoring RF power detector 32, and from these values calculates several n th -harmonic resonant frequencies, the fundamental resonant frequency, and the length of the liquid-free portion of coaxial cavity 10. The computer is programmed to repeat continuously the above procedure, thus constantly monitoring the level of liquid in the storage container.
It is noted that 10 resistance temperature detectors (not shown in the figures) are uniformly spaced within the hollow center of inner conductor 12. These detectors are used to measure the temperature of various levels of the liquid in the storage container. The reason for this is as follows. The dimensions of the container and therefore the distance, L T , from the top of coaxial cavity 10 to the bottom of the container varies with the temperature of the container. The temperature of the container depends upon and is related to the temperature of the liquid within the container. The temperature of the liquid is not uniform throughout the tank. It has been determined experimentally how the temperature of the liquid at various levels in the container effect the value of L T . The value of L T can be calculated by monitoring the temperature at various levels of the container and correcting the value of L T to compensate for these thermal effects.
It is also noted that in order to keep an accurate record of the quantity of liquid in a container the thermal effects on the dimensions of the container, and the density of the liquid within the container must also be taken into consideration.
In the preferred embodiment of the invention the output power of coaxial cavity 10 is monitored at the top of annular region 24 by coupling loop 66. The output power of coaxial cavity 10 is monitored at this point merely for convenience. The output power of coaxial cavity 10 could be monitored anywhere along the liquid-free portion of annular region 24. Further, although in the preferred embodiment the magnetic field is monitored, the electric field could be monitored for minimum and maximum output levels, the only difference being that the electric field is 180° out of phase with the magnetic field.
For the preferred embodiment, coupling loop 64 is used to inject energy into coaxial cavity 10 and a separate coupling loop, coupling loop 66, is used to monitor the output power of coaxial cavity 10. It is possible to use the same coupling loop to inject energy into and monitor the output power of coaxial cavity 10. However, if this were done, appropriate coupling devices well known in the art would be needed to separate the input and output signals.
The invention can be used to measure the level of any liquid in a container as long as the liquid has a different propagation coefficient from that of air. As long as the liquid does have a different propagation coefficient then some RF energy will be reflected from the liquid-air junction in annular region 24 and thus set up a standing-wave pattern. It is this standing-wave pattern which is monitored for minimum and maximum power levels by RF power dectector 84.
Where possible all parts of coaxial cavity 10 are fabricated from stainless steel. This is done because of the highly corrosive nature of the contents of the storage container.
Tests have been performed to determine the accuracy of the invention when connected to a liquid waste storage container of the Idaho Chemical Processing Plant. The storage containers have a 50-foot diameter and there are approximately 50 gallons of liquid per inch of height. Statistical averaging of successive level estimates produce a resultant estimate with a standard deviation of less than 0.001 inch.
|
A method and means for measuring the level of a liquid in a container. A coaxial cavity having a perforated outer conductor is partially submerged in the liquid in the container wherein the liquid enters and terminates the annular region of the coaxial cavity. The fundamental resonant frequency of the portion of the coaxial cavity which does not contain liquid is determined experimentally and is used to calculate the length of the liquid-free portion of the coaxial cavity and thereby the level of liquid in the container.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for pneumatically launching high explosive VOLCANO and MOPMS mines in order to simulate flight trajectories and impacts typically encountered in field use.
2. Description of Related Art
VOLCANO and MOPMS mines are cylindrically shaped high explosive devices which can be used as either anti-tank (AT) or anti-personnel (AP) weapons. In order to test the mines, the mines must be launched in a manner which simulates field conditions while maintaining the capability of performing required measurements and ensuring safety.
Two general types of launch configurations are required for testing VOLCANO and MOPMS mines. The first is the air-launch configuration, in which the mine is launched into the air at various specified testing elevation angles. The second is the control-impact configuration, in which the mine is shot into a chamber where it hits an impact surface and then falls into a trapped area. The mines must be monitored for timing of various functions in the arming sequence and tested for impact survival.
At present, no launchers suitable for testing individual VOLCANO and MOPMS mines exist. A prior mine launcher was developed to launch box-shaped GATOR mines into an impact chamber, through a drop chute to a test cell area. The prior GATOR mine launcher mine required a rectangular rather than a cylindrical launch tube, however, and was not suitable for VOLCANO and MOPMS type mines because of changes in arming methods and testing specifications.
SUMMARY OF THE INVENTION
It is accordingly an objective of the invention to provide an individual mine launcher capable of launching high explosive VOLCANO and MOPMS mines in order to simulate field conditions while performing required measurements and ensuring safety.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an individual VOLCANO mine launcher arranged in accordance with a preferred embodiment of the invention.
FIG. 2 is a block diagram of an individual MOPMS mine launcher arranged in accordance with the preferred embodiment of the invention.
FIG. 3 is a schematic circuit diagram of a velocity trigger circuit card for the mine launcher of FIGS. 1 or 2.
FIG. 4 is an elevated side view of a preferred breech and launcher tube assembly for air-launching VOLCANO and MOPMS mines, and for control-input launching MOPMS mines.
FIG. 5 is an elevated side view of the launcher tube assembly of FIG. 4, in position on a pressure chamber.
FIG. 6 is an elevated end view of a volcano mine with timer.
FIG. 7 is an elevated side view of a preferred VOLCANO breech and launcher tube assembly for control-input launching VOLCANO mines.
FIG. 8 is an end view of a forward tube for the launcher tube assembly of FIG. 7.
FIG. 9 is an end view of a rearward tube for the launcher tube assembly of FIG. 7.
FIG. 10 is a plan view of a spacer for the tube of FIG. 8.
FIG. 11 is a plan view of a cover plate for the tube of FIG. 8.
FIG. 12 is a plan view of a spacer for the tube of FIG. 9.
FIG. 13 is a plan view of a cover plate for the tube of FIG. 9.
FIG. 14 is an elevated end view of an exit band for the tube of FIG. 8.
FIG. 15 is an elevated top view of the tube of FIG. 8.
FIG. 16 is an elevated top view of the tube of FIG. 9.
FIG. 17 is an elevated rear end view of the tube of FIG. 8.
FIG. 18 is an elevated front end view of the tube of FIG. 9.
FIG. 19(a) is an elevated end view of a breech assembly for the VOLCANO control-impact launch configuration of FIGS. 7-18.
FIG. 19(b) is a side view of the breech assembly of FIG. 19(a).
FIG. 20(a) is a plan view of the front side of a link housing for the breech assembly of FIG. 19(a) and 19(b).
FIG. 20(b) is a plan view of a top for the link housing for the breech assembly of FIGS. 19(a)and 19(b).
FIG. 20(c) is a plan view of a side for the link housing of the breech assembly of FIGS. 19(a) and 19(b).
FIG. 20(d) is a plan view of a top cleat for the link housing of the breach assembly of FIGS. 19(a) and 19(b).
FIG. 21 is an elevated side view of a link for the breech assembly of FIGS. 19(a) and 19(b).
FIG. 22 is an elevated end view of a breech block for the VOLCANO control-impact launch configuration of FIGS. 7-18.
FIG. 23 is an elevated side view of the breech block of FIG. 22.
FIG. 24(a) is an elevated side view of the breech block of FIGS. 21 and 22, including a lift block assembly.
FIG. 24(b) is an elevated end view of the breech and lift block assembly of FIG. 24(a).
FIG. 25(a) is an elevated side view of a lift block for the lift block assembly shown in FIGS. 23 and 24.
FIG. 25(b) is an elevated end view of the lift block of FIG. 25(a).
FIG. 26 is an elevated side view of a cam for the lift block assembly of FIGS. 23 and 24.
FIG. 27 is an elevated side view of a pivot for the cam of FIG. 26.
FIG. 28(a) is an elevated side view of a paddle for the lift block assembly of FIGS. 23 and 24.
FIG. 28(b) is an elevated top view of the paddle of FIG. 28(a).
FIG. 28(c) is an elevated end view of the paddle of FIG. 28(a).
FIG. 29(a) is an elevated bottom view of a bottom piece for the lift block assembly of FIGS. 23 and 24.
FIG. 29(b) is an elevated end view of the bottom piece of FIG. 29(a).
FIG. 30 is a plan view of a top piece for the lift block assembly of FIGS. 23 and 24.
FIG. 31 is a plan view of a side piece for the lift block assembly of FIGS. 23 and 24.
FIG. 32 is an elevated end view of a preferred arming coil and spacer assembly for an MOPMS mine.
FIG. 33 is an elevated side view of the arming coil and spacer assembly of FIG. 32.
FIG. 34 is a perspective view of a control-impact configuration monitoring assembly arranged in accordance with the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1 and 2, an individual mine launcher according to a preferred embodiment of the invention includes a launch vehicle 1 and a launcher 2. The launch vehicle 1 communicates with the launcher 2 via three quick disconnect cables, including a launcher control cable 3, a launcher arm cable 4, and a launcher camera cable 5. The mine launcher shown in FIG. 1 is configured for VOLCANO mines while the launch vehicle shown in FIG. 2 is configured for MOPMS mines.
Launch vehicle 1 is similar to the mobile launch vehicle previously used to launch GATOR mines, including an armored cab for housing the necessary control systems while protecting the test operator during launch simulations. By utilizing quick disconnect cables, the launcher may be used with or without the launch vehicle, and the launch vehicle may be used with different launcher configurations as required for testing different types of mines.
The launch vehicle 1, as shown in FIGS. 1 and 2, includes a power distribution box 6 connected to receive power from, for example, a 24V tank battery 7 via a 12V voltage regulator 8. Power distribution box 6 distributes power to a video circuit which includes a camera controller 9, a video cassette recorder 10 for recording tests for subsequent analysis, a video monitor 11 for directly monitoring the test, and a timer 12. The video circuit is connected by camera cable 5 to a video camera 13 which is positioned on the launcher 2, and preferably includes a zoom lens controlled by controller 9. The distribution box 6 is also provided with audio input and output connections for a headset driver 14 which enables communications through headsets 15-17. Communications external to the launch vehicle are provided by an external communications enclosure 19. Monitoring of audible signals generated by a microphone 20 adjacent the arming mechanism, as described below, is carried out through headsets 16 and 17, the signals from microphone 20 being transmitted by quick disconnect cable 3.
Velocity transducers 21-24 are located near the exit of a launching tube 100 provided on the launcher and described in greater detail below. Two of the transducers are used for the start time of a velocity measurement and two are used for the stop time in order to enable redundant monitoring of the velocity of a mine during launch.
The four velocity transducers 21-24 are connected to a circuit card 25 mounted in velocity junction box 26 on the launcher 2. As shown in FIG. 3, start time transducers 21 and 23 are each connected to a trigger pulse generating circuit 27 which includes diode 28, zener diode 29, resistors 30-33, and op amp 34. Stop time transducers 22 and 24 are connected to identical pulse generating circuits 35, including diode 36, zener diode 37, resistors 38-41, and op amp 42. In this example, the sensors are Model 3030 sensors provided by Electro Corp. of Sarasota, Fla. However, it will be appreciated by those skilled in the art that a variety of alternative velocity transducer arrangements may be substituted for the Electro Corp. sensors, with modifications to the sensor circuitry as appropriate. The velocity signals are transmitted to dual redundant velocity counters 43 and 44 via quick disconnect launcher control cable 3.
As shown in FIG. 1, a separate junction box 47 connects the VOLCANO mine arming coil 48 to quick disconnect cable 4, the arming signal being generated in launch vehicle 1 by fuze setter 49, which is connected to cable 4 through distribution box 6. However, as shown in FIG. 2, a modified arming coil 48', shown in FIGS. 32 and 33 and described in detail below, is required for MOPMS launches. Arming coil 48' is set by fuze setter 49' powered by a separate 6V battery 50.
The electrical control lines on the launcher chassis require 19-pin quick disconnect connectors and are preferably threaded through conduits mounted on the chassis. A tee junction box 46 near the rear of the chassis distributes control lines to firing coil 45 of a solenoid operated air valve used to activate the air cylinder that triggers the launch. Other lines are distributed from junction box 46 to the arming microphone 20, which is in the launcher pressure chamber assembly, and to velocity junction box 26 for velocity measurements.
The launching tubes, designated collectively by reference numeral 100 in FIGS. 1 and 2, are close fitting cylinders adapted specifically to accommodate VOLCANO and MOPMS mines. The MOPMS launch tube is interchangeable on either the air-launch or the control-impact launching configurations, while different VOLCANO launch tubes are provided for each configuration.
The basic launcher tube for volcano air-launch and MOPMS air launch and control-impact launch configurations, but not for the VOLCANO control-impact launch configuration, includes a breech and tube assembly 101, shown in FIG. 4, made up of a single pipe 102 fitted at one end within a breech tube 103 having a flange 104 through which two mounting/positioning holes 105 are drilled for positioning the launcher tube on a pressure chamber. A breech ring assembly includes a tube 106 and a flange 107 which fit respectively within corresponding opening 108 in tube 103 and opening 109 in flange 104.
The dimensions of the launcher tube components depend on whether the tube is to be used for VOLCANO or MOPMS launches, as will be appreciated by those skilled in the art, but both types of mines are in the shape of a cylinder approximately 5 inches in diameter and approximately three inches high, and thus the inner diameter of tube 102 and breech ring assembly tube 106 is preferably approximately five inches, while the length of tube 106 is three inches. Tube 102 is approximately 27 inches in length. Velocity sensors 21-24 are positioned on opposite sides of the tube by plates 306, only one of which is shown in FIG. 4. Plates 306 include tap holes 307 and 308 spaced approximately six inches apart for the sensors.
The pressure chamber assembly is, as shown in FIG. 5, preferably made of the cylinder 309 of a pneumatic baseball pitching machine which supplies launching power via the solenoid operated air valves distributed by junction box 46 and activated through quick disconnect cable 3. The same model of cylinder was also used on the previously built GATOR launcher. Reference numeral 300 denotes either a VOLCANO or MOPMS mine. Microphone 20 may be placed in an adapter ring 310 fitted on the pressure chamber assembly cylinder to monitor the mine for clicking sounds which occur in the arming sequence of the mine. The support chassis (not shown) for the launcher tube and the pressure type assembly is preferably constructed to be carried by fork lift tongs on the launch vehicle 1 in order to enable testing of high explosive mines at an outdoor test site where rapid evacuation is possible. If for example, a live mine becomes stuck in the launcher hardware, the operator could separate the launch vehicle from the launcher and leave the launcher on the field without leaving the safety of the instrumentation vehicle 1. In addition, casters (not shown) are preferably provided on the chassis to allow the launcher 2 to be positioned manually when testing non-high explosive mines at, for example, an indoor test facility.
When launching MOPMS mines, a modified coil and spacer assembly 180 as shown in FIGS. 32 and 33 is required. The modified coil and spacer assembly 180 includes a disk-shaped plexiglas encased coil mounted on the front and center of the pressure chamber, the MOPMS mine fitting snugly in the breach of the launcher tube. A groove 181 is provided for accommodating the coil leads. As the mine loaded launcher tube is clamped over the front of the pressure chamber, the mine is pressed against the coil 182 on the face of the modified coil and spacer assembly. For VOLCANO mines, the arming coil is set by the timer, either before or during launch depending on tube configuration. The launcher tubes are preferably mounted on rollers (not shown) that allow the tubes to be rolled away from the pressure chamber while inserting a mine. The tube is then clamped tightly to the pressure chamber with three clamps (not shown) mounted on the chamber.
VOLCANO mines have a timer assembly 110 attached to the face of the mine that creates an oblong area on the circumference of the mine body, as depicted in FIG. 6. One step in the arming sequence of the mine is to allow a trigger pin 111 to protrude from the oblong area, a function normally accomplished in the field as the mine escapes a close fitting launch tube. Due to the arming sequence timing constraints in the tests for the control-impact launch configuration, a modified VOLCANO launch tube is provided which has a keyway 112 to allow the triggering pin 111 to be released before the mine leaves the launch tube. This configuration is shown in FIGS. 7-31.
In the VOLCANO control-impact launch configuration, the launch tube 100' is formed from two flanged tubes 120 and 121 shown in cross-section in FIGS. 8 and 9. Flats Spacers 122 having tapped holes 123 for the velocity transducers 21-24 are provided at the forward or exit end of forward tube 120. Tube 120 includes a gap or slot 224, the edges of which are flattened at areas 125, as shown in FIGS. 8 and 11, to accommodate tapped mounting strips or spacers 225, shown in FIGS. 8 and 10, on which is fitted cover plate 126, shown in FIG. 11, to form a groove or slot of keyway 112. At the forward end of tube 100' is a band 128, shown in FIG. 14, dimentioned to fit over end of forward tube 120. Rearward tube 121 also includes a gap 130, the edges of tube 121 having flattened areas 131, to accommodate mounting strips or spacers 132, shown in FIGS. 9 and 12, on which are fitted cover plate 133, illustrated in FIG. 13, to complete keyway 112. FIGS. 17 and 18 show the manner in which tubes 120 and 121 are joined at flanges 134 and 135, and illustrate the keyway in cross-section.
The interior surface of the rearward end of tube 121 is chamfered to permit insertion of breech assembly, which consists of a slotted ring 137 and flange 138, as shown in FIGS. 19(a) and 19(b). Extending over the slot 144 is a link housing 139 formed from end plate 140 and a portion of flange 138, top plate 141 being positioned on end plate 140 by cleats 142 and 143, and side plates 242, only one of which is shown, as depicted in FIGS. 20(a)-20(d). A hole 243 is provided for insertion of a link 124, shown in FIG. 21, opening 168 of which is threaded onto stud 169 of paddle 167, shown in FIGS. 28(a)-28(c), and which serves to hold timing trigger pin 11 prior to launch, as will be explained below.
The breech block 145 mounted on the end of tube 121, and shown in FIGS. 21-24, includes a ring 146 with a slot 147, a flange 148 having mounting/positioning holes 149, and grooves 151 and 152 for accommodating, respectively, link 124 and link housing 139 when the breech assembly is mounted on the launching tube within openings 153 and 154 of the breech block.
The triggering pin is held down prior to launch by link 124, the head 269 of which fits within a slot 155 provided in a lift block 156, shown in FIG. 25(b), of a bore rider release mechanism (BRRM) which, in turn, is moved up and down by engagement between aperture 157 and arm 158 of a cam 159, shown in FIG. 26. Cam 159 is pivotally mounted on the breech block by a pivot 161, shown in FIG. 27, which is supported by sides 162, top piece 163, and bottom piece 164, shown respectively in FIGS. 31, 32, and 29(a) and (b). The BRRM also includes a side plate 165 seated on top of the block. The second end of cam 159 may be connected to a pneumatic or electro-magnetic cylinder or other actuating mechanism by a member whose horizontal motion causes lift block 156 to be moved vertically to permit link 124 to rise against a spring bias, thus permitting the timer triggering pin 111 to also be raised, actuating the timer mechanism for the VOLCANO arming sequence before launch if desired.
In the control-impact configuration, the mine is launched into a chamber where it hits a wooden impact surface and drops through a chute to the monitoring area. Different angles of impact are achieved by adjusting the angles of the impact surface relative to the line of fire of the launched mine. The wooden impact surface, for example, a 41/2 inch of particle board, is replaced for each mine. FIG. 34 shows the mine trap and positioning assembly that is used to position the mine in or on the monitoring area for the various test requirements. Below the impact chamber is a chute 200 through which the mine is dropped. The mine trap and positioning assembly 201 is attached to the mouth of the chute. VOLCANO and MOPMS mines each have two separate mine configurations, one for anti-tank (AT) and another for anti-personnel (AP) mines. AT mines must be placed on a monitoring board underneath a set of target plates. The AT mine is launched into the impact chamber and drops to the trapping chamber, after which the launcher unit is backed up until the mine is in front of the pneumatic remotely controlled positioning guide 202. Air cylinders 203 are activated to lower the guide behind the mine and push it outward from the trap assembly. The launcher is then moved forward pushing the mine onto a monitoring board and under the target plate test unit.
Since AP mines do not require plate penetration tests, the pneumatic positioning assembly is not used. The trap is positioned directly over the monitoring board and the mine is launched and trapped on the board. An alternative method is used when testing mines that do not contain high explosive filler. Functions from these mines can be monitored in enclosed wooden test cell boxes at an indoor test facility, in which case the mouth of the impact chamber fits into the top opening of the test cell box and the mine falls directly into the box.
Having thus described a specific preferred embodiment of the invention, it will be appreciated by those skilled in the art that variations are possible within the scope of the invention. Consequently, it is intended that the invention not be limited to the disclosed embodiments as illustrated in the drawings, but rather that they be defined solely in accordance with the appended claims.
|
An individual mine launcher is designed to pneumatically launch high explve VOLCANO and MOPMS mines to simulate flight and impact typically encountered in field use. Electronic components and controls are used to monitor and initiate the arming sequence of the mine. Two configurations are used with the same pneumatic and electronic controls. The air-launch configuration allows the mine to be launched into the air at various specified testing elevation angles. The control impact configuration shoots the mine into a chamber where the mine hits an impact surface and then falls into a test monitoring area below.
| 5
|
BACKGROUND OF THE INVENTION
1. Filed of the Invention
This invention relates in general to energy conservation by imparting insulation and air and moisture impermeability property to existing structures and to permanently improve the appearance and wearing surfaces of the structures.
2. Description of the Prior Art
The addition of insulating materials to buildings has been known and generally has comprised filling empty wall spaces with insulation material which is blown into the walls or, alternatively, insulation has been applied by attaching sheets of the insulation material between joints or above the ceiling.
SUMMARY OF THE INVENTION
The present invention is particularly suitable for refitting of existing structures although it can be utilized in new construction of buildings. The present apparatus and system promotes essential conservation of heating/cooling system energy and also allows diverse appearance opportunities within the cost limitations established by the insulation process. All of the components of the system have been tested and proven materials and systems are readily available which can be utilized in various applications of the invention.
The present invention provides "in situ" of continuous and monolithic insulating impermeable material which is externally or internally placed for optimum thermal and/or aesthetic and/or application opportunities onto the existing structure of a building. The membrane or layer of insulation is integrally surfaced to resist climatic fire or physical damage and also provides the desired appearance. Inherent properties of the insulation are superior thermal resistance (R=6:8 per inch), impermeability to air infiltration and moisture passage and provides added structural capabilities. The insulation of the apparatus and method may be applied to virtually any type of surface.
The primary elements of the apparatus and system are:
1. An in-place surface which may be the walls of the existing building which is termed the inner form.
2. A protective surface which is positioned and spaced to the inner form or in another manner which is approximately parallel to the inner form which creates a void between the inner and outer form.
3. A "cured-in-place" foam filler which is placed into the space between the inner and outer form so as to bond the assembly together which is designated as the foam fill.
4. Attachment and support devices which are utilized to hold the position of the outer form relative to the inner form until completion of the foam fill and bonding as occurred.
5. The addition of trim and closures so as to finish the installation.
The following definitions give general descriptions of these elements, but it is to be realized that they are not limited to the specific definitions given herein.
The inner form may comprise any in-place surface or substrate of a structure free from unprotected openings which might cause leakage of the foam fill and which are structurally adequate to resist or support application and final loads and which is clean, dry and free from deleterious contaminants which would prevent the adhesion of the foam fill. Examples are the internal or external walls of an existing building, regular or irregular surfaces containing windows and the like which might be weathered and unsightly and having inadequate thermal properties. The technique is also applicable to new structure but it would appear to have its greatest economic application to existing structures.
The outer form may be any sheet type surface which when attached in an appropriate position defines a void for foam fill between the outer form and the inner form and provides a durable protective finished surface over the foam fill. The assembly of the outer forms are so arranged to provide the desired finished appearance and are attached with spacers or bulk heads to secure and space the outer form and prevent foam leakage or deformation of the foam due to internal foaming pressures. Openings are placed in the outer form normally at the top so as to provide openings for inserting the foam between the forms.
Example of outer forms for external use might be plywood sheets, composition board or metal siding sheets which could possibly be prefinished with ship-lap, lap or tongue and groove joining of abutting sheets. The outer form for internal use might be sheets of gypsum board having the required 15 minute minimum thermal barrier specification.
The foam fill could be a polyurethane frothed foam formulated to suit the particular application criteria and ambient conditions. The foam could be closed cell, inert, stable, impervious to deterioration due to solvents, insects, moisture, temperature variations or other service conditions. The foam should import structural and adhesive bonding properties adequate to resist transmitted loadings imposed on the outer form and support and retain the outer form and resist delamination of the assembly. The cured density should be approximately 1.5 to 2 pounds per cubic foot. The formulation of the foam should be useable in standard mixing-placement apparatus and adaptable in gel time and be self curing. The uncured mixture should flow easily during placement, provide expansion or blowing action to ensure complete filling of the void between the foams with low internal pressures and with wet foam surfaces so as to promote and assure adequate adhesion and bond strength.
Attachments and support devices should be compatible with the other components, be non-corrosive and of minimum cross-section or thermal conductivity. They should be adjustable to provide for irregular surfaces and have adequate strength to resist application loadings and to improve and augment the foam bond capacity.
Trim and closures should provide closure of the foaming openings, cover exposed edges and complement the outer form so as to provide a finished appearance.
Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut-away sectional view illustrating the inner and outer form with spacers and foam being placed between the forms;
FIG. 2 is a sectional view on line II--II from FIG. 1;
FIG. 3 is a sectional view taken on line III--III of FIG. 2;
FIG. 4 is a sectional view illustrating the application of the technique over an area that includes a window;
FIG. 5 illustrates a modification of the invention wherein the foam is applied to the inner wall surface of an existing structure;
FIG. 6 illustrates a modification of the invention; and
FIG. 7 illustrates another application of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1, 2 and 3 illustrate the invention as applied to the outer surface of an existing building 10 which has an outer wall 11. All contaminants and openings of the inner wall 11 are covered and cleaned to provide a supporting surface of the inner form. A first spacer block 12 is mounted adjacent the bottom of the wall 11 so as to provide spacing for the outer form. Intermediate spacers 14 are attached to the wall 11 as shown and top spacers 13 are attached to the outer wall as shown. Outer form 16 which may be of sheet material are attached to the spacers 12, 14 and 13 and are provided with openings 17 adjacent their upper end for insertion of the foam. The outer form 16 may have any desired external surface for appearance. Frothed foam is applied from a container 21 through a hose 22 and a gun 23 which has a nozzle 24 through the opening 17 to fill the void between the inner form 11 and the outer form 16 with frothed foam. After the foam has been applied, trim 18 is attached to the outer form 16 so as to cover the openings 17 adjacent the upper surface 19.
FIG. 2 is a sectional view taken on line II--II from FIG. 1 and shows the inner form 11, the outer form 16 and the spacers 12, 13 and 14.
FIG. 4 illustrates a modification of the invention wherein the wall 11 of the existing structure includes a window 31 mounted in a suitable frame 32 and in which the window 31 is to be covered by the outer form 16 and foam 26. Suitable reinforcing sheets 33 and 34 are mounted on the outer side of the window glass 31 on the side toward the foam 26 which is to be inserted so as to prevent the glass from breaking when the foam is placed between the outer and inner forms and the procedure is completed as illustrated relative to FIGS. 1 through 3 with the foam 26 being inserted between the inner and outer form so it will harden.
FIG. 6 illustrates a modification of the invention wherein the outer wall 11 is covered with a suitable siding 41 as, for example, lap siding and spacers 42 are attached to the wall 41 and inner form 11 and suitable outer sheets 43 are attached to the spacers 42 so as to provide the outer form. Foam 44 is applied between the inner and outer forms so as to provide the composite wall shown in sectional view in FIG. 6. It is to be noted that the outer form sheets 43 are provided with grooves 50 to provide a decorative effect.
FIG. 7 illustrates a further modification wherein the outer form comprises sheets 46 and 47 which are laterally offset from each other and are connected by a horizontal form member 48 so that foam 49 can be injected between the inner form 11 and the forms 46, 47 and 48 to provide the offset as illustrated. Cover flashing 51 can be attached to the top of the building to cover the foam and the top of form 47. The spacers would, of course, be utilized in the embodiment of FIG. 7 but are not illustrated in the view of FIG. 7 since such use would be obvious.
FIG. 5 illustrates the invention as applied to the inside of existing wall 11. The form 36 is attached to the inside of wall 11 by spacers 40 and 45 and foam 38 is inserted between form 36 and wall 11. Trim 39 is mounted to cover the foam inserting holes.
Heat Losses: Present Structure
For a building having 2,400 sq. ft. Note: Operational losses are not included as they will not affect comparisons.
Assumptions: tl=tc=70° F., to =0° F., infiltration through masonry=6CFH reduced 40% for exterior paint and 60% for exterior/interior paint.
Attic Temperature: ta: ##EQU1##
ta=33.7° F.
Transmission Loss Lt=Ua(tl-to).
______________________________________Item Factor Area/Length (tl - to) Loss.sub.t______________________________________Floor Slab Edge .50 200 10000Roof .25 2400 33.7 20200Attic Wall .36 700 33.7 8490Wall .36 1550.3 70 39070Ceiling .33 2400 36.3 28750Sash 1.13 156 70 12340Display Window 1.13 64 70 5060Door Assembly 1.13 29.7 70 2350 Loss.sub.t 126260______________________________________
Infiltration Loss LI=0.018 V(tl-to).
______________________________________Item Factor Area/Length (tl - to) Constant Loss.sub.I______________________________________Attic Wall 3.6 700 33.7 .018 1530Wall 2.4 1550.3 70 .018 4690Sash 62 88 70 .018 6870Door 200 20 70 .018 5040 Loss.sub.I = 18130______________________________________ Combined Loss = 144390 BTU/HR
If the techniques of the invention utilizing foams and outer forms are applied to the building as shown by the Figures below:
Elevations
__________________________________________________________________________ Compilation of Areas/Lengths__________________________________________________________________________ Perimeter 200 LF Sash 136.5 SF Floor/Roof/Ceil Area 2400 SF ○D Sash (6" Foam) 19.5 SF○A Attic Wall (8" Foam) 683 SF ○E Display Window (16" Foam) 64 SF○B Attic Wall (12" Foam) 12 SF Door Assembly 29.7 SF Wall (2" Foam) 1542.3 SF Sash Crack Length 77 LF○C Wall (12" Foam) 8 Door Crack Length 0 LF__________________________________________________________________________
then the heat losses of the refaced surface would be as follows:
Heat Losses: Refaced Structure
Assumptions: tl=tc=70° F., to =0° F., foam impermeable to air.
Attic Temperature: ta: ##EQU2##
Transmission Loss Lt=UA(tl-to).
______________________________________ Area/Item Factor Length (tl - to) Loss.sub.t______________________________________Room .25 2400 39.5 23700Attic Wall (8" Foam) .019 688 39.5 520Attic Wall (12" Foam) .013 12 39.5 6Wall (2" Foam) .062 1542.3 70 6694Wall (12" Foam) .013 8 70 7Sash 1.13 136.5 70 20800Sash (6" Foam) .024 19.5 70 33Display Window .01 64 70 45Door Assembly 1.13 29.7 70 2350Ceiling .33 2400 30.5 24155 Loss.sub.t 68310______________________________________
Infiltration Loss LI=0.018 V(tl-to).
______________________________________Item Factor Area/Length (tl - to) Constant Loss.sub.I______________________________________Sash 62 77 70 0.018 6015Door 299 20 70 0.018 5040 Loss.sub.I 11055______________________________________
Combined Loss=79365 BTU/HR.
Net Reduction of heat loss=144390-79365=65025 BTU/HR.
This represents an improvement of 45% for the gross building envelope with only 48% of the envelope refaced. Actual improvement of the refaced areas is 90%.
Relative Effect on Cooling Load (Instantaneous sensible gain)
Assumptions: tl=78° F., to=94° F., t=2:00PM, South wall=8° F.
______________________________________Outside Surface (7.5MPH) 0.258" LT. WT. Conc. Block 2.00Inside surface 0.68R = 2.93U = 1/R = .34Outside surface (7.5MPH) 0.255/8" Plywood Facing 0.782" Urethane Foam 12.58" LT. WT. Conc. Block 2.0Inside surface 0.68R = 16.2U = 1/R = .062Gain.sub.t = UA t= .34 × 1 × 8 Gain.sub.t = UA tGain.sub.t = 2.72 BTU/SF/HR = .062 × 1 × 8Gain.sub.I = 0.018V(tl - to) Gain.sub.t = .49 BTU/SF/HR= 0.018 × .27 (94 - 78)Gain.sub.I = .08 BTU/SF/HR______________________________________
Combined Gain=2.8 BTU/SF/HR.
Net reduction of instantaneous sensible gain: 2.8-0.49-2.3 BTU/SF/HR.
This represents an improvement of 82% for this assembly.
Similar results can be expected for other assemblies.
Conclusion
The refacing technique illustrated can be translated to other construction assemblies, with similar reductions in both heating and cooling loads.
Treatments as illustrated produce improved acoustical properties. The nature of the foam fill absorbs certain sound frequencies and consolidation of the surfaces eliminates sound transmission leaks.
Optimum placement of these systems will generally favor external surfaces as follows:
1. As the mass of the structure will be encompassed within the thermal barrier, internal temperature fluctuations will be stabilized by the heat sink effect of the structural moss. Further, sharp variations in the outdoor ambient conditions will have little effect on internal loads. These response characteristics are especially beneficial in comfort terms in structures which have essentially continuous occupancy.
2. Where structures are severely weathered resulting in masonry deterioration, cracks and jointing problems, the lamination of a new external skin serves to consolidate and cover these conditions and imports added structural strength. Thermal expansion/contraction is also minimized reducing structural working.
3. With refacing, property values are appreciated and useful life is extended.
4. External treatment obviates most code constraints.
5. External treatment is simplified, not requiring extension of mechanical-electrical devices as is occasioned with internal treatment.
6. Disruption to occupants is minimized with external treatment.
Occasions favoring internal applications are:
1. Structures with limited or sporatic occupancy where fast recovery is required from set-back temperatures will benefit from internal treatment. As the mass of the structure lies outside the thermal barrier, less energy for warm-up is required and response is faster as the mass of the structure is not heated. Thermal expansion/contraction is minimized as a result.
2. Where it is desirable to preserve external finishes, internal treatment is indicated.
Although the invention has been described with respect to preferred embodiments, it is not to be so limited as changes and modifications may be made therein which are within the full intended scope as defined by the appended claims.
|
Foamed construction apparatus and method wherein the walls of existing structures are used as one side of a form and a second form is attached either to the outside or the inside of the existing wall and spaced therefrom with suitable spacers and then filled with an expanding foam so as to substantially improve the insulating properties of the structure as well as to change its internal and/or external appearance. The insulating properties of the foam substantially increase the efficiency of the structure and the technique results in new and improved external and internal appearance of the structure.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non provisional application claims the benefit of French Application No. 03 05557 filed on May 7, 2003, and U.S. Provisional Application No. 60/472,463 filed on May 22, 2003, the entire disclosure of which is incorporated by reference herein.
FIELD OF INVENTION
[0002] The present invention relates to devices and methods for treating the hair, and more particularly hair roots.
BACKGROUND
[0003] Devices for applying substance to the hair are known from French patent documents FR-A-2,828,999 and FR-A-2,805,442.
SUMMARY OF THE INVENTION
[0004] Exemplary embodiments of the present invention provide devices and methods that give volume to the hair, for example, by applying substance to hair roots that hardens as the substance dries so as to cause the hair roots to be more upstanding on the scalp.
[0005] In various exemplary embodiments, the invention provides a novel device that enables such a substance to be applied.
[0006] In various exemplary embodiments, the invention provides a device comprising: a receptacle containing a substance for application to at least one of the hair and the scalp; a lifter member for lifting the hair, the lifter member being secured to the receptacle and movable relative thereto; and at least one dispenser endpiece for dispensing the substance on at least one of the hair and the scalp, after the hair has been lifted by the lifter member.
[0007] Various exemplary embodiments of the invention allow a user to easily apply a substance to the hair for the purpose of stiffening the root ends thereof while the hairs are upstanding on the scalp, thereby obtaining a desired volume effect.
[0008] Since the lifter member that lifts the hair is secured to the receptacle, in such embodiments the device is advantageously made in such a manner as to enable the user to actuate the lifter member using a same hand as is being used to hold the receptacle. Thus, the other hand of the user remains available, for example, for helping to obtain a desired hairstyle.
[0009] In exemplary embodiments, the receptacle preferably includes a substance dispenser valve which is actuated by moving the lifter member. This makes the device simpler to use.
[0010] Further, in exemplary embodiments, the device preferably includes a dispenser endpiece distinct from the lifter member. This makes it possible, for example, to spray substance in a direction substantially perpendicular to a portion of the hair that extends between the scalp and the lifter member.
[0011] In exemplary embodiments, the lifter member advantageously comprises a comb, for example, having at least one row of teeth, or indeed a single row of teeth. The teeth may have bases that are in alignment. For example, the comb may comprise two to forty teeth. Further, the comb may comprise five to twenty teeth. Free ends of the teeth may point in a direction that is substantially away from the receptacle, particularly while the lifter member is being actuated.
[0012] In exemplary embodiments, the hair lifter member may advantageously include an actuator portion defining a location on which the user can press in order to cause the lifter member to move relative to the receptacle.
[0013] In exemplary embodiments, the lifter member may be connected via at least one tab to a base portion fastened on the receptacle. The tab may include at least one film-hinge. For example, the lifter member may include two such tabs, each provided with a film-hinge and spaced apart from each other sufficiently to enable the dispenser endpiece to engage therebetween while dispensing the substance, after the lifter member has been moved to lift the hair.
[0014] In exemplary embodiments, the device may also include a portion for bearing against the scalp, which portion may be stationary relative to the receptacle. The bearing portion may rest on the scalp while the lifter member is being moved to lift the hair. The bearing portion may comprise, for example, two rods which may be parallel and situated at equal distances from the dispenser endpiece. For example, the rods may be of a length that is selected so that free ends thereof are at substantially a same level as the bases of the teeth of the comb, prior to the lifter member being actuated, and when the device is observed in a direction perpendicular to a longitudinal axis of the receptacle.
[0015] In exemplary embodiments, the dispenser endpiece may include an abutment against which the lifter member can bear at an end of displacement thereof. The abutment can come into contact, for example, with the actuator portion of the lifter member.
[0016] In exemplary embodiments, the dispenser endpiece may be connected to the base portion via at least one film-hinge, and the abutment may be situated on a side of the dispenser valve that is opposite from the film-hinge.
[0017] The dispenser endpiece may be provided with a nozzle arranged to generate a spray.
[0018] The substance contained in the receptacle may contain polymers and may have a drying time that is relatively short, for example, less than 30 seconds.
[0019] Exemplary embodiments of the present invention provide a device for treating the hair, the device comprising: a receptacle containing a substance for application to at least one of the hair and the scalp; a lifter member for lifting the hair, the lifter member comprising a comb secured to the receptacle and movable relative thereto; and at least one dispenser endpiece for dispensing the substance on at least one of the hair and the scalp, after the hair has been lifted by the lifter member.
[0020] In exemplary embodiments, the comb may comprise at least one row of teeth, for example, a row of two to forty teeth. Free ends of the teeth may point in a direction going substantially away from the receptacle, for example, while the lifter member is being actuated.
[0021] Exemplary embodiments of the present invention provide a hair treatment device comprising: a receptacle containing a substance for application to at least one of the hair and the scalp, and including a substance dispenser valve; a lifter member for lifting the hair, the lifter member being secured to the receptacle and movable relative thereto, movement of the lifter member enabling the substance dispenser valve to be actuated; and at least one dispenser endpiece for dispensing the substance onto at least one of the hair and the scalp, after the hair has been lifted by the lifter member.
[0022] Exemplary embodiments of the present invention provide a hair treatment device comprising: a receptacle containing a substance for application to at least one of the hair and the scalp; a hair-lifter member secured to the receptacle and movable relative thereto; and at least one dispenser endpiece for dispensing the substance on at least one of the hair and the scalp, after the hair has been lifted by the hair-lifter member; the hair-lifter member being connected via at least one film-hinge to a base portion that is fastened to the receptacle.
[0023] In exemplary embodiments, the hair-lifter member may be connected to the base portion via at least one tab, for example, two tabs, each provided with a respective film-hinge, the tabs being spaced apart from each other sufficiently to allow the dispenser endpiece to engage therebetween while dispensing the substance, after the hair-lifter member has been displaced to lift the hair.
[0024] Exemplary embodiments of the present invention provide a method of applying a substance to the hair, the method comprising: providing a device as defined above; lifting the hair with the hair-lifter member; and dispensing a substance onto the roots of the hair when lifted.
[0025] After the substance has been dispensed, the hair can be held in a desired lifted position for a length of time that is sufficient to allow the substance to dry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention can be better understood on reading the following detailed description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which:
[0027] [0027]FIG. 1 is a diagrammatic elevation view showing a device according to an exemplary embodiment of the invention;
[0028] [0028]FIG. 2 is a side view of the exemplary device as seen looking along arrow II of FIG. 1;
[0029] [0029]FIG. 3 is a diagrammatic and fragmentary axial section view of the exemplary device taken along line III-III of FIG. 1; and
[0030] FIGS. 4 to 6 illustrate the exemplary device of FIGS. 1 to 3 in use for giving volume to the hair.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0031] [0031]FIG. 1 show a device 1 comprising a receptacle 2 containing a substance pressurized by a propellant gas, for example, a substance rich in polymers and suitable for drying quickly, together with a dispenser head 3 fastened on the receptacle 2 via a base portion 4 . As shown in FIG. 3, the base portion 4 may comprise an assembly skirt 5 snap-fastened in an annular groove 6 near a top of the receptacle 2 . In the exemplary embodiment shown, the receptacle 2 includes a cup 7 that supports a dispenser valve 8 , the cup 7 being crimped to the body of the receptacle 2 .
[0032] In a conventional manner, the dispenser valve 10 may comprise a hollow control rod 11 , a body 12 held by the cup 7 and into which the rod 11 can be depressed, and a spring 13 for returning the rod 11 into a position in which the rod 11 bears via a sealing lip 14 against an annular gasket 15 . In this position, the lip 14 closes off communication between an inside of the body 12 and a lateral orifice 16 of the rod 11 , through which orifice 16 the substance can flow from the receptacle 2 when the rod 11 is depressed.
[0033] In embodiments of the invention, the dispenser head 3 also comprises a hair-lifter member 20 and a dispenser endpiece 30 .
[0034] The hair-lifter member 20 may comprise a comb 21 and an actuator portion 22 against which a user can press to move the comb 21 , thereby lifting the comb 21 .
[0035] In the exemplary embodiment shown, the comb 21 and the actuator portion 22 are made integrally by molding a plastics material, together with two tabs 23 that connect to the base portion 4 , each having a thin portion 24 defining a film-hinge, thereby enabling the comb 21 and the actuator portion 22 to pivot about an axis perpendicular to the plane of FIG. 3 and to a longitudinal axis X of the receptacle 2 when the user presses on the actuator portion 22 . The base portion 4 may be made integrally, i.e., monolithically, with the tabs 23 . It should be understood that the thin portion 24 may be replaced by any other suitable hinge means, either known or hereafter developed.
[0036] In the exemplary embodiment shown, the comb 21 comprises a row of teeth 25 having bases 26 that are in alignment, and free ends 27 of the teeth 25 that are directed generally away from the receptacle 2 .
[0037] The dispenser endpiece 30 and the comb 21 are offset along the axis X. Further, the endpiece 30 comprises a body 31 of generally frustoconical shape, in the exemplary embodiment shown, provided with an internal channel 32 whose bottom end opens into a housing 33 that receives an end of the control rod 11 . The house 33 is extended downward by a cone 35 that facilitates insertion of the rod 11 .
[0038] The body 31 of the dispenser endpiece 30 receives a nozzle 36 at a top end thereof and is connected to the base portion 4 by a tab 37 made integrally, i.e., monolithically, with the body 31 , the tab 37 including a thin zone 38 defining a film-hinge. Thus, the body 31 and the dispenser endpiece 30 can pivot about an axis that is substantially parallel to the axis about which the lifter member 20 can tilt. The tabs 37 can be made integrally, i.e., monolithically, with the base portion 4 . As sown in FIG. 3, the thin zones 24 and 38 are situated on a same side of the device 1 relative to the axis of the control rod 11 , which coincides with the axis X.
[0039] On a side remote from the tab 37 , the dispenser endpiece 30 is made to have an abutment 39 against which the actuator portion 22 can come to bear when the user presses thereon, for example, with an index finger I, as shown in FIGS. 4 to 6 .
[0040] In the exemplary embodiment shown, the device 1 further comprises two rods 40 that extend parallel to the longitudinal axis X of the receptacle 2 and are connected to the base portion 4 in a vicinity of the assembly skirt 5 .
[0041] Free ends 41 of the rods 40 are rounded in shape and are situated substantially at a same level as the bases 26 of the teeth prior to the hair-lifter member 20 being actuated, as shown in FIG. 3.
[0042] The device 1 may be used as follows.
[0043] A user takes hold of the receptacle 2 in one hand, placing the index finger I on the actuator portion 22 , and slides the comb 21 tangentially to the scalp S so as to select a portion of the hair that is to be made to stand up, as shown in FIG. 4. The user can take advantage of the rods 40 which bear against the scalp S.
[0044] Once the device 1 is in place, the user can press on the actuator portion 22 until the actuator portion 22 comes into abutment with the abutment 39 on the dispenser endpiece 30 .
[0045] The pressure exerted by the index finger I lifts the comb 21 so that the comb 21 takes up an angle relative to an initial orientation of the comb 21 . The hair-lifter member 20 is made somewhat easier to move by the presence of the rods 40 .
[0046] The hair taken between the teeth 25 of the comb 21 follows the movement so the roots R of the hair extend in a direction substantially perpendicular to the scalp S, thereby exposing the hairs for subsequent operations, as shown in FIG. 5.
[0047] By pressing a little harder on the actuator portion 22 , the abutment 39 of the dispenser endpiece 30 is caused to move, thereby entraining the control rod 11 and opening the dispenser valve 10 , thus causing the spray to be released. The spray is deposited directly on the roots of the hair, between the scalp S and the portion of the hair that is engaged in the comb 21 , as shown in FIG. 6.
[0048] Once the desired quantity of substance has been deposited, the user can relax the pressure applied to the actuator portion 22 a little so as to cause dispensing of the substance to stop.
[0049] The user can hold the hair-lifter member 20 in this intermediate position for a length of time needed to allow the substance to dry, thus enabling the roots R to be fixed in a desired position so as to give the hair a desired volume. When the user releases the actuator portion 20 , the actuator portion can return to the initial position shown in FIG. 2, for example, because the thin zones 24 possess a certain amount of shape memory.
[0050] Naturally, the invention is not limited to the exemplary embodiment described above.
[0051] Exemplary embodiments of the invention contemplate that the shape of the hair-lifter member can be modified. For example, it is possible to use hair-holding elements of some other form. It is also possible to modify the shape of the dispenser endpiece and the shape of the actuator portion, amongst other possible modifications. Where appropriate, the hinge of the hair-lifter member and/or the means for possible return thereof to the initial position can be provided other than by a film-hinge.
[0052] Throughout the description, including in the claims, the term “comprising a” should be understood as being synonymous with “comprising at least one,” unless specified to the contrary.
[0053] Although the present 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.
|
Embodiments of a device for treating the hair includes: a receptacle containing a substance to be applied to at least one of the hair and the scalp; a lifter member for lifting the hair and comprising a comb secured to the receptacle and movable relative thereto; and at least one dispenser endpiece for dispensing the substance on at least one of the hair and the scalp after the hair has been lifted by the lifter member.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for the temperature balancing control of a plurality of heat exchangers.
2. Description of the Prior Art
As various plants become larger in size, various heat exchangers for use in them ought to be enlarged correspondingly. It is the actual situation, however, that the enlargement of the heat exchangers is limited in relation to manufacturing equipment and fabricating techniques.
For this reason, in a large-sized plant, the case of using a plurality of heat exchangers connected in parallel by piping is increasing. On that occasion, the control of the distribution of fluid flow rates to the respective heat exchangers becomes a problem.
More specifically, even when the respective heat exchangers are fabricated in accordance with the same specifications, the dispersion of fluid resistances is inevitable, and dispersions arise also in the fluid resistances of pipes connecting the heat exchangers, the fluid resistances of valves disposed midway of pipes, etc. Therefore, the flow rate distribution to the individual heat exchangers becomes unbalanced, with the result that unbalanced temperatures develop in various parts of the heat exchangers.
It is necessary to correct the unbalance and to operate all the parallel heat exchangers while their temperatures are being balanced.
The temperature balancing control is performed by equipping the respective heat exchangers with control valves for regulating the fluid flow rates and regulating the control valves individually. When only the temperature balance is considered, the temperatures may be balanced with all the control valves kept close to their fully closed states. In order to realize the stable operation and efficient operation of the plant, however, the temperatures should preferably be balanced with the control valves kept close to their fully open states.
A known prior-art method for the temperature control of a plurality of heat exchangers is disclosed in the official gazette of Japanese Patent Application Publication No. 51-30304.
In the aforementioned known temperature control method for a multiple heat exchanger in which a plurality of heat exchangers are arranged in parallel, temperatures are sensed at the same positions of the respective heat exchangers except for the inlets thereof for a fluid subject to heat exchange, the mean temperature of the sensed temperatures is evaluated, and the sensed temperatures are compared with the mean temperature so as to regulate the flow rates of a heat exchanging fluid, whereby the temperatures of the fluid subject to the heat exchange are averaged.
With this known method, the flow rates of the heat exchanging fluid in the respective heat exchangers are controlled using the mean temperature as a reference value. It is theoretically possible, however, that the balanced relationship of the temperatures holds in the state in which the openings of all control valves for controlling the flow rates are close to the full opening or the full closure. Therefore, the method left intact is problematic in practical use.
In addition, a prior-art control method according to which the temperatures do not become balanced in the full closure direction is disclosed in the official gazette of Japanese Patent Application Publication No. 58-9920.
In a multiple heat exchanger wherein a plurality of heat exchangers are used in parallel, this method consists in sensing the temperatures of the same positions of the respective heat exchangers except for the inlets thereof for a fluid subject to heat exchange and the inlets thereof for a heating fluid, selecting the temperature of any desired one of the positions as a control reference value, and adjusting the fluid flow rates of the respective heat exchangers so that the sensed temperatures may agree with the control reference value.
In such method, using the desired position for the control reference value, the fluid flow rates of the respective heat exchangers are adjusted so that the sensed temperatures may agree. However, when control valves have become fully open, they cannot be opened more, and the method becomes uncontrollable.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method and apparatus for the temperature balancing control of a plurality of heat exchangers, which are free from the drawbacks mentioned above and which are high in reliability.
In one aspect of performance of the present invention, a method for the temperature balancing control of a plurality of heat exchangers wherein temperatures of the same positions of the plurality of heat exchangers used in parallel, the positions being except for inlets of the heat exchangers for a medium to-be-heated, are respectively sensed, the sensed temperature values are respectively compared with a temperature setting value so as to calculate control signals for balancing temperatures of the medium to-be-heated which flows out of the respective heat exchangers, and regulation means for the respective heat exchangers are controlled on the basis of the control signals; is characterized by revising all the control signals so that a maximum value among said control signals may agree with a preset control reference value, and controlling said regulation means on the basis of the revised control signals.
In another aspect of performance of the present invention, an apparatus for the temperature balancing control of a plurality of heat exchangers connected in parallel, comprising thermometers or temperature sensors which sense temperatures of the same positions of the heat exchangers respectively, the positions being except for inlets of the heat exchangers for a medium to-be-heated, regulation means to control temperatures of the medium to-be-heated in the heat exchangers respectively, and arithmetic control means to receive the sensed temperature values of the temperature sensors, to compare the respective sensed temperature values with a temperature setting value so as to calculate control signals for balancing temperatures of the medium to-be-heated which flows out of the respective heat exchangers, and to supply the control signals to the regulation means; is characterized in that said arithmetic control means has a function of revising all the control signals so that a maximum value among said control signals may agree with a preset control reference value, the revised control signals being supplied to said regulation means.
Other objects and features of the present invention will become apparent from the following description taken with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram showing an embodiment of the present invention.
FIG. 2 is an operating flow chart showing the detailed operation of the embodiment in FIG. 1.
FIG. 3 is a diagram for explaining the operation of the embodiment in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, the present invention will be described in detail with reference to the drawings.
FIG. 1 is a block diagram showing an embodiment of the present invention, while FIG. 2 is an operating flow diagram thereof.
In FIG. 1, symbols H1, H2, H3, . . . and Hn denote heat exchangers, which have the function of affording the amount of heat of a heating medium A to a medium to-be-heated B. Here, the heating medium A signifies a heating fluid or a cooling fluid. In addition, the medium to-be-heated B signifies a fluid to-be-heated or a fluid to-be-cooled. Hereinbelow, the heating medium shall be explained as the heating fluid, and the medium to-be-heated as the fluid to-be-heated. Symbols 11, 12, 13, . . . and 1n indicate temperature sensors, which deliver electric signals corresponding to temperatures. The temperature sensors 11-1n are disposed in the same positions of the corresponding heat exchangers, the positions being except for the inlets of the fluid to-be-heated B in the heat exchangers. In the arrangement of FIG. 1, the temperature sensors 11-1n are installed at the outlets of the fluid to-be-heated B in the respective heat exchangers. Symbol 2A denotes a temperature sensor which is disposed at the entrance of the heating fluid A, and symbol 2B a temperature sensor which is disposed at the exit of the fluid to-be-heated B posterior to a confluence. Symbols CV1, CV2, CV3, . . . and CVn denote control means which are disposed on the outgoing sides of the fluid to-be-heated B in the corresponding heat exchangers H1, H2, H3, . . . and Hn so as to control the temperatures of the fluid to-be-heated B. In the arrangement of FIG. 1, control valves for controlling flow rates are employed as the control means. Shown at numeral 10 is arithmetic control means, which is a computer in FIG. 1. Each of the control valves CV1, CV2, CV3, . . . and CVn is actuated in accordance with a control signal (valve opening command) which is delivered from the computer 10.
The apparatus shown in FIG. 1 operates as follows. The heat exchangers are supplied with the heating fluid A and the fluid to-be-heated B and supply the heat of the fluid A to the fluid B, so that the fluid B is heated. The temperatures of the heat exchanger outlets of the fluid to-be-heated B are sensed by the temperature sensors 11-1n, the sensed values T 1 -T n of which are applied to the computer 10. The computer 10 calculates the optimum control signals on the basis of the sensed value inputs, and supplies them to the corrresponding control valves CV1-CVn so as to control the flow rates of the fluid to-be-heated B. The internal operations of the computer 10 are as illustrated in FIG. 2. The output of a timer (not shown), which delivers a start signal every fixed time, starts a control program so as to perform a series of operations. First, the sensed values T 1 -T n of the respective temperature sensors 11-1n are received as inputs (step S10). Next, a temperature setting value T s which serves as the reference of a temperature balancing control is calculated on the basis of the input values (step S20). Subsequently, each of the sensed temperature values T 1 -T n is compared with the temperature setting value T s , whereupon the valve opening variation ΔV i of each control valve is calculated on the basis of a deviation ΔT i (i=1, 2, . . . , n) obtained by the comparison. The control signal (valve opening) V i of each control valve is evaluated from the variation ΔV i . That is, the following is calculated:
ΔT.sub.i =T.sub.i -T.sub.s (1)
ΔV.sub.i =α·ΔT.sub.i (2)
V.sub.i =V.sub.i.sup.(-1) +ΔV.sub.i (3)
where
α: the coefficient of conversion,
V i .sup.(-1) : the control signal of the i-th control valve in the last control.
These are operations indicated in steps S30-S80. After all the control signals V i for the control valves have been calculated, the operating flow proceeds to the next step. At step S90, the maximum value V max is selected from among all the control signals V i . Next, the maximum value V max is compared with a preset control reference value V o at step S95. Subject to V max >V o , the processing flow proceeds to step S100. The reference value V o is selected at a magnitude corresponding to a valve opening of 50%-100%, in consideration of the overall efficiency. However, V o is not restricted thereto, but any desired magnitude other than 0% can be selected therefor. Moreover, if necessary, V o can be altered during the operation of the apparatus. Step S100 executes the calculation of revising the control signal V i . This calculation is as follows:
Δk=|V.sub.max -V.sub.o | (4)
V.sub.i '=V.sub.i -Δk (5)
where
i=1, 2, . . . , n
V i '; revised control signal.
As the result of the calculation, V max is revised to V o , and also the other control signals V i are equally revised by Δk.
When V max =V o or V max <V o holds, the control flow proceeds to step S110. When V max <V o holds at step S110, the processing flow proceeds to step S120, which revises the control signal V i as follows:
V.sub.i '=V.sub.i +Δk (6)
As the result of the calculation, V max is revised to V o , and also the other control signals V i are equally revised by Δk. In case of V max =V o , the processing flow proceeds to step S130, and the control signal is not revised in this case. That is, V i '=V i is held. At step S140, the revised control signals V i ' are fed to the respective control valves. On the basis of the control signals V i ', the control valves regulate the valve openings so as to control the flow rates of the fluid to-be-heated B.
The operations of FIG. 2 are intelligibly illustrated in FIG. 3. Let's consider the state in which, at a point of time t 1 , the valve opening of the control valve CV1 is 80%, that of the control valve CV2 is 60%, that of the control valve CV3 is 100%, and that of the control valve CVn is 90%. It is assumed that the calculations up to step S80 in FIG. 2 have given the control signals V i with which the valve openings of the control valves fall into a state b (CV1: 80%, CV2: 70%, CV3: 105%, CVn: 85%). On this occasion, the control valve CV3 comes to have the valve opening of 105% and becomes uncontrollable in actuality. Accordingly, the actual control signals V i ' at a point of time t 2 are revised so as to bring the valve openings of the control valves into an illustrated state c (CV1: 75%, CV2: 65%, CV3: 100%, CVn: 80%). The control reference value V o in the case of FIG. 3 corresponds to the valve opening of 100%.
Although, in the above example, the revision of the control signals V i has been made on the basis of the difference Δk between the maximum value V max and the reference value V o , this is not restrictive. For example, it is also allowed to take the ratio of the values V max and V o and to revise all the control signals on the basis of the ratio. The revision of the control signal in the case of employing the ratio can be realized with the following equations by way of example:
M=V.sub.o /V.sub.max (7)
V.sub.i '=V.sub.i ·M (8)
where M; proportion coefficient.
Although the temperature control means in FIG. 1 has been the valves for controlling the flow rates of the medium to-be-heated B, the present invention is not restricted thereto. For example, it is also allowed to employ an appliance which changes the temperature or flow rate of the heating medium A. A heater may well be employed. Anyway, means capable of controlling the temperature of the medium to-be-heated B suffices.
In the foregoing embodiment, the temperature setting value T s may concretely be any of the sensed temperature values T 1 -T n mentioned before or the mean value of the values T 1 -T n . It may well be the sensed value of the temperature sensor 2B which is located at the exit of the fluid to-be-heated B in FIG. 1.
The sensed value of the temperature sensor 2A in FIG. 1 is utilized for a predictive control which predicts the temperature fluctuations of the fluid to-be-heated B attributed to a temperature fluctuation on the incoming side of the heating fluid A and which serves to mitigate the temperature fluctuations of the fluid B. The sensed value of the temperature sensor 2B is utilized, not only as the temperature setting value stated above, but also for a feedback control which maintains the temperature of the fluid to-be-heated B at a desired value.
As described above, according to the present invention, the drawbacks of uncontrollability etc. can be eliminated, and the temperature balancing control of high reliability can be realized.
|
A method for the temperature balancing control of a plurality of heat exchangers wherein, in case of operating the heat exchangers connected in parallel, the temperatures of a medium to-be-heated on the outlet sides of the respective heat exchangers are balanced. According to the method, the temperatures of the same positions of the heat exchangers except for the inlets thereof for the medium to-be-heated are sensed, the respective sensed values are compared with a temperature setting value so as to calculate control signals, all the control signals are subsequently revised so that the maximum value among the control signals may agree with a preset control reference value, and temperature regulation means disposed for the respective heat exchangers are controlled on the basis of the revised control signals.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/066,008, filed on Oct. 20, 2014. The entire disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to a compressor, and more particularly, to a crankshaft-connecting rod assembly of a compressor.
BACKGROUND
[0003] This section provides background information related to the present disclosure and is not necessarily prior art.
[0004] Reciprocating compressors typically include a motor and one or more piston-cylinder arrangements. Operation of the motor drives a crankshaft, which imparts a force on each piston via connecting rods to move the pistons within and relative to respective cylinders. In so doing, a pressure of working fluid disposed within the cylinders is increased.
[0005] Reciprocating compressors may be used in climate control systems such as heating, ventilation, air conditioning and refrigeration systems (HVACR) to circulate a refrigerant amongst the various components of the climate control system. For example, a reciprocating compressor may receive low-pressure, gaseous refrigerant from an evaporator and compress the refrigerant to a higher pressure. The compressed refrigerant may exit the compressor and flow through a condenser to allow some or all of the refrigerant to change phase from a gas to a liquid. Thereafter, the refrigerant may be expanded via an expansion valve prior to returning to the evaporator where the cycle begins anew.
[0006] After being manufactured, compressors often sit idle (e.g., in a manufacturer's inventory or in an installation contractor's inventory) for a relatively long period of time (often several months or more) prior to being installed into and/or operated in a climate control system. Furthermore, compressors sometimes sit idle for long periods of time between periods of operation (i.e., when the climate control system is shut off for a prolonged period of time). As a result, lubricants applied to various moving components of the compressor during assembly of the compressor can, over time, drip off of various components and settle in the bottom of the compressor. Furthermore, during such prolonged idle periods, refrigerant from throughout the climate control system can migrate into the bottom of the compressor, which can hinder lubricant flow through the crankshaft at initial startup of the compressor. Therefore, a compressor that has been sitting idly for a relatively long period of time before initial installation and/or initial operation or a compressor that has been sitting idly (i.e., shutoff) for a relatively long period of time between periods of operation can have moving components that are under-lubricated (i.e., having no lubricant or not enough lubricant) at the initial startup of the compressor, which can cause damage to the compressor. For example, interfaces between the connecting rods and the crankshaft of the compressor can be particularly susceptible to such under-lubrication, which can lead to a seizure of the connecting rods and crankshaft. Such a seizure can catastrophically damage the compressor.
SUMMARY
[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0008] A compressor may include a shell, a crankshaft, a piston and a connecting rod. The shell may define a cylinder. The crankshaft is supported for rotation relative to the shell. The piston reciprocates within the cylinder in response to rotation of the crankshaft. The piston and the cylinder define a compression chamber therebetween. The connecting rod includes a first bushing rotatably coupled to the piston and a second bushing rotatably coupled to the crankshaft. The second bushing may include an arched driving surface contacting the crankshaft and having a recess formed therein. The recess may receive an insert.
[0009] In some configurations, the insert is formed from a different material than the driving surface. The insert may contact the crankshaft or a piston pin.
[0010] In some configurations, the insert is formed from a material having a higher lubricity than a material of the driving surface.
[0011] In some configurations, the insert is formed from a polymeric material.
[0012] In some configurations, the insert is formed from an unleaded bearing alloy.
[0013] In some configurations, the driving surface is formed from aluminum.
[0014] In some configurations, the insert includes a first lubricant bore in fluid communication with a second lubricant bore extending through the second bushing.
[0015] In some configurations, at least a portion of the insert is aligned with a longitudinal axis of the connecting rod.
[0016] In some configurations, opposing edges of the insert are angularly spaced apart from the longitudinal axis such that the longitudinal axis extends through a central portion of the insert.
[0017] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by thirty degrees.
[0018] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by sixty degrees.
[0019] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by an angle between thirty and sixty degrees.
[0020] In some configurations, a surface of the insert is flush with the driving surface.
[0021] In some configurations, the insert extends through first and second opposing axial ends of the second bushing.
[0022] In some configurations, the insert engages the recess by a press fit.
[0023] In some configurations, the connecting rod can be cast around the insert.
[0024] In another form, the present disclosure provides a reciprocating compressor that includes a crankshaft, a piston reciprocating within a cylinder in response to rotation of the crankshaft, and a connecting rod. The piston and the cylinder define a compression chamber therebetween. The connecting rod includes a first bushing coupled to the piston and a second bushing coupled to the crankshaft. Each of the first and second bushings includes a driving surface that is formed of a first material. The first bushing may contact a piston pin. The second bushing may contact the crankshaft. The driving surface of one of the first and second bushings may have a recess formed therein in which an insert is received. The insert may be formed from a second material (e.g., a high-lubricity material).
[0025] In some configurations, the insert is formed from a polymeric material.
[0026] In some configurations, the insert is formed from an unleaded bearing alloy.
[0027] In some configurations, the driving surface is formed from aluminum.
[0028] In some configurations, the insert includes a first lubricant bore in fluid communication with a second lubricant bore extending through the second bushing.
[0029] In some configurations, at least a portion of the insert is aligned with a longitudinal axis of the connecting rod.
[0030] In some configurations, opposing edges of the insert are angularly spaced apart from the longitudinal axis such that the longitudinal axis extends through a central portion of the insert.
[0031] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by thirty degrees.
[0032] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by sixty degrees.
[0033] In some configurations, another portion of the insert is angularly spaced apart from the longitudinal axis by an angle between thirty and sixty degrees.
[0034] In some configurations, a surface of the insert is flush with the driving surface.
[0035] In some configurations, the insert extends through first and second opposing axial ends of the second bushing.
[0036] In some configurations, the insert engages the recess by a press fit.
[0037] In some configurations, the connecting rod can be cast around the insert.
[0038] In another form, the present disclosure provides a compressor that may include an insert received in a recess in a surface contacting a crankshaft connected to a piston by a connecting rod. The piston reciprocates within a cylinder upon rotation of the crankshaft. The piston and cylinder define a compression chamber.
[0039] In some configurations, the surface is a driving surface of a bushing of the connecting rod.
[0040] In some configurations, the insert is flush with the driving surface.
[0041] In some configurations, the insert includes a lubricant bore.
[0042] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0043] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0044] FIG. 1 is a cross-sectional view of a compressor having connecting rods according to the principles of the present disclosure;
[0045] FIG. 2 is a plan view of one of the connecting rods of FIG. 1 ;
[0046] FIG. 3 is a partial perspective view of the connecting rod;
[0047] FIG. 4 is a partial plan view of another connecting rod according to the principles of the present disclosure;
[0048] FIG. 5 is a partial perspective view of the connecting rod of FIG. 4 ;
[0049] FIG. 6 is a partial plan view of yet another connecting rod according to the principles of the present disclosure; and
[0050] FIG. 7 is a partial plan view of yet another connecting rod according to the principles of the present disclosure.
[0051] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0052] Example embodiments will now be described more fully with reference to the accompanying drawings.
[0053] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0054] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0055] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0056] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
[0057] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0058] With reference to FIG. 1 , a compressor 10 is provided that can compress a working fluid from a suction pressure to a discharge pressure to cause the working fluid to circulate amongst various components of a climate control system (e.g., a refrigeration system, an air conditioning system or a heat-pump system). The compressor 10 may be a reciprocating compressor and may include a shell 12 and a cylinder head assembly 14 . The shell 12 may house a compression mechanism 16 that may include a crankshaft 18 , one or more pistons 22 , and one or more connecting rods 26 . The shell 12 may include one or more cylinders 30 and first and second bearing housings 34 , 36 . The pistons 22 are reciprocatingly received in respective cylinders 30 such that compression chambers 32 are defined within the cylinders 30 between the pistons 22 and the cylinder head assembly 14 . The first and second bearing housings 34 , 36 rotatably support the crankshaft 18 . A motor 38 may drive rotation of the crankshaft 18 relative to the shell 12 . The motor 38 could be disposed inside of the shell 12 or outside of the shell 12 . The crankshaft 18 can be formed from iron, steel, aluminum, titanium, or a polymeric material, for example, or any other suitable material.
[0059] Referring now to FIGS. 1-3 , each of the connecting rods 26 includes a body 40 , a first bushing 42 and a second bushing 44 . The body 40 and the first and second bushings 42 , 44 can be formed from aluminum, steel, iron, titanium, an unleaded bearing copper alloy, or a polymeric material, for example, or any suitable material. The body 40 is disposed between and interconnects the first and second bushings 42 , 44 . The first and second bushings 42 , 44 define first and second aperture 46 , 48 , respectively. The first aperture 46 may have a smaller diameter than the second aperture 48 . The first bushing 42 may be integrally formed with the body 40 and may rotatably engage a piston pin 50 ( FIG. 1 ) of a corresponding piston 22 .
[0060] The second bushing 44 may be formed by first and second bushing halves 52 , 54 . The first and second bushing halves 52 , 54 include first and second arched driving surfaces 58 , 60 , respectively, that cooperate to define the second aperture 48 and rotatably engage a bearing journal 56 ( FIG. 1 ) of a corresponding crank throw 62 of the crankshaft 18 . The first bushing half 52 can be integrally formed with the body 40 and the first bushing 42 . The second bushing half 54 can be removably fastened to the first bushing half 52 by one or more bolts 64 and/or other fasteners to selectively couple and uncouple the connecting rod 26 to the corresponding crank throw 62 .
[0061] The first bushing half 52 may include a recess 66 formed in the first arched surface 58 . A lubricant bore 68 may extend through a portion of the first bushing half 52 to the recess 66 . In some configurations, the lubricant bore 68 may extend through a portion of the body 40 of the connecting rod 26 . In some configurations, the lubricant bore 68 may extend from the first bushing 42 to the second bushing 44 . In the example depicted in FIGS. 2 and 3 , the recess 66 spans the entire axial thickness T of the first bushing half 52 . That is, sidewalls 70 of the recess 66 can extend in an axial direction (i.e., in a direction parallel to a rotational axis of the second bushing 44 ) through opposing axial ends 71 , 73 of the second bushing 44 . In other configurations, the recess 66 could span only a portion of the axial thickness T of the first bushing half 52 .
[0062] In the particular example depicted in FIGS. 2 and 3 , one of the sidewalls 70 of the recess 66 may be aligned with a longitudinal axis A ( FIG. 2 ) of the connecting rod 26 (i.e., a centerline or axis of symmetry of the connecting rod 26 ), and the other side wall 70 may be angularly spaced about thirty degrees) (30° apart from the longitudinal axis A. In other configurations, the positioning of either or both of the sidewalls 70 relative to the longitudinal axis A could vary from the configuration shown in FIGS. 2 and 3 . That is, either of both of the side walls 70 could be angularly spaced apart from the longitudinal axis A by less than or greater than thirty degrees. For example, the configuration shown in FIG. 6 depicts the recess 66 having one sidewall 70 aligned with the longitudinal axis A and another sidewall 70 angularly spaced apart from the longitudinal axis A by sixty degrees (60°).
[0063] In other examples, one sidewall 70 can be spaced apart from the longitudinal axis A by about thirty or sixty degrees (or any other suitable angle) in a first direction, and the other sidewall 70 can be spaced apart from the longitudinal axis A by about thirty or sixty degrees (or any other suitable angle) in a second direction opposite the first direction. That is, the recess 66 can be generally centered on the longitudinal axis A, as shown in FIG. 7 . Such an arrangement may be particularly beneficial in three-phase compressor applications in which the crankshaft 18 can rotate in either direction depending on the operational mode of the compressor 10 .
[0064] Furthermore, while the sidewalls 70 are depicted in FIGS. 2 and 3 as being planar and extending in parallel directions, in some configurations, either or both of the sidewalls 70 could have any desired shape and could extend in any desired direction. For example, FIGS. 4 and 5 illustrate an exemplary configuration in which the sidewalls 70 are curved and extend in serpentine paths. The size, shape and location of the recess 66 may be chosen to correspond to an area of the second bushing 44 that is subjected to particularly high loading during operation of the compressor 10 and/or an area of the second bushing 44 that is subject to particularly high wear forces.
[0065] An end wall 72 of the recess 66 can be a curved surface that is concentric with the first arched surface 58 , as shown in FIGS. 2, 3 and 6 . In other configurations, the end wall 72 can be a substantially flat, planar surface, as shown in FIGS. 4 and 5 . It will be appreciated that the end wall 72 could have any other shape or configuration.
[0066] As shown in FIGS. 2-6 , an insert 74 may be received in the recess 66 . The insert 74 can include a lubricant bore 76 that may be aligned with and in fluid communication with the lubricant bore 68 extending through the first bushing half 52 . The insert 74 can have a substantially identical complementary shape as the recess 66 in which the insert 74 is received. In some configurations, the shape of the insert 74 can vary from that of the recess 66 . The insert 74 can be shaped and sized for a press fit or interference fit with the recess 66 . Additionally or alternatively, the insert 74 could be adhesively bonded within the recess 66 . A bearing surface 78 of the insert 74 can have the same radius of curvature as the first and second arched surfaces 58 , 60 so that when the insert 74 is fully installed in the recess, the bearing surface 78 of the insert is flush with the first arched surface 58 . The insert 74 can be formed from a material having a high lubricity relative to the material(s) of the rest of the second bushing 44 . For example, the insert 74 can be formed from a polymeric material (including polymeric materials with or without reinforcement and/or with or without anti-wear additive, or polymer composites containing anti-wear and/or lubricating additives such as fibrous materials, ZnS, CaF 2 , graphite, PTFE or MoS 2 , for example), a metallic material (e.g., an unleaded metallic bearing alloy or any other alloy having suitable lubricity), a composite material, or any suitable high lubricious, solid material. In some configurations, the insert 74 can be formed from a thermoplastic or thermoset resin. In some configurations, the material of the insert 74 may or may not have lubricating additives and/or reinforcement additives.
[0067] Exemplary heat-resistant thermoplastic resins may include but are not limited to those from the polyaryletherketone (PAEK) family (such as polyaryletherketone (PAEK), polyetherketone (PEK), Polyetheretherketone (PEEK), polyetheretheretherketone (PEEEK), polyetherketoneketone (PEKK), polyetheretherketoneketone (PEEKK), polyetherketoneetheretherketone (PEKEEK), polyetheretherketoneetherketone (PEEKEK), and combinations thereof), polyphenylene sulfide (PPS), and Polyphthalamide (PPA). Exemplary heat resistant thermoset resins may include, but are not limited to, polyimide (PI), polyamideimide (PAI), polyester, vinylester, and epoxy resins. Exemplary lubricating additives may include, but are not limited to, graphite, graphene, molybdenum disulfide (MoS2), polytetrafluoroethylene (PTFE), tungsten disulfide (WS2), hexagonal boron nitride, carbon nanotubes, carbon fiber, polybenzimidazole, and combinations thereof. Exemplary reinforcement additives may include, but are not limited to, glass fiber, carbon fiber, aramid fiber, and combinations thereof. In some configurations, the inserts 74 may be formed from polyimide (PI) containing graphite (e.g., DuPont Vespel SP21).
[0068] In some configurations, the connecting rod 26 can be cast or molded around the insert 74 , thereby locking the insert 74 into the recess 66 . That is, the insert 74 can be placed on or in a die-casting or molding tool (not shown) so that the connecting rod 26 can be cast around the insert 74 . The insert 74 could include one or more pins or protrusions (not shown) that can act as locking features and engage and/or extend into the end wall 72 of the recess 66 .
[0069] The high lubricity of the inserts 74 of the connecting rods 26 provides sufficient local lubricity between the second bushings 44 and the journals 56 of the crankshaft 18 at immediately following a first, initial startup of the compressor 10 after manufacturing or following an extended period (e.g., several months or more) during which the compressor 10 was not operating. That is, the high lubricity of the inserts 74 provides enough local lubricity between the second bushings 44 and the journals 56 at the highest loadbearing portions of the second bushings 44 to preventing binding or seizure of the connecting rods 26 until a normal flow of lubricant can be established through operation of the compressor 10 . Thereafter, the normal flow of lubricant caused by operation of the compressor 10 will provide additional lubrication between the second bushings 44 and the journals 56 . Additionally, the high lubricity of the insert 74 and the positioning of the insert at a location subjected to the highest loading and wear can increase the lifecycle of the connecting rods 26 and reduce wear on the connecting rods 26 and crankshaft 18 .
[0070] While the examples provided above include the recess 66 and insert 74 being in the first bushing half 52 of the second bushing 44 , the connecting rods 26 could additionally or alternatively include one or more recesses and inserts in the second bushing half 54 and/or in the first bushing 42 , for example. Furthermore, in some configurations, the first bushing half 52 could include multiple recesses and inserts. In some configurations, the connecting rods 26 could be one-piece connecting rods (i.e., the first and second bushing halves 52 , 54 could be integrally formed as a single piece.
[0071] In some configurations, the insert 74 could be received in a recess in an bushing that is a discrete component from the body 40 and/or formed from a different material than the body 40 (i.e., the insert could be received in a recess in a driving surface of a bushing that is received within bushing 42 or 44 ).
[0072] Referring again to FIG. 1 , operation of the compressor 10 will be described. Rotary motion of the crankshaft 18 (caused by operation of the motor 38 ) is transmitted to the pistons 22 by the connecting rods 26 , thereby causing the pistons 22 to reciprocate within the cylinders 30 . In the particular configuration shown in FIG. 1 , the pair of pistons 22 reciprocate out-of-phase with each other in linearly alternating directions as the crankshaft 18 rotates.
[0073] Working fluid enters the cylinders 30 during suction strokes of the corresponding pistons 22 (i.e., when the pistons 22 move from a top-dead-center (TDC) position to a bottom-dead-center (BDC) position). When a particular piston 22 is at the TDC position, the crankshaft 18 may rotate approximately one-hundred-eighty degrees (180°) to move the particular piston 22 into the BDC position, thereby causing the piston 22 to move from a location proximate to a top portion of the particular cylinder 30 adjacent the cylinder head assembly 14 to a bottom portion of the cylinder 30 spaced apart from the cylinder head assembly 14 . When one of the pistons 22 is moved into the BDC position from the TDC position, the compression chamber 32 corresponding to that piston 22 is placed under a vacuum, which causes suction-pressure working fluid to be drawn into the corresponding cylinder 30 .
[0074] When the piston 22 travel toward the TDC position, the effective volume of the compression chamber 32 is reduced, thereby compressing the working fluid disposed within the compression chamber 32 . At or near the TDC position, the working fluid may exit the cylinders 30 and enter a discharge chamber 80 in the cylinder head assembly 14 . From the discharge chamber 80 , the working fluid may be expelled from the compressor 10 through a discharge port 82 in the shell 12 , for example.
[0075] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
|
A compressor may include a shell, a crankshaft, a piston and a connecting rod. The shell may define a cylinder. The crankshaft is supported for rotation relative to the shell. The piston reciprocates within the cylinder in response to rotation of the crankshaft. The piston and the cylinder define a compression chamber therebetween. The connecting rod includes a first bushing rotatably coupled to the piston and a second bushing rotatably coupled to the crankshaft. The second bushing may include a driving surface contacting the crankshaft and having a recess formed therein. The recess receives an insert.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Provisional U.S. Patent Application No. 61/987,400, filed on May 1, 2014 and titled LINEAR LOCKABLE ELECTRICAL DEVICE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/987,409, filed on May 1, 2014 and titled LOCKABLE ELECTRICAL DEVICE WITH BUTTON RELEASE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/984,042, filed on Apr. 25, 2014 and titled LOCKABLE ELECTRICAL DEVICE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/984,261, filed on Apr. 25, 2014 and titled WEATHERPROOF SELF-SECURING ELECTRICAL RECEPTACLE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/987,403, filed on May 1, 2014 and titled INWARD LOCKABLE ELECTRICAL DEVICE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/988,256, filed on May 4, 2014 and titled CAM ENGAGEMENT ROTATABLE DEVICE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 61/991,590, filed on May 11, 2014 and titled LOCKING ROTATABLE DEVICE AND CORD LOCK to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 62/047,022, filed on Sep. 7, 2014 and titled WATER RESISTANT CORD END to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application claims priority to Provisional U.S. Patent Application No. 62/104,832, filed on Jan. 18, 2015 and titled ELECTRICALLY ISOLATED RECEPTACLE to Baldwin et al., the disclosure of which is hereby incorporated herein by reference. This application hereby incorporates by reference co-filed applications titled LOCKING ELECTRICAL DEVICE and ROTATING ELECTRICAL DEVICE both to Baldwin et al. and filed on the same day as this application.
BACKGROUND
Electrical devices and receptacles are well known to provide electrical current to a number of devices within a building once connected to the electrical receptacle. Some features of electrical devices include tamper resistant shutters to prevent inappropriate access to the device and to make sure the electrical device is as safe as possible.
SUMMARY
Aspects of this disclosure relate to an electrical receptacle. The electrical receptacle may include a body having a plurality of electrical connections, a device face connected to the body, and wherein the device face is slidable with respect to the body.
In an implementation, a plurality of electrical receptacle apertures may be located on the device face. The slidable movement may be in the vertical direction. The slidable movement may be in the horizontal direction. The body may further include at least one locking prong which is engaged when the device face is slide to a locked position. The locking prong may extend inward when the device face is moved to the locked position. The body may further include at least one ramp which operates in conjunction with the at least one locking prong. The at least one ramp may be two ramps. The at least two ramps may be angled towards each other. The body may further include at least one spring biased member which prevents sliding movement unless an electrical plug is fully inserted into the receptacle.
An electrical plug may not be removable when the electrical receptacle is moved to the locked position. The at least one prong may be positioned within at least one aperture in the electrical plug when the device face is moved to a locked position. The device face may be at least two device faces which are slidable independent of each other. A release button may be included which can be engaged to slide the device face from a locked position to an unlocked position. A removal force between 20 to 50 pounds removes an electrical plug from the electrical receptacle when the device face is in a locked position. A removal force between 32 and 40 pounds removes an electrical plug from the electrical receptacle when the device face is in a locked position.
In another aspect, the electrical device may include a body having a face, a locking mechanism positioned within the body, and wherein the locking mechanism interacts with an electrical plug when the face is slide to a locked position.
In an implementation, the face may be slidable in the vertical direction. The locking mechanism may be at least one pivotable component with a tab. The locking mechanism may be two pivotable components each having a tab. The two pivotable components may each engage with separate ramps in the body.
Aspects and applications of the disclosure presented here are described below in the drawings and detailed description. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims.
The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.
The foregoing and other aspects, features, and advantages will be apparent to those artisans of ordinary skill in the art from the DESCRIPTION and DRAWINGS, and from the CLAIMS.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:
FIG. 1 is a perspective view of a linear electrical receptacle with an electrical plug separated.
FIG. 2A is a perspective view of some internal components of the linear electrical receptacle.
FIG. 2B is a perspective view of some internal components of the linear electrical receptacle.
FIG. 3 is a rear perspective view of the body of the linear electrical receptacle.
FIG. 4 is a rear perspective view of the front body of the linear electrical receptacle.
FIG. 5 is a rear perspective view of a device face.
FIG. 6 is a partial sectional view taken generally about line 6 - 6 in FIG. 1 .
FIG. 7 is a sectional view taken generally about line 7 - 7 in FIG. 6 .
FIG. 8 is a partial sectional view taken generally about line 6 - 6 in FIG. 1 with an electrical plug inserted into the electrical receptacle.
FIG. 9 is a sectional view taken generally about line 9 - 9 in FIG. 8 .
FIG. 10 is a sectional view taken generally about line 10 - 10 in FIG. 8 .
FIG. 11 is a sectional view taken generally about line 11 - 11 in FIG. 8 .
FIG. 12 is a perspective view of the electrical receptacle with an electrical plug inserted.
FIG. 13 is a sectional view of the electrical receptacle taken generally about line 13 - 13 in FIG. 12 .
FIG. 14 is a sectional view of the electrical receptacle taken generally about line 14 - 14 in FIG. 13 .
FIG. 15 is a sectional view of the electrical receptacle taken generally about line 15 - 15 in FIG. 13 .
FIG. 16 is a perspective view of an electrical receptacle with a release button.
DETAILED DESCRIPTION
This disclosure, its aspects and implementations, are not limited to the specific components or assembly procedures disclosed herein. Many additional components and assembly procedures known in the art consistent with the intended operation and assembly procedures for an electrical receptacle will become apparent for use with implementations of an electrical receptacle from this disclosure. Accordingly, for example, although particular components are disclosed, such components and other implementing components may comprise any shape, size, style, type, model, version, measurement, concentration, material, quantity, and/or the like as is known in the art for such implementing components, consistent with the intended operation of an electrical receptacle.
FIGS. 1-5 illustrate various views of electrical receptacle 20 . Electrical receptacle 20 includes a rear body 22 with sidewalls 22 A and back wall 22 B. A front body 24 which may be a separate piece from rear body 22 and they may be connected together while front body 24 includes a front surface 26 . A tamper resistant tab mounting structure 22 C may extend forward from and be formed in part from back wall 22 B. A device face 28 is positioned on front surface 26 and includes a plurality of receptacle openings 30 and ground prong opening(s) 30 A. Electrical receptacle 20 may also include electrical connection screws 32 , yoke 34 , and grounding screw 36 as is commonly known in the electrical receptacle art. Grounding screw 36 may be positioned on a ground wire connection tab 41 having a hole 43 , while connection screws 32 may be positioned in apertures 97 in sidewalls 22 A of rear body 22 for accessing receiving arms 96 of connectors 92 while in rear body chamber 23 . Yoke 34 may include mounting flanges 35 on each end with a vertical portion 37 having a hole 39 therein which is positioned to mount the yoke to rear body 22 at hole 25 in the rear body back wall 22 B.
Referring to FIG. 1 , an electrical plug 38 is shown separated from electrical receptacle 20 . Electrical plug 38 may include plug blades 40 and ground prong 40 A extending therefrom and having apertures 42 in the plug blades. While a 3 prong electrical plug and plug blades is shown, it is within the spirit and scope of the present disclosure to incorporate a two prong electrical plug or any other suitable numbers of prongs.
Device face 28 may include a device face surface 44 and a rear surface 45 with a device face 28 rear portion 46 having a top surface 47 . Tabs 48 extend from top surface 47 and may include angled surface 50 , top surface 52 , and rear surfaces 49 . Device face 28 includes retainer tabs 54 used to secure the device face with front body 24 having a back surface 27 . Rear portion walls 56 may include ramped portions 58 and form a cavity 60 for receiving locking arms therein. The rear portion walls 56 may include apertures 57 for contact mechanisms 62 to be accessible.
Each contact mechanisms 62 may include inner contact surfaces 64 and outer contact surfaces 66 which are adapted to convey electrical current from the electrical connections to the electrical plug when inserted. A ground tab 68 may include a mounting hole 70 and a ground tab body 72 having ground angled walls 74 therein for securely retaining an electrical plug ground prong within aperture 75 . A ground connector 76 may include a washer and crimp 78 on each end of wire 77 with apertures 80 therein. A ground support 79 includes an aperture 81 and is used in conjunction with ground tab 68 and ground connector 76 to further secure and retain the ground prong. A rivet 130 may be used to secure ground connector 76 to ground tab 68 and yoke mount strip 37 to back wall 22 B. Front body 24 may also include a front body opening 82 with locking arms 84 positioned behind a front surface 26 . Locking arms 84 may include offset portions 86 and ends 88 with a locking arm prong 90 near end 88 .
Connectors 92 may include connector protrusions 94 on a first end and connector arms 96 with connector apertures 98 therein. Connector apertures 98 may be threaded and arranged to receive electrical connection screws 32 . A block 100 includes tamper resistant tabs 102 which include angled front faces 104 and are connected to block 100 with springs 106 . Apertures 101 in back wall 22 B communicate with channels 103 in mounting structure 22 C. Tamper resistant tabs 102 are used to prevent the sliding motion without an electrical plug engaged as will be discussed in greater detail below.
FIG. 4 illustrates a back perspective view of body front 24 which highlights locking arm 84 within body front cavity 110 . Locking arm 84 may include ramped surfaces 108 on an outer portion of the locking arm ends 88 . In this orientation, ramped surfaces 108 assist with deflecting the locking arm ends 88 inwards as will be discussed in greater detail.
FIG. 6 illustrates a pair of receptacle blade cavities 112 formed by contact mechanism 62 , locking arm 84 , device face rear portion walls 56 . Receptacle blade cavities 112 may also be slightly increased or decreased, depending on the configuration, by compressing springs 106 and moving tamper resistant tabs 102 with electrical plug blades 40 during insertion or decompressing springs 106 and moving tamper resistant tabs 102 when electrical plug blades 40 are removed.
FIG. 7 illustrates a side view of tamper resistant tabs 102 having clearance surfaces 114 . Clearance surfaces 114 are used to permit and facilitate easier vertical movement of the device face. Specifically, clearance surface 114 are used as a chamfer which allows the tamper resistant tabs to engage and disengage the device face and permit movement in both the upwards and downwards direction.
FIGS. 8-15 illustrate various operational views of the electrical device. FIGS. 8-11 illustrate various views of the electrical plug 38 with plug blades 40 inserted through device face 28 and receptacle openings 30 . Specifically, plug blades 40 are inserted in the direction associated with arrow 116 . With movement in the direction of arrow 116 , plug blades 40 also contact tamper resistant tabs 102 and compress springs 106 until the tamper resistant tabs 102 extend beyond a rear surface of device face rear portion 46 . When the tamper resistant tabs 102 are forced behind device face rear portion 46 , device face 28 may be moved linearly in the direction associated with arrows 118 as seen in FIG. 12 .
FIGS. 12-15 illustrate the next movement of the device face 28 and the electrical receptacle in general after an electrical plug is fully inserted through receptacle openings 30 . Specifically, the electrical plug and device face 28 are moved in the direction associated with arrow 118 so that they both move relative to body front 24 . Movement of device face 28 in the direction of arrow 118 forces device face 28 and particularly rear portion walls 56 downward onto locking arms 84 . Rear portion walls 56 and specifically ramped portions 58 communicate with the locking arms and specifically locking arm end 88 with locking arm ramped surface 108 which are received within cavities 60 . When ramped surfaces 108 contact ramped portions 58 , the locking arm end 88 and locking arm prong 90 are forced in the direction associated with arrows 120 . Since electrical plug blades 40 are positioned within the electrical receptacle 20 , locking arm prongs 90 are positioned within blade apertures 42 . With the locking arm prongs 90 within blade apertures 42 , the electrical plug blades 40 and the electrical plug 38 cannot be pulled outwards easily.
In another implementation, the electrical plug 38 may be removed after a specified amount of force, such as 50 pounds of pulling force overcoming the locking arm prongs 90 and thereby permitting the electrical plug to be removed without inadvertently dislodging the electrical receptacle. In yet another implementation, the electrical plug may only be removed when the locking arm prongs 90 are disengaged from blade apertures 90 . Specifically, the electrical plug is removable from the electrical device with less than 15 pounds of removal force in the unlocked position and in one implementation between 3 to 15 pounds of force removes the plug as identified in UL498. In another implementation, the removal force in the unlocked removable force is between 0 and 30 pounds of removal force.
In the locked position, the removal force may be higher. The removal force in the locked position may be between 32 and 38 pounds of removal force or between 25 and 50 pounds of removal force in another implementation. As can be seen, any suitable holding force may be utilized in the locked position between 25 to 50 plus pounds of force as the electrical code, UL, and various requirements may specify. In another implementation, the removal force may be less than 20 or 15 pounds. Accordingly, any suitable unlocked and locked force may be utilized to secure the electrical cord within the receptacle. While the above description relates to a three prong electrical plug, a similar analysis may be accomplished for a two prong electrical plug whereby the two prong electrical plug may have higher or lower removal force in the locked or unlocked positions selectively between 0 and 50 plus pounds.
In order to remove the electrical plug 38 , the user simply slides the device face upwards to allow the locking arm ends 88 to move outwards against the ramped portions 58 to remove locking arm prongs 90 from plug apertures 42 . The additional movement upwards moves the device away from the locking prongs. The user may then remove the electrical plug blades 40 and tamper resistant tabs 102 may be repositioned by springs 106 to prevent unwanted access to the electrical device.
In another aspect, the electrical receptacle 20 may include an electrical current control or cutoff circuit. In this instance, the electrical contact mechanisms may be electrically isolated from the electrical connection screws and other line voltage until the electrical receptacle is slide to the active, engaged, or locked position.
In another aspect, a person of skill in the art will immediately appreciate that the sliding electrical face may be duplicated to provide more than one sliding face on the electrical device. For example, two sliding faces may move vertically together or independently. Further, the two sliding faces may slide horizontally in the same or different directions. Still further, one sliding face could move vertically while the other sliding face could move horizontally. Any number of sliding faces may be utilized and slide in any suitable direction without departing from the spirit and scope of the present disclosure. While not specifically shown, the same features may be implemented in any suitable electrical receptacle, whether on a power strip, surge protector, cord reel, power tap, extension cords, or the like.
FIG. 16 illustrates another implementation electrical receptacle 20 A with a lock and release button 122 . The electrical receptacle is moveable in a manner similar to the above-referenced disclosure but may lock in the engaged, active, or locked position. Accordingly the electrical receptacle remains locked until release button 122 is depressed, thereby allowing the device face 28 to be moved upwards or into the unlocked position. In another implementation, device face 28 may be spring biased to the unlocked or upwards position such that when the spring is compressed or extended by moving to the locked position, the device face will return to its natural position and force the device face to the unlocked position.
It will be understood that implementations are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for an electrical receptacle may be utilized. Components may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of a method and/or system implementation for an electrical receptacle.
While this and other embodiments illustrate the use of a side-wired receptacle, a person of skill in the art will immediately appreciate that a back wired, side wired, hard wired, or any other suitable connection method to the structural wiring system may be utilized without departing from the spirit and scope of the present disclosure.
The concepts disclosed herein are not limited to the specific implementations shown herein. For example, it is specifically contemplated that the components included in a particular implementation of an electrical receptacle may be formed of any of many different types of materials or combinations that can readily be formed into shaped objects and that are consistent with the intended operation of an electrical receptacle. For example, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; polymers and/or other like materials; plastics, and/or other like materials; composites and/or other like materials; metals and/or other like materials; alloys and/or other like materials; and/or any combination of the foregoing.
Furthermore, embodiments of the electrical receptacle may be manufactured separately and then assembled together, or any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled or removably coupled with one another in any manner, such as with adhesive, a weld, a fastener, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material(s) forming the components.
In places where the description above refers to particular implementations of an electrical receptacle, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other electrical receptacles. The accompanying claims are intended to cover such modifications as would fall within the true spirit and scope of the disclosure set forth in this document. The presently disclosed implementations are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.
|
An electrical receptacle including a body having a plurality of electrical connections a device face connected to the body, wherein the device face is slidable with respect to the body. An electrical device including a body having a face, a locking mechanism positioned within the body, and wherein the locking mechanism interacts with an electrical plug when the face is slide to a locked position.
| 7
|
[0001] The present disclosure relates to an improved material and system for fabric that may be used for the sterilization of medical equipment, and to produce medical gowns and drapes.
[0002] Medical materials used in surgery are, of course, required to be in a sterile state for use. Many of these items like forceps, scissors, clamps, scalpels, towels, gowns, drapes and the like are reusable and so need to be sterilized prior to reuse. Some of these items are generally disposable or single use items like surgical gowns and drapes and, unless they are pre-packaged in a sterile state, also need to be sterilized by the hospital prior to their single use.
[0003] Hospitals have developed protocols for the collection, cleaning and sterilization of materials to be used in surgery. After surgery, the instruments are gathered and sent for cleaning or laundering as necessary, and then sent to a hospital department responsible for sterilization. Sterilization involves placing the items in a stainless steel instrument tray, wrapping the tray with a “sterilization wrap” and sterilizing the package, generally with steam or ethylene oxide, though other methods of sterilization are also sometimes used. After sterilization, the wrapped instrument tray may be taken directly to surgery for use or may be stored for future use. Storage involves the placement of the wrapped tray on a shelf, or on top of another wrapped tray on shelf, in a storage area of the hospital.
[0004] Sterilization wrap is most commonly a nonwoven material that is pliable and lightweight, though woven fabrics such as cotton linen are also used. The sterilization wrap functions by allowing the sterilization gas (e.g. steam or ethylene oxide) to pass through the wrap and contact the interior contents of the wrap. It is critical that the sterilization wrap prohibit the passage of microorganisms from the outside of the package to the interior once the wrapped package has been sterilized.
[0005] Once the wrapped package has been sterilized it must be transported to surgery or storage, as noted above. It has been found that this transportation and storage result in multiple instances of the sterilized packages being handled and moved. It should be clear that each instance of movement and handling of the sterilized package makes them vulnerable to a breach of the medical fabric and the admission of microorganisms. It is important to keep the handling of sterile packages to a minimum, or baring that, to ensure that the wrap being used is sufficiently durable to resist breach and compromise.
[0006] One way to ensure that the package has been wrapped in a sufficiently durable manner is to use a dual layer sterilization wrap. U.S. Pat. No. 5,635,134 to Bourne, et al. discloses a multi-ply sterilization wrap which is formed by joining one or more sheets of sterilization wrap (e.g., two separate sheets or one sheet folded over) together to form two similarly sized, superposed panels that allow convenient dual wrapping of an article. As another example, US patent publication 2001/0036519 by Robert T. Bayer discloses a two ply sterilization wrap that is formed of a single sheet of sterilization wrap material which is folded to form two similarly sized, superposed panels that are bonded to each other. As yet another example, US patent publication 2005/0163654 by Stecklein, et al. discloses a sterilization wrap material that has a first main panel and a second panel that is smaller than the main panel. The second panel is superposed and bonded to the central portion of the main panel such that it is contained entirely within the main panel to reinforce the main panel and/or provide additional absorbency. Still another example is U.S. patent application Ser. No. 12/850,697 that provides a multi-panel sterilization assembly that includes a barrier panel formed of a permeable material, a fold protection panel, and at least one panel attachment means.
[0007] Even with the use of multiple ply sterilization wrap fabric, however, breaches in the wrap and contamination of the sterilized items are still possible. The movement of sterilized packages onto shelves and trays has been found to result in abrasion and compression of the wrap. This produces “pressure holes”, very small holes that extend from the outermost layer to the inside of the package. These holes are seen by hospital personnel after the package has been unwrapped, usually by holding the open wrap up to a light. The light can be seen clearly through the holes and indicates a problem in sterility that must be addressed.
[0008] In addition to the pressure holes, repeated movement, particularly sliding of the sterilized package, can result in larger holes being formed, especially at the corners of the package. This shear-type of hole is easier to see prior to opening of the package but is nonetheless quite serious and must be rectified and the items re-sterilized prior to use.
[0009] In addition to the use of medical fabric as sterilization wrap, surgeons and other healthcare providers often wear an over garment made from medical fabric during operating procedures in order to enhance the sterile condition in the operating room and to protect the wearer. The over garment is typically a gown made from the medical fabric that has a main body portion to which respective sleeves are attached. In order to prevent the spread of infection to and from the patient, the surgical gown prevents bodily fluids and other liquids present during surgical procedures from flowing through the gown. Gowns usually have ties that are used to encircle the wearer and secure the gown around the wearer's body. The attachment point of the tie to the gown has been found to be a weak point, often resulting in the tie being pulled or torn off of the gown as the tie is being used to secure the gown around the body.
[0010] Drapes are used to cover a patient during surgery. There are a myriad of different shapes and surgeries that drapes are designed for, but they are generally desired to be impervious to liquid. Drapes are also made from a medical fabric that may be sterilized and that should be free of holes.
[0011] One skilled in the art can recognize that despite the improvements in medical fabric that have occurred over the past few decades, the problem of pressure and shear induced holes in medical fabric remains a concern. This results in increased costs for hospitals, patients, insurers and governments because of the required re-sterilization of surgical materials and requires greater time and heightened vigilance from healthcare workers lest unsterile materials be introduced into the sterile surgical setting.
SUMMARY
[0012] The problems discussed above have found a solution to a large degree in the present disclosure, which describes a multilayer non-woven medical fabric wherein the basis weight of particular layers within the fabric is asymmetrically skewed toward one side.
[0013] In one embodiment the medical fabric is a laminate having a first (outer) spunbond layer, a meltblown layer and a second spunbond layer (i.e., SMS) in which the first spunbond layer is on the side, once an item to be sterilized is wrapped, that is away from the item and that has a greater basis weight than the second spunbond layer that is on the side nearer the item to be sterilized. In this wrap the laminate desirably has a basis weight of between about 17 and 119 gsm. Other embodiments may have a basis weight between about 34 and 87 gsm and still others may have a basis weight of less than 30 gsm.
[0014] The SMS laminate wrap may have its construction skewed so that the first or outer spunbond layer contains between 40 and 80 percent of the basis weight of the laminate. Alternatively, the SMS laminate may have a first spunbond layer that has between 50 and 70 percent of the basis weight of the laminate. The SMS wrap may have a meltblown layer having between 10 and 40 percent of the basis weight of the laminate.
[0015] In another embodiment, there is provided a multilayer medical fabric having at least two SMS layers, the first SMS layer on a side away from an item to be sterilized having a basis weight between 17 and 89 gsm and having an asymmetrical construction with an outer spunbond layer having a greater basis weight than an inner spunbond layer. In this construction the term “outer” refers to the spunbond layer away from the item to be sterilized. In this embodiment, the spunbond layer of the second SMS layer having the greater basis weight is on the side away from the item to be sterilized. Alternatively, the spunbond layer of the second SMS layer having the lower basis may be on the side away from the item to be sterilized.
[0016] Other objects, advantages and applications of the present disclosure will be made clear by is the following detailed description of a preferred embodiment of the disclosure and the accompanying drawings wherein reference numerals refer to like or equivalent structures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows the ternary diagram for a 1.2 osy SMS laminate, overlaid with the least squared fit values of the Simulating Handing test results tested using a 12.5 lb tray.
[0018] FIG. 2 shows the ternary diagram for a 1.85 osy SMS laminate, overlaid with the least squared fit values of the Simulated handling test results tested using a 12.5 lb tray.
[0019] FIG. 3 shows the ternary diagram for a 1.2 osy SMS laminate, overlaid with the least squared fit values of the Sliding Compression test.
[0020] FIG. 4 shows the ternary diagram for a 1.85 osy SMS laminate, overlaid with the least squared fit values of the Sliding Compression test results.
[0021] FIG. 5 shows a SMS “construction” ternary diagram. Each point on the diagram represents a particular SMS construction. Note the “symmetric construction line” representing a laminate having spunbond of equal basis weights on either side.
[0022] FIG. 6 shows the Sliding Compression results (Y axis) from Table 4, plotted as a function of overall weight percentage of the SMS laminate that is comprised of spunbond oriented toward the probe (X axis). Within this Figure the plus signs represent the data for a 1.85 osy laminate and the circles represent the data for a 1.7 osy laminate. FIG. 6 also shows a linear fit of the data. Parameter estimates of the equation for this line are presented in Table 5.
[0023] FIGS. 7A and 7B show cross-sectional views of a co-oriented and counter oriented SMS laminate, respectively.
DETAILED DESCRIPTION
[0024] The typical medical fabric material is a nonwoven fabric or web such as a spunbond, meltblown, spunbond laminate in which the layers are usually produced one onto another, resulting in a sandwich with the meltblown layer in the middle. This is generally referred to as “SMS”.
[0025] As used herein the term “nonwoven fabric or web” means a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).
[0026] The term “spunbonded fibers” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns, more particularly, between about 10 and 20 microns. The fibers may also have shapes such as those described in U.S. Pat. No. 5,277,976 to Hogle et al., U.S. Pat. Nos. 5,466,410 to Hills and 5,069,970 and 5,057,368 to Larg man et al., which describe fibers with unconventional shapes.
[0027] The term “meltblown fibers” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than 10 microns in average diameter, and are generally tacky when deposited onto a collecting surface.
[0028] A “multilayer nonwoven laminate” means a laminate wherein some of the layers are spunbond and some meltblown such as a spunbond/meltblown/spunbond (SMS) laminate and others as disclosed in U.S. Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,169,706 to Collier, et al, U.S. Pat. No. 5,145,727 to Potts et al., U.S. Pat. No. 5,178,931 to Perkins et al. and U.S. Pat. No. 5,188,885 to Timmons et al. Such a laminate may be made by sequentially depositing onto a moving forming belt first a spunbond fabric layer, then a meltblown fabric layer and last another spunbond layer and then bonding the laminate. Alternatively, the fabric layers may be made individually, collected in rolls, and combined in a separate bonding step. Multilayer laminates generally may also have various numbers of meltblown layers or multiple spunbond layers in many different configurations and may include other materials like films (F) or coform materials, e.g. SMMS, SM, SFS, etc.
[0029] SMS laminates used in the production of medical fabrics have been “symmetrical”, meaning that the outer layers of spunbond fabric have had basis weights equivalent to one another. This allows a hospital employee wrapping an item to be sterilized, for example, to use the material without concern about which side is facing downwardly and which fabric is facing the items to be sterilized, except in the case of sterilization wraps that are “sided” for other reasons. While this has simplified the process of wrapping items, this has also resulted in the unanticipated production of shear and pressure holes, as discussed above.
[0030] It is desirable that SMS material for use in this disclosure be made in the sequential manner as described above wherein the individual layers are deposited onto a moving forming belt; first a spunbond fabric layer, then a meltblown fabric layer and last another spunbond layer and bonded to form the laminate. As noted above, however, the layers may be made separately, stored for a time in roll form, and unrolled and bonded together to form the laminate in a separate step. In still another alternate method of manufacturing, one or more of the layers (e.g. the spunbond layer) may be made separately and stored as a roll. At a later time the spunbond layer may be unrolled and the other layers (e.g. the meltblown, spunbond) formed and directly deposited onto the spunbond layer.
[0031] The disclosures have found that an asymmetrical SMS laminate construction, or one having differing basis weights between the two outer spunbond layers, can reduce the number of pressure and/or shear-induced holes significantly (if oriented appropriately relative to the application of use). In addition, when used as a gown fabric, the asymmetrical SMS can improve the attachment of ties to the gown.
[0032] In order to test this proposition, numerous SMS laminates of varying basis weights within the range of those used in sterilization wrap were produced. Symmetrical control fabrics and asymmetrical test fabrics as detailed in Table 1 were tested using two methods; a Simulated Use test and a Sliding Compression test.
[0033] The Simulated Use test compares the relative durability of medical fabric materials wherein durability for this test is defined as the resistance to pressure hole formation. Pressure holes can appear as pinholes in wrap fabric which become visible when the wrap is positioned between a strong light and the viewer. It has been found that the wrap exhibiting this mode of failure is characterized as having fused fibers around the edge of the hole. Failures of this type are usually found along the perimeter of the bottom of the sterilization tray or, more particularly, at the corners of the tray. Failure is believed to result when a layer of wrap is sandwiched between two hard surfaces (e.g. the bottom of the tray and a shelf) and when sudden or excessive pressure is applied, pinching the fabric. The Simulated Use test was developed to force failure in medical fabric material via pressure holes. The method does this by simulating aggressive wrap in-use conditions.
[0034] The Simulated Use test for wrap is performed, generally, by loading trays with a prescribed amount of weight, ranging from 2.5 lbs to 40 lbs (1.14 to 18.2 kg). The trays are wrapped with the material to be tested and the wrapped trays placed on a sterilization cart having wire mesh shelving. The cart is pushed over a rough surface for a prescribed number of cycles, the trays are unwrapped and the fabrics are inspected under low power magnification for holes at the tray corner regions. A percent failure is calculated utilizing the number of corner regions that failed and then dividing by the total number of corners tested.
[0035] More specifically, the Simulated Use test is performed using wire mesh surgical trays and, typically, four sheets of wrap per sample per tray weight are tested (i.e. number of corners per sample per tray weight is sixteen). The preferred tray design is manufactured by Hupfer® Metallwerke GmbH & Co. KG with a 0.5 mm diameter wire base and is approximately 22.5 cm×22.5 cm×5 cm (length×width×height). The cart has a wheel width of 2.54 cm and a wheel diameter of 12.7 cm. The shelves on the cart are comprised of 1/16″ (1.6 mm) diameter wire in the basket weave configuration. The rough floor surface is a No Trax® floor mat from Superior Manufacturing Group, Inc. and is a 3′×6′ (91.4 cm by 182.9 cm) black rubber mat, ⅜″ (0.95 cm) thick. The floor mat has holes with a density of about 20 per square foot (929 square cm) and each hole is rectangular with dimensions of ½″×2″ (1.3 cm by 5.1 cm) with the long dimension of the hole running across the width of the mat.
[0036] In order to perform the test, the samples of individual base sheets are cut into rectangles of 18″×22″ (45.7 cm by 55.9 cm), though sheet size can vary if alternate size trays are used. The desired weight is placed in four empty trays and the trays are wrapped making sure that wrap material is snug around the tray base. The corners of the tray should be wrapped using triangular folds. For consistency, if the wrap is excessively baggy around the corners, tape is used to lift and pull the sides of material tight around the base of the tray. The trays are placed on the wire shelf, making sure two corners of the tray, preferably the tray end with folds on the side, are on the wire portion of the shelf. The remaining two corners may hang over the edge of the shelf. Trays are set down on the shelf, not slid onto the shelf, to prevent premature damage. Once the trays are on the shelf, adjustment and sliding of the trays are kept to a minimum.
[0037] The cart is rolled at a brisk walking pace over the rough surface. One time over the mat and one time back constitutes one cycle over the rough surface. Rolling of the cart over the rough surface is repeated for five cycles. Upon completing five cycles, trays are rotated 180 degrees such that the tray corners that hung off the shelf now are on the wire mesh shelf and the five cycles repeated. The trays are unwrapped and removed from the cart. The wrap samples are then evaluated for holes using low power optical magnification (i.e. microscope with approximately 3× magnification). To help enhance the visualization of holes/tears, a backlight is used. The number of failures observed is recorded along with the total number of corners tested, generally sixteen. A percentage failure is then calculated for a particular sample at a given tray weight.
[0038] In the Sliding Compression test a weighted probe is placed on a sample of medical fabric and the probe with the weight resting on it is slid a specified distance. The tendency of the wrap to develop holes can be determined from a representative sample.
[0039] In order to perform the Sliding Compression test, 50.8 by 152.4 mm (2 by 6 inch) specimens are cut from a sample. They should be inspected to ensure they are free of cuts, folds, wrinkles, etc. A weighted probe having a predetermined weight placed on it is placed on the wrap. In the case of asymmetric samples, the probe may be placed on the “light” spunbond side or the “heavy” spunbond side. In the case of symmetric constructions, the probe was placed against either side during testing. However, within a sample set the same side of the symmetric samples was used consistently. The weighted probe is moved forward and backwards for one cycle. If a hole is formed, weight is reduced by a predetermined increment (typically 50 g) and the test repeated. If a hole is not formed, weight is increased by the same predetermined increment and the test repeated. The test is repeated until ten of the last 20 cycles results in a failure. The average weight used over those cycles is then recorded.
[0000]
TABLE 1
Asymmetric and Symmetric SMS sample
details and test methods performed.
Basis
Simulated
Sliding
S/M/S
Weight
Use Test
Compression
S/M/S (osy)
(percentage)
(osy)
Performed?
Performed?
1
0.76/0.33/0.76
41/18/41
1.85
yes
yes
2
0.63/0.59/0.63
34/32/34
1.85
yes
yes
3
0.43/0.33/1.09
23/18/59
1.85
yes
yes
4
0.38/0.29/1.18
20/16/64
1.85
yes
yes
5
0.43/0.34/0.43
36/28/36
1.20
yes
yes
6
0.30/0.34/0.56
25/28/47
1.20
yes
yes
7
0.30/0.60/0.30
25/50/25
1.20
yes
yes
8
1.33/0.26/0.26
72/14/14
1.85
yes
yes
9
2.06/0.26/0.26
80/10/10
2.58
yes
yes
10
0.26/1.33/0.26
14/72/14
1.85
yes
yes
11
0.26/2.06/0.26
10/80/10
2.58
yes
yes
12
0.38/0.29/0.38
36/28/36
1.05
yes
yes
13
0.48/0.44/0.48
34/32/34
1.40
yes
yes
14
0.73/0.40/0.73
39/22/39
1.85
yes
yes
15
0.81/0.43/0.81
39/21/39
2.05
yes
yes
16
1.04/0.50/1.04
40/20/40
2.57
yes
yes
17
0.71/0.27/0.36
53/20/27
1.34
no
yes
18
1.18/0.29/0.59
29/14/57
2.06
no
yes
19
1.44/0.35/0.72
57/14/29
2.51
no
yes
[0040] Symmetric and asymmetric SMS samples were obtained and tested as summarized by Table 1. Ternary diagrams were used as a convenient means to illustrate how the results of the Simulated Use and Sliding Compression tests changed as a function of composition as well as how the SMS was oriented. Various ternary diagrams are presented in FIGS. 1 though 6 . The effect of sidedness was tested by orienting the heavier spunbond side against the cart shelf or probe as well as orienting the heavier spunbond side away from the cart shelf or probe. Results from these two test methods were collected and input into JMP® 8.0 statistical software. A standard least square fitting method was used to determine statistically significant testing and sample factors, and correlate their effect on Sliding Compression and Simulated Handling test results. A zero-intercept form of the multiple regression model was used since the three factors SB percentage, MB percentage, and SB (cart shelf or probe side) percentage, must sum to 1.
[0041] For the Simulated Handling test results, the following factors were used in the standard least square fit of the data;
Total BW (osy) Tray Wt (lbs) SB percentage MB percentage SB (cart shelf side) percentage SB percentage×SB (cart shelf side) percentage MB percentage×SB (cart shelf side) percentage
[0049] For the Sliding Compression test results, the following factors were used in the Standard Least Square fit of the data;
Total BW (osy) SB percentage MB percentage SB (probe side) percentage SB percentage×SB (probe side) percentage MB percentage×SB (probe side) percentage
[0056] Tables 2a and 2b provide summary statistics for the respective fit models. RSquare is a value between 0 and 1 indicating how much of the variation in the response is due to the model and how much is residual error. A value of 1 indicates all variation is accounted for by the model, while 0 indicates no variation is accounted for by the model. The majority of the variation in both data sets is captured by the respective fit models.
[0000]
TABLE 2a
Summary statistics for fit of Simulated Handling data
RSquare
0.669261
RSquare Adj
0.64315
Root Mean Square Error
0.216923
Observations (or Sum Wgts)
83
[0000]
TABLE 2b
Summary statistics for fit of Sliding Compression data
RSquare
0.869815
RSquare Adj
0.862333
Root Mean Square Error
275.0788
Observations (or Sum Wgts)
93
[0057] Tables 3a and 3b provide the model parameters used to fit the Simulated Handling and Sliding Compression data, respectively. The prediction formula used to fit the data is the linear combination of the values in the Estimate Column, multiplied by their corresponding terms. The tables also provide a Prob>|t| measure. Prob>|t| is the probability of getting, by chance alone, a t-ratio greater (in absolute value) than the computed value, given the null hypothesis. A value below 0.05 is interpreted as evidence that the parameter is significantly different from zero.
[0000]
TABLE 3a
parameter estimates for Simulated Handing data
Term
Estimate
Std Error
t Ratio
Prob > |t|
Total BW (osy)
−0.466598
0.065017
−7.18
<.0001*
Tray Wt (lbs)
0.0494607
0.005062
9.77
<.0001*
SB percentage
0.3411615
0.238441
1.43
0.1566
MB percentage
1.2999507
0.393658
3.30
0.0015*
SB (cart shelf side)
0.476491
0.345021
1.38
0.1713
percentage
SB percentage*SB (cart
3.6083094
1.200156
3.01
0.0036*
shelf side) percentage
MB percentage*SB (cart
−2.995546
2.250682
−1.33
0.1872
shelf side) percentage
[0000]
TABLE 3b
parameter estimates for Sliding Compression data
Term
Estimate
Std Error
t Ratio
Prob > |t|
Total BW (osy)
1335.0801
86.46295
15.44
<.0001*
SB percentage
549.24112
254.1128
2.16
0.0334*
MB percentage
−3677.834
439.3463
−8.37
<.0001*
SB (probe side)
−695.5863
428.3525
−1.62
0.1080
percentage
SB percentage*SB
−10403.16
1050.37
−9.90
<.0001*
(probe side)
percentage
MB percentage*SB
10018.813
2365.352
4.24
<.0001*
(probe side)
percentage
[0058] From these Tables several variables related to the composition of SMS were found to be statistically correlated to the response variables. In particular, in the case of the Simulated Handling data, MB percentage and the SB percentage×SB (cart shelf side) percentage cross term were determined to be significant, while in the case of the Sliding Compression data, SB percentage, MB percentage, and the two cross terms SB percentage×SB (probe side) percentage and MB percentage×SB (probe side) percentage, were found to be significant.
[0059] The Standard Least Squares fit of each data set was plotted as a function of the three compositional components, SB percentage, MB percentage and SB (cart shelf or probe side) percentage using a ternary diagram. Within a ternary diagram, each point represents a unique combination of the three compositional components, in this case MB percentage, SB percentage, and SB (cart shelf side or probe) percentage. The three of these compositional components must sum to 1 (or 100 percent). Overlaid on the ternary diagrams given in FIGS. 1 , 2 and 3 , 4 are the least squared fit values of the Simulating Handing and Sliding Compression test results, respectively.
[0060] FIG. 1 shows the ternary diagram for a 1.2 osy laminate and FIG. 2 shows the ternary diagram for a 1.85 osy laminate, both tested using a 12.5 lb tray. In FIGS. 1 and 2 , the percentage of spunbond on the outermost side (cart shelf side) is on the right hand side of the pyramid, the meltblown (center layer) percentage is on the left hand side of the pyramid and the spunbond percentage on the side facing inwardly (away from the cart shelf) is on the bottom of the pyramid. The three percentages add up to 1.0. As an example, point “A” in FIG. 1 represents an SMS laminate having 0.5 percent of the laminate weight on the side away from the cart, 0.4 percent of the weight as meltblown and 0.1 percent as spunbond on the cart facing side.
[0061] The lines that are labeled in FIGS. 1 and 2 represent the relative amount of samples that failed the Simulated Handling test, with durability increasing as indicated by the line and chart legend. The increasing failure rate is shown with line 1 representing the lowest failure rate and line 5 representing the highest failure rate. As can be deduced from the diagrams ( FIGS. 1 and 2 ) the most durable laminate in the Simulated Use test is one that has approximately 0.5 to 0.8 spunbond facing the cart, approximately 0.5 to 0.2 meltblown and virtually no spunbond on the side away from the cart. It should be noted that although such a laminate would be very durable, this test does not take into account other desirable features of the laminate and so would probably not actually be used. It is here for illustrative purposes only.
[0062] The ternary diagrams shown as FIGS. 3 and 4 represent the predicted grams of force needed to cause a hole via the Sliding Compression test at 1.2 osy and 1.85 osy total basis weight, respectively. In FIGS. 3 and 4 , the percentage of spunbond on the outermost side (probe side) is on the right hand side of the pyramid, the meltblown (center layer) percentage is on the left hand side of the pyramid and the spunbond percentage on the side facing inwardly (away from the probe) is on the bottom of the pyramid. The lines represent the relative average amount of weight (grams force) needed to result in a hole in the sample. Grams force was found the change as indicated by line and chart legend. The increasing amount of force required to create a hole is shown with line 6 representing the least amount of force and line 10 representing the greatest amount of force. The three percentages add up to 1.0 in the same manner as in FIGS. 1 and 2 .
[0063] In the Sliding Compressing test, the greater the grams force needed to produce a hole, the greater the durability. In both data sets, durability was found to be strongly correlated to overall basis weight of the SMS. However, for a given basis weight, several compositional trends can be observed. In general, durability is observed to increase at greater overall SB percentages (lower MB percentage). There is, however, observed to be a lower limit in MB percentage, below which durability is adversely affected. This is believed to be due to the greater coverage efficiency of the MB and because below a critical amount of MB the test methods can no longer differentiate between a hole and interstitial fiber spacing. Furthermore, in practicality MB can only be reduced so far before bacterial barrier is compromised.
[0064] Surprisingly, durability is increased further by changing from a symmetric SMS construction to that of an asymmetric construction. More specifically, greater durability is gained when SB (cart shelf or probe side) percentage is greater than the SB percentage on the opposing side. In contrast, durability is lost when the SB (cart shelf or probe side) percentage is less than the SB percentage on the opposing side. In addition, when used as a gown or drape fabric with the heavier spunbond side outward, it is believed that the tie will be more firmly attached to the gown or the attachment mechanism will secure more durably to the drape. These generalities are illustrated by FIG. 5 . Note the “symmetric construction line” representing an SMS laminate having equal weights of spunbond on either side. Also note the region to the right which represents asymmetric SMS structures, as well as a progressively more durable construction laminate.
[0000]
TABLE 4
Symmetric and asymmetric SMS samples tested via Sliding Compression
SB
Sliding
SB
(probe
Com-
Sam-
Tar-
(probe
SB
MB
side)
pression
ple
get
SB %
MB %
side) %
(osy)
(osy)
(osy)
(g)
1
1.70
69%
19%
12%
1.17
0.32
0.20
380
580
1060
2
1.70
12%
19%
69%
0.20
0.32
1.17
1320
1120
1060
3
1.70
65%
23%
12%
1.11
0.39
0.20
690
620
630
4
1.70
12%
23%
65%
0.20
0.39
1.11
820
710
790
5
1.85
68%
21%
11%
1.26
0.39
0.20
850
650
1060
6
1.85
11%
21%
68%
0.20
0.39
1.26
930
990
1370
7
1.70
38%
25%
38%
0.64
0.42
0.64
1050
520
890
810
650
720
8
1.85
37%
25%
37%
0.70
0.47
0.70
1090
1090
890
680
980
1000
9
1.85
64%
26%
11%
1.17
0.47
0.20
1160
780
700
10
1.85
11%
26%
64%
0.20
0.47
1.17
690
1030
1190
[0065] Sliding compression results, presented in Table 4, plotted as a function of SB percentage oriented towards the probe (i.e., SB Probe percentage) are shown in FIG. 6 . A linear fit of the data is also plotted in FIG. 6 , illustrating the general increase in durability as a function of SB Probe percentage.
[0066] Table 5 contains parameter estimates of equation of the linear fit presented in FIG. 6 . In FIG. 6 , the Sliding Compression results are plotted on Y axis as a function of overall weight percentage of the SMS laminate that is comprised of spunbond oriented toward the probe (X axis). Note that the overall weight percentage of the SMS laminate that is comprised of spunbond oriented towards the probe (i.e., SB Probe percentage) is found to be a statistically significant effect.
[0000]
TABLE 5
Term
Estimate
Std Error
t Ratio
Prob > |t|
Intercept
706.04988
69.41786
10.17
<.0001*
SB Probe %
442.76503
155.5839
2.85
0.0075*
[0067] Asymmetric SMS laminate can also be used in multiple SMS sheet form. In multiple sheet form the asymmetric SMS sheets can be co-oriented with one another or counter-oriented with one another. This is illustrated in FIGS. 7A and 7B , which shows a cross-sectional view of a co-oriented ( FIG. 7A ) and counter oriented ( FIG. 7B ) SMS laminate. By “co-oriented” it is meant that the heavier basis weight side of the layers is facing the same direction.
[0068] In the disclosed wrap each SMS laminate desirably has a basis weight of between about 17 and 119 gsm. Other embodiments may have a basis weight between about 34 and 87 gsm and still others may have a basis weight between 17 and 30 gsm.
[0069] The SMS laminate wrap may have its construction skewed so that the first spunbond layer contains between 40 and 80 percent of the basis weight of the laminate. Alternatively, the SMS laminate may have a first spunbond layer that has between 50 and 70 percent of the basis weight of the laminate. The SMS wrap may have a meltblown layer having between 10 and 40 percent of the basis weight of the laminate.
[0070] In addition to durability, a medical fabric must have sufficient permeability to allow the sterilization gas to pass freely through it. The permeability of the wrap material may range from 10 to about 500 cubic feet per minute (CFM) as characterized in terms of Frazier permeability. For example, the permeability of the wrap material may range from 10 to about 400 cubic feet per minute. The Frazier permeability, which expresses the permeability of a material in terms of cubic feet per minute of air through a square foot of area of a surface of the material at a pressure drop of 0.5 inch of water (or 125 Pa), was determined utilizing a Frazier Air Permeability Tester available from the Frazier Precision Instrument Company and measured in accordance with Federal Test Method 5450, Standard No. 191 A. When the wrap material may be determined generally in accordance with ISO 9237:1995 (measured with an automated air permeability machine using a 38 cm 2 head at a test pressure of 125 Pa, an exemplary air permeability machine is TEXTEST FX 3300 available from TEXTEST AG, Switzerland). If multiple plies or layers of SMS material are used to provide basis weights ranging from about 2 osy (67 gsm) to about 5 osy (167 gsm), the permeability of the wrap material may range from about 10 cubic feet per minute to about 30 cubic feet per minute when determined generally in accordance with ISO 9237:1995.
[0071] As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps.
[0072] While the disclosure has been described in detail with respect to specific embodiments thereof, it will be apparent to those skilled in the art that various alterations, modifications and other changes may be made to the disclosure without departing from the spirit and scope of the present disclosure. It is therefore intended that the claims cover all such modifications, alterations and other changes encompassed by the appended claims.
|
There is provided an SMS laminate for use as a medical fabric. The multilayer non-woven SMS fabric is designed to have the basis weight of the fabric asymmetrically skewed toward one side. In one embodiment the medical fabric is a laminate used as a sterilization wrap having a first spunbond layer, a meltblown layer and a second spunbond layer in which the first spunbond layer is on the side, once an item to be sterilized is wrapped, that is away from the item and that has a greater basis weight than the second spunbond layer that is on the side nearer the item to be sterilized. The medical fabric may also used to produce medical gowns to and drapes.
| 3
|
FIELD OF THE INVENTION
The present invention relates to the piecing a broken yarn at a spinning station of an open end spinning machine by means of a service unit for supplying the spinning stations of the machine, and more particularly to a piecing operation wherein a trailing end of yarn from a winding bobbin is pieced in an open end spinning unit to fibers fed into the spinning unit to be formed therein into a yarn so that the yarn produced in the spinning unit is wound onto the winding bobbin accelerated by a winding power take-off.
BACKGROUND OF THE INVENTION
Open end spinning machines, such as are known, for example, from the manual "Autocore" of W. Schlafhorst & Co., have a plurality of aligned work stations, which are serviced during the spinning operation by an automatically operating service unit, often referred to as a piecing cart, which can be moved along the work stations.
As described, for example, in German Patent Publication DE 43 13 523 A1, the piecing cart can exchange finished yarn cheeses for empty winding tubes and can also repair yarn breaks at the spinning stations. In case of a yarn break, the piecing cart first cleans the respective spinning station and thereafter reattaches the yarn with the fibers being spun within the spinning station by a so-called piecing operation.
Automatic yarn piecing by the piecing cart takes place within a predetermined range of rotational speeds (rpm) of the spinning rotor which are optimal for piecing. Accordingly, the piecing cart is equipped with a device for measuring the rotor speed. Following cleaning, the cart starts the speed measurement when a rotor brake is disengaged from the rotor shaft and the rotor is accelerated to its operating speed. The actual yarn piecing cycle is started at predetermined optimal piecing speed.
So that the pieced yarn has a continuous thickness and twist during the continuing acceleration of the rotor to its operating speed, the draw-in of fibers into the rotor and the draw-off of yarn from the rotor must be accelerated in the same way as the rotor speed increases.
During the piecing process the piecing cart therefore takes over the drawing-in of the fiber into the spinning unit as well as the yarn draw-off from the spinning unit, and at the same time also accelerates a drive of the cheese onto which the yarn is being wound. The drive of the cheese, which may also be called a winding bobbin, is performed in this case by means of a so-called lap drive. The lap drive has a drive roller disposed at the end of a drive arm, which is pivoted against the surface of the winding bobbin for accelerating it.
This known method has proven effective in actual use and is employed in connection with a number of open end rotor spinning machines. However, as the productivity of open end rotor spinning machines has continued to increase, very high rotor speeds and correspondingly high yarn draw-off speeds have become common. This increase in the yarn draw-off speed makes it likely that in the future difficulties will arise during the piecing process, since the present-day lap drives are not well suited to accelerate large yarn bobbins, which have a correspondingly high moment of inertia, sufficiently that the yarn winding speed can follow the high acceleration of the yarn draw-off device. In this context it must be taken into consideration that the moment transfer by means of a friction wheel is limited, even if the acceleration capability of such drives can be optimized, for example by means of the material selected for the drive roller, its contact pressure against the winding bobbin, its looping around the yarn roller, the pressure surface of the latter and its profile.
OBJECT AND SUMMARY OF THE INVENTION
In light of the above described state of the art in piecing up a yarn end at an open end spinning station following a yarn break, it is a basic object of the present invention to improve the known methods and devices.
In accordance with the invention this object is attained by providing a method for piecing a broken end of wound yarn from a winding bobbin to fibers being spun into yarn within a spinning unit at an open end spinning station, utilizing a spinning station service unit for driving the winding bobbin and withdrawing spun yarn from the spinning unit during restarting of spinning operation of the spinning station. According to the present invention, the method basically comprises the steps of inserting the broken end of the wound yarn into the spinning unit and unwinding a defined length of the wound yarn off the winding bobbin and temporarily storing the unwound yarn in a yarn reservoir on the service unit. Thereafter, the driving of the winding bobbin is initiated sufficiently in advance of initiating withdrawal of spun yarn from the spinning unit for accelerating the winding bobbin to a first predetermined winding speed as of the time the withdrawal of spun yarn from the spinning unit resumes.
In the preferred embodiment of the present method, the length of unwound yarn temporarily stored in the yarn reservoir approximately corresponds to the yarn length which is wound on the winding bobbin during restarting of spinning operation of the spinning station. The winding bobbin is accelerated from the first predetermined winding speed to a second predetermined winding speed approximately corresponding to the yarn withdrawal speed at an optimum piecing speed of the spinning unit. In one variant of the present method, the winding bobbin is accelerated from the second predetermined winding speed synchronously with the yarn withdrawal until reaching a predetermined production speed of normal spinning operation of the spinning station, during which acceleration the bobbin acceleration follows that of the spinning unit to the predetermined production speed. In another variant of the method, the winding bobbin accelerates from the second predetermined winding speed at a slower rate than the yarn withdrawal until reaching a predetermined production speed of normal spinning operation of the spinning station for storing a length of the spun yarn in the yarn reservoir. Which one of these variants is more advantageous in a given case depends on a number of parameters, which can be determined by means of appropriate tests.
The present invention also provides an apparatus for carrying out the aforedescribed method of piecing a broken end of wound yarn from a winding bobbin to fibers being spun into yarn within a spinning unit at an open end spinning station. Basically, the apparatus comprises a spinning station service unit having a drive for driving the winding bobbin, a yarn draw-off device for withdrawing spun yarn from the spinning unit during restarting of spinning operation of the spinning station, a yarn reservoir for temporarily storing a length of yarn, and means for inserting the broken end of the wound yarn into the spinning unit. According to the present invention, control means is also provided for actuating the drive and the yarn reservoir for unwinding a defined length of the wound yarn off the winding bobbin and temporarily storing the unwound yarn in the yarn reservoir and for thereafter initiating the driving of the winding bobbin sufficiently in advance of the yarn draw-off device for accelerating the winding bobbin to a first predetermined winding speed as of the time the withdrawal of spun yarn from the spinning unit resumes.
In the preferred embodiment of the apparatus, the yarn reservoir is operative intermittently or discontinously and is arranged for the stored yarn to be exhausted by first withdrawing the last extent of yarn placed into the reservoir, referred to herein as the "last in-first out" principle. Preferably, the yarn reservoir comprises an entrance tube opening into an adjoining conical reservoir having a perforated bottom wall formed with a plurality of bores, the radially outwardmost of which are of a larger diameter. A source of suction is applied to the bottom wall of the yarn reservoir to draw the stored yarn into the reservoir.
The basic operation of the afore-mentioned method and apparatus of the present invention proceeds from the realization that, with further increasing yarn draw-off speeds of open end spinning machines, it will become very difficult in the future to accomplish the acceleration of the winding bobbin necessary during the piecing process utilizing the lap drives of currently conventional service units known as piecing carts, even at a maximally acting moment of acceleration.
It is therefore proposed by the present invention to separate chronologically the process of accelerating the winding bobbin from the yarn draw-off process, thereby to avoid the problematic process of accelerating the winding bobbin by starting the acceleration of the winding bobbin at a time sufficiently in advance of the piecing process that the winding bobbin has already been accelerated by the lap drive to a predetermined winding speed as of the time the yarn draw-off from the rotor begins.
The acceleration of the winding bobbin is preferably begun sufficiently in advance of the start of yarn draw-off from the rotor so that, by the time of the yarn draw-off step is started, the winding speed of the winding bobbin almost corresponds to the yarn draw-off speed.
In order to have a sufficient length of yarn available for winding over the period of time from the start of the pre-acceleration of the winding bobbin to the start of the yarn draw-off, a defined length of yarn is pulled from the winding bobbin prior to the start of the piecing process and is temporarily stored in a yarn reservoir disposed between the yarn draw-off device and the lap drive. The length of yarn stored in the yarn reservoir is determined in this case to compensate for the difference in yarn length which occurs because of the chronologically offset start of the lap drive and of the yarn draw-off.
The predetermined wind-up speed to which the lap drive accelerates the winding bobbin is preferably a function of the optimum piecing speed of the spinning rotor, or a function of the yarn draw-off speed corresponding to this rotor speed.
In a preferred manner, the piecing cart which executes the method has a separate drive for the lap drive accelerating the winding bobbin, and a separate drive for the yarn draw-off device. The drives are connected to the control device of the piecing cart and can be programmed in a defined manner.
In performing the present method, a yarn guide is inserted between the yarn draw-off device and the lap drive to withdraw from the winding bobbin a sufficient length of yarn to enable a time-offset start of the lap drive and the yarn draw-off device. The length of yarn brought back from the winding bobbin and stored in the yarn reservoir in this case permits even large cheeses, which are known to have a considerable moment of inertia, to be accelerated in sufficient time and at a relatively gentle rate to the high rotational winding speed necessary for the piecing process. In this manner, high acceleration speeds for drawing-off the yarn from the rotor are controllable during the piecing process with the present invention, even if there are large winding bobbins involved.
As explained above, in a preferred embodiment the yarn reservoir is arranged to function as a discontinuously operating reservoir in accordance with a "last in-first out" principle under which the last extent of yarn brought into the reservoir is pulled out first in the process of pre-accelerating the winding bobbin. A reservoir of this type has the advantage that the uppermost extent of yarn closest to the winding bobbin is always pulled out first, so that snarls, tangles and the like in the yarn can be avoided to the greatest possible extent.
The described structure and operation of the reservoir result in an uncomplicated, dependably operating reservoir, which can be easily cleaned when required. The perforated bottom wall of the reservoir further results in pressure conditions in the area of the bottom wall which assure that, even at larger yarn lengths, an orderly deposition of the yarn into the reservoir in loops is accomplished with the loops starting in the edge area of the reservoir becoming smaller towards the interior.
Further details and features of the present invention will be understood from an exemplary embodiment of the present invention described below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of an open end rotor spinning machine showing one representative spinning station with a piecing cart also schematically represented thereat,
FIG. 2 is a partial enlargement of the area of the spinning station of FIG. 1, as well as an adjacent portion of the piecing cart, depicting in particular the lap drive, the yarn draw-off device and the discontinuously operating yarn reservoir,
FIG. 3 is a graph diagrammatically representing the operation of a first variant of the method in accordance with the present invention, and
FIG. 4 is another graph diagrammatically representing the operation of a second variant of the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, one side of an open end rotor spinning machine is indicated schematically and identified as a whole by 1. In such spinning machines, each machine side has a plurality of work stations 2 aligned with one another, with the aligned stations of each side arranged back-to-back and with each spinning station being equipped with a spinning unit 3 and a winding device 4. At each station, a sliver 6 delivered from a sliver can 5 is spun in the spinning unit 3 into a yarn 7, which is withdrawn and wound into the form of a cheese 8 by a winding device 4.
As represented, each winding device 4 is equipped with a bobbin frame 9 for rotatably supporting a winding bobbin 8 while being formed into a cheese, and a winding drum 11 for driving the winding bobbin during normal winding operations.
In addition, the open end rotor spinning machine 1 has a circulating tube and bobbin transport device 12 for providing the work stations of the spinning machine with empty tubes and for moving away the finished cheeses.
A service unit, for example a piecing cart 16, is disposed at or on the spinning machine 1 and is movable on guide rails 13, 14 and a support rail 15 along the aligned spinning stations by means of rollers 18 and a support wheel 19 forming the running gear 17 for this piecing cart 16. The piecing cart 16 is preferably supplied with operating electrical energy, as indicated, via a sliding contact device 20.
Such piecing carts 16 are known to have numerous winding and yarn manipulation devices, for example a lap drive 10 and a yarn draw-off device 21, and continuously patrol along the open end rotor spinning machine 1 until there is need for action at one of the work stations 2, whereupon the piecing cart 16 is automatically stopped at the station needing service and is actuated to perform the necessary service operation. Such a need for action exists, for example, if a yarn break has occurred at a work station 2, or when a cheese 8 has reached its prescribed diameter at one of the work stations and needs to be exchanged for an empty tube.
In such a case the piecing cart 16 moves to the appropriate work station, is positioned there and, in case of most yarn breaks, i.e., a "normal" yarn break, searches with a pneumatic yarn seeking nozzle (not shown) for the torn yarn end trailing from on the circumferential surface of the winding bobbin 8. Following the cleaning of the spinning unit, the located yarn end is brought back in a known customary manner after appropriate yarn end preparation into the area of the spinning unit 3 by means of known manipulating devices, and is threaded thereat into the yarn draw-off tube to be kept ready for the actual piecing process. Simultaneously, a defined length of yarn is unwound off the winding bobbin 8 by means of the lap drive 10, and is temporarily stored in a yarn reservoir 22.
As represented on a larger scale in FIG. 2, both the lap drive 10 and the yarn draw-off device 21 have their own respective drives 24 or 25, which can be directly controlled by a control device 23 which is part of the piecing cart. The drive 24 acts on a drive roller 26 of the lap drive 10, while the drive 25 is connected to a draw-off roller 27 of the yarn draw-off device 21 of the piecing cart 16. As is customary, the yarn draw-off device 21 also has an opposing pressure nip roller 28.
The yarn reservoir 22 is arranged between the yarn draw-off device 21 and the lap drive 10. The yarn reservoir 22 operates discontinuously, i.e., it is emptied during each piecing process, operates in accordance with the "last in-first out" principle as afore-mentioned, and can be charged with suction air via an negative pressure source 29.
In the exemplary embodiment represented in the drawings, the yarn reservoir 22 consists of a small reservoir tube 30 opening into an enlarged reservoir cone 31 having a perforated bottom plate 32 which is connected to the suction source 29 via a connecting line 33. The bottom plate 32 has a plurality of tapering bores 34, whose diameter preferably becomes smaller towards the interior of the cone, so that a suction air flow 33 with different pressure conditions is present in the area of the bottom plate 32, i.e., the suction pressure which fixes the yarn 7 pulled off the winding bobbin 8 in the area of the bottom plate 32 is reduced from the outside of the cone toward the inside of the cone corresponding to the size of the bores 34.
The method in accordance with the present invention basically makes possible the piecing even of large winding bobbins at high yarn draw-off speeds by means of a corresponding pre-acceleration of the winding bobbin, as will be explained below by means of two contemplated embodiments graphically represented in FIG. 3 and FIG. 4.
In the graphs of FIGS. 3 and 4, the coordinate system represented plots a time t along the abscissa of the graph and a production speed v of a spinning station during the piecing process along the ordinate of the graph. The curves R, Sp, F respectively represent the course of acceleration of the rotor, the winding bobbin and the yarn draw-off device.
Referring initially to FIG. 3, it can be seen that, in this embodiment, the rotor, which is braked during the cleaning process, thereafter accelerates at a rate represented by the curve R to an optimum yarn piecing speed (rpm), which correspond to approximately 70% of the production speed of the rotor (rpm), reaching this piecing speed after an elapsed time T2. The yarn draw-off device is not started until this time T2 but, based on the relatively low moment of inertia of the yarn draw-off device, is accelerated very rapidly, as represented by the curve F, to a high yarn draw-off speed which, as of the elapsed time T2', achieves a yarn draw-off speed which corresponds to the rotor speed at this same point in time. As represented by the curve Sp, the lap drive 10 is started at the time T1 to begin accelerating the winding bobbin 8 earlier during the acceleration of the rotor to the optimum piecing speed for the lap drive. The length of time between times T1 and T2 is selected according to the accelerating capability of the lap drive 10 so that the winding speed of the winding bobbin approximately corresponds to the yarn draw-off speed at the time T2'.
From the time T2', the rotor, the yarn draw-off device and the lap drive are accelerated synchronously, with the accelerating speed of the rotor constitute the command variable. As of the subsequent point in time T3, the spinning rotor, the yarn draw-off device and the winding bobbin reach their full normal production speed (100%). Since as of the time T1 when the lap drive 10 is started the spinning unit 3 has not yet resumed production of yarn and correspondingly no yarn is being delivered at such time via the yarn draw-off device 21, a reserve length of yarn must be provided to be taken up by the bobbin 8 while being thusly driven by the lap drive 10 during the period between the time T1 and the time T2', which is provided by the extent of yarn previously unwound off the winding bobbin and stored in the reservoir 22. The required yarn length which needs to be unwound from the winding bobbin 8 is represented by the area A1 in FIG. 3.
With reference now to FIG. 4, the alternative variant of the present method represented therein is identical to that of the exemplary embodiment of FIG. 3 up to the time T2', i.e., up to the time at which the yarn reserve A1 placed in the yarn reservoir 22 is exhausted by the pre-acceleration of the winding bobbin 8, and the bobbin winding speed and the yarn draw-off speed are identical at least for such moment. In this embodiment, beginning at the time T2', the yarn draw-off device, following the rotor speed as a command variable, is accelerated faster than the lap drive 10 is able to accelerate the relatively heavy winding bobbin 8, so that an excess of yarn is produced between the rotor and the bobbin. This yarn excess is also temporarily drawn into and stored in the yarn reservoir 22 until finally reaching an excess yarn length A2, whereby the yarn reservoir 22 still contains the yarn length A2 at the time when the rotor and the yarn draw-off device initially reach their full production speed, which are identified at the 100% level of value v in the diagram. In order to empty this yarn excess A2 from the yarn reservoir 22, it is therefore necessary to briefly accelerate the lap drive 10 to a speed which, as indicated in FIG. 4, temporarily exceeds the production speed of the spinning station and therefore exceeds the yarn draw-off speed. In this case, the winding speed of the winding bobbin and the yarn draw-off speed are matched in such a way that the additional yarn length A3 needed to be taken up by the bobbin in this case exactly corresponds to the yarn length A2 just theretofore temporarily stored in the yarn reservoir 22. Accordingly, at the subsequent point in time T3 at which the yarn reservoir 22 is empty again, the lap drive 10 returns to its normal full production speed and the spinning station again resumes normal winding operation.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
|
A method and apparatus for piecing a broken end of yarn at an open end spinning station utilizing a piecing cart servicing the spinning station. To repair the yarn break, a defined yarn length is unwound off the winding bobbin and is temporarily stored in a yarn reservoir disposed between a yarn draw-off device and a lap drive of the piecing cart. Subsequently, the winding bobbin is acceleratively driven by the lap drive sufficiently in advance of actuating the yarn draw-off device to achieve a predetermined winding speed as of the time the withdrawal of spun yarn from the spinning unit resumes.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to navigational systems for use with ships or aircraft and more particularly to an aircraft or ship navigation system which uses packet radio technology to remotely report position information.
2. Description of the Prior Art
Prior art methods of remotely determining the position of ships or aircraft normally involve the use of systems with a beacon on the ship or aircraft whose position is being tracked and then reported, or radar systems which track a ship or aircraft by means of microwave energy reflected from the ship or aircraft being tracked. Other methods involve multilateration of a beacon signal from multiple receiving sites. Using these prior art methods, a complex and expensive ground station sends interrogation signals to ships or aircraft being tracked. Return signals indicate ranges to the beacon on the ship or aircraft whose position is being tracked. Actual geographic or relative position of the aircraft or ship is then calculated by computers inherent within these systems. These systems tend to be complex, physically large, expensive and are not easily deployed.
Systems used for remote position monitoring/tracking of ships and aircraft in weapons test and evaluation applications are typically radars and multilateration tracking systems. Test ranges incorporate various types of radar for surface and air surveillance or precision tracking of vehicles under test. These radars are normally shore-based and their coverage does not extend above the horizon. Multilateration systems can extend their coverage over the horizon only if a complex and expensive transponder is installed in the unit to be tracked as well as aboard a relay aircraft.
Packet systems have been known for several years: see for example "Computer Networks" by Andrew S. Tanenbaum, published by Prentice Hall (1981) and "Advances in Packet Radio Technology" by R. E. Kahn et. al., Proc. IEEE, Vol. 66 (November 1978), pages 1468-1496. A packet radio system is a data communications radio network comprising a plurality of stations.
Generally, packet radio communication systems include a plurality of stations each covering a respective zone. A data message to be communicated is divided into discrete segments of fixed length, called "packets". Packets are transmitted from a station of origin to a destination station and if the packets are received by the destination station without error, an acknowledgement is provided by the destination station. Thus, two way communication may be accomplished by two or more stations within a network.
Specifically, packet radio communications systems may have a central station that administers a plurality of remote stations each covering a respective zone. In response to a polling packet from the central station, data packets are assembled at the remote stations and transmitted to the central station. When the packets arrive at the central station, the central station transmits an acknowledgement of that fact.
Packet radio systems have many uses in the communications field, such as, providing mobile battlefield data users with a common communications service which is comparable in terms of service and reliability to a static system. U.S. Pat. No. 4,989,204 to T. Shimizu et. al. is illustrative of a packet radio communication system which provides for mobile stations and may be used in tactical mobile areas of a forward battlefield. However, packet radio technology has not been utilized to remotely report aircraft or ship locations.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provided a relatively simple, inexpensive and easy to install position reporting system.
It is another object of the present invention to provide an autonomous means of position reporting independent of other ship/aircraft systems which would interface with on board ship/aircraft navigation systems.
It is yet another object of the present invention to provide a position reporting system whereby external monitoring of transmitted radio packets is permitted which allows for ships and aircraft to be tracked and displays to be provided showing the position of each ship and aircraft in the area.
It is still another object of the present invention to provide a position reporting system which would allow for rapid and inexpensive setup for aircraft tracking and control at small airports where radars are not in the vicinity or cannot be justified in terms of cost.
It is a further object of the present invention to provide a low cost tracking system for offshore vessels in congested areas with fixed site local hazards being permanently entered into shore station monitoring stations to be transmitted to ships at periodic intervals.
These and other objects of the present invention are accomplished by a stand alone multiple unit tracking system which utilizes packet radio technology to periodically transmit information identifying the geographic position of ships, aircraft and other land mobile vehicles by means of a packet radio link. The stand alone multiple unit tracking system of the present invention comprises a base station, relay stations and a plurality of remote sites or stations placed on board ships, aircraft or the like. The base station includes a VHF radio transceiver, a terminal node controller, a cathode ray tube display device and a personal computer, while each remote station includes a Loran-C device, a personal computer, a terminal node controller and a radio transceiver.
The packet radio links which transmit position information/data between the remote sites and the base station operate on a simplex channel, that is, one channel is used to both transmit and receive information. Each station within the stand alone multiple unit tracking system of the present invention monitors the simplex channel and when it has information to send checks to see if the channel is busy transmitting or receiving. If the channel is busy, the station with information to send or transmit waits until the channel is clear. When the simplex channel clears, the station transmits and if the transmission is successful an acknowledge message will be provided by the receiving station. If two or more stations transmit at the same time, then the data from both stations collides and the transmitting stations will not receive an acknowledge message, each station then waits a programmed time period and transmits again. Time periods are different at each station which allows for successful transmission by each station within the system.
The Loran C device at each remote station provides position data that is the latitude and longitude of the remote station as well as data which indicates the quality of the position data being provided. The computer at the remote station generates "packet" radio frames in accordance with the AX.25 Amateur Packet-Radio Link-Layer Protocol to transmit latitude and longitude position data from the remote station to the base station. The terminal node controllers at the remote stations function as modems passing the "packets" of position data between the remote station computer and the transceiver, provide for transceiver control so that each remote station may be successfully linked to reliably transport position data between the stations and provide a High Level Data Link Control (HDLC) frame check sequence for error free transmission of position data between stations.
When the base station receives the "packets" of positional data from the remote sites, the computer at the base station will sift through the positional data and correlate the data so that it may be combined into a single intelligible form for presentation by the cathode ray tube display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of the base station of the present invention;
FIG. 2 is a functional block diagram of a remote station of the present invention;
FIG. 3 is an illustration of the AX.25 Amateur Packet-Radio Link-Layer Protocol frame employed by the present invention during the transmit and receive modes of the base and remote stations;
FIG. 4 illustrates a range map which appears on a monitor at the base station and which depicts the location of the base station and each remote station of the present invention;
FIG. 5 is a table illustrating the message formats used by the multiple unit tracking system of the present invention;
FIGS. 6A and 6B illustrate the binary format for longitude and latitude positional data provided by a remote station of the present invention;
FIG. 7 defines the user table for the base station and remote station software;
FIG. 8 is an example of the user table of FIG. 7 for the base station;
FIG. 9 is an example of the user table of FIG. 7 for a remote station;
FIG. 10(A)-10(D) is an example illustrating the use of the output buffers for the computers at the base and remote stations of the present invention;
FIG. 11 illustrates the binary data file used to generate the map of FIG. 4; and
FIG. 12 is a functional block diagram of a relay station of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2 the multiple unit tracking system 18 of the present invention comprises a base station 20 and one or more remote stations 22 with the base station 20 being adapted to receive positional data from each remote station 22 and then sift through the positional data and correlate the data so that it may be combined into a single intelligible form for viewing on a cathode ray tube display 24 or such other devices as are customarily used to display information to an operator.
At each remote station 22, a personal computer 28 accepts data from a Loran-C 30 which establishes the longitudinal and latitudinal position of a ship, an aircraft or a vehicle respectively on the sea, in the air or on land. Personal computer 28 assembles the positional data into a "packet" or frame format, provides the "packet" to a terminal node controller 32 and coordinates with the base station 20 the transmission of positional data provided by Loran-C 30. Terminal node controller 32, in turn, controls the transmission of this positional data by a VHF radio transceiver 34 to the base station 20 by keying transceiver 34 whenever transceiver 34 needs to send data.
Referring to FIGS. 4 and 12, it should be noted at this time that the multiple unit tracking system of the present invention may utilize repeater/relay stations 23 which relay position data from a remote station 22 to the base station 20. The relay station 23 utilizes the same computer equipment as the remote station, but generally does not include a Loran-C 30 since its function is to relay information or data "packets" between the base station and the remote stations. However, it should also be understood that a remote station 22 may also be utilized as a relay station 23. Further, it should be understood that a relay station 23 may require only a VHF transceiver 37 and a terminal node controller 39 to relay information when the terminal node controller adheres to AX.25 Amateur Packet-Radio Link-Layer Protocol.
Referring to FIGS. 1 and 2, base station 20 includes a VHF radio transceiver 36 for receiving positional information packets/frames transmitted by each remote station 22, a terminal node controller 38 which provides the positional information in the "packet" format to a personal computer 40. Personal computer 40 then disassembles and processes the positional information for a map display on cathode ray tube display 24 or for display by printer 26.
In the preferred embodiment of the present invention remote station equipment does not require operator intervention. Upon application of power, the remote site Loran C 30, computer 28, terminal node controller 32 initialize and remain quiescent until activated by base station 22. Base station 22, following power up and software loading, interacts with a human operator utilizing a keyboard 35 to identify the remote station links and relay stations 23 to be used by multiple unit tracking system 18 Base station 20 next attempts to establish contact with each remote station 22 and inform the operator of the remote station's status. If the operator instructs system 18 to continue, base station 20 instructs each remote station 22 to transmit its position to the base station, which is overlaid on a range map 42, FIG. 4, appearing on monitor 24.
Base station 20 also performs a link monitoring function. Base station 20 maintains for each remote station 22 a built-in software time period which is up to five times the remote station's reporting period. If a remote station's message is not received within this time period the operator is informed of a time-out or inactivation of the remote station 22 and the base station 20 periodically transmits a request for status to the remote station 22 in an attempt to reactivate station 22.
The reporting period in seconds for each remote station 22 is calculated as follows: ##EQU1## The inclusion of the factor User Table Column ÷10, where the User Table Column is the column the remote station appears in the base station user table illustrated by FIG. 8, provides a variable for calculating the reporting period for each remote station: thus reducing the possibility that two remote stations will report during the same time interval.
Base station 20 also sends an acknowledge message when requested by each remote stations 22. After ten position reports have been sent by a particular remote station 22, it begins to request an acknowledge from base station 20. If the remote station 22 does not receive an acknowledge message from base station 20 after sending twenty position messages, the remote station 22 resets to a quiescent state. This procedure prevents the remote station 22 from continuing to transmit position messages indefinitely should the system data links fail to connect or not operate properly. Each remote station 22 does not request an acknowledge after every position report as this would greatly increase the messages transmitted and thus increase the chances of data collision.
The terminal node controllers 32 and 38 used in the preferred embodiment of the present invention operate at 1200 Baud, are manufactured by Kantronautics Inc. and are their version 2.85 Terminal Node Controller. Terminal node controllers 32 and 38, in turn, make use of the AX.25 Amateur Packet-Radio Link-Layer Protocol to provide a means for the reliable transport of data between the base station 20 and each remote station 22.
As is best illustrated by FIG. 3, each frame 50 or "packet" of data consists of a pair of eight bit flags 52 and 54 respectively at the beginning and end of the frame which are generated by controllers 32 and 38 and which delimit the frame. For the multiple unit tracking system 18 flags 52 and 54 are set at 0, 1, 1, 1, 1, 1, 1, 0.
Frame 50 also includes an address field 56 provided by computers 28 and 40 which is used to identify both the source of the frame and the destination of the frame, as well as one or more intermediate stations which may be used to relay data from the source to the destination. In the AX.25 Amateur Packet-Radio Link-Layer Protocol, the destination address subfield of the address field 56 consist of seven octets/eight bit bytes and is sent first to allow each receiving station 20 or 22 of the frame to check the destination address subfield to see if the frame 50 is being addressed to that particular receiving station while the rest of the frame is being transmitted. The source address subfield is then sent in seven octets/eight bit bytes. The AX.25 Amateur Packet-Radio Link-Layer Protocol also provides for a repeater or relay address subfield consisting of seven octets/eight bit bytes appended to the end of the address field. The link-layer AX.25 protocol further provides for up to eight repeaters or relay stations 23 by extending address field 56 to 512 binary bits. When there is more than one repeater or relay address in the address field the repeater address immediately following the source address subfield is considered the address of the first repeater or relay station 23 of a multiple relay station chain.
The frame of FIG. 3 also includes an eight bit control field 58 which provides status and control information; an eight bit protocol identifier field (PID) 60 which for purposes of the present invention is an arbitrary eight bit digital word "F0" hexadecimal or 1, 1, 1, 1, 0, 0, 0,0 binary selected to occupy the field; and an information field 62 which may consist of up to 256 octets/eight bit bytes and is used to convey latitude and longitude positional data between the remote stations 22 and the base station 20 and any repeater or relay stations 23 which is used to relay positional information between the remote stations 22 and the base station 20.
Referring to FIGS. 3 and 5, messages which are information or status frames provided by multiple unit tracking system 18 conform to the AX.25 Version 2.0 packet-radio link layer protocol except for eight bit control field/word 58. The address field 56 is defined by AX.25 Version 2.0 packet-radio link layer protocol. Certain bits in control field 58 have been redefined for use by the multiple unit tracking system 18 of the present invention.
The messages transmitted by each remote station 22, an intermediate station or base station 20 are either information frames or status frames as defined by bit zero of the control field 58. An information frame is identified by a zero in bit zero of control field 58, while a status frame is defined by a one in bit zero of control field 58. In accordance with the AX.25 packet-radio link layer protocol, bit four of a status word is used to request a reply or to indicate a response to a request. The PID field for the information frames is set to F0 hexadecimal as is best illustrated by FIG. 5.
The four information frames messages used by multiple unit tracking system 18 are Initialize Terminal Node Controller (TNC), Report Mode, Position Report and Terminate.
The Initialize Terminal Node Controller message directs each remote station 22 to initialize its terminal node controller 32 with a Slottime value and a Persistence value which are contained in the message. The control field 58 is 10 hexadecimal which indicates an information frame and a request for response. The first word of the information field 62 is the message type of 51 hexadecimal which is a predetermined number selected to indicate the Initialize Terminal Node Controller message, thereby informing the remote station of the message purpose. The second word is the Persistence value for the terminal node controller 32 at the remote station. The third word is the Slottime value for the terminal node controller 32 at the remote station.
Terminal node controllers 32 and 38 use a mode of operation identified as KISS which is embedded in the firmware of the terminal node controller to allow communication respectively with computers 28 and 40. The KISS mode of operation allows terminal node controllers 32 and 38 to transfer all received data respectively to computers 28 and 40 for processing by the computers. In the KISS mode of operation terminal node controllers 32 and 38 each convert received HDLC type synchronous data frames into an asynchronous frame format which is then provided to the serial port of computer 28 or 40; likewise asynchronous data frames from computers 28 and 40 are respectively transmitted by transceivers 34 and 36 once the data is converted from an asynchronous format to HDLC synchronous format by terminal node controllers 32 and 38. Terminal node controllers 32 and 38 also determine proper timing for channel access. It should be understood by those skilled in the communications art that there are a number of commercially available terminal node controllers which will convert between asynchronous data frames and a synchronous HDLC type frame format for either transmission or reception by a radio transceiver. It should also be understood that while terminal node controllers 32 and 38 are capable of performing full AX.25 Amateur Packet-Radio Link-Layer Protocol functions, protocol responsibility is off-loaded to computers 28 and 40.
In the KISS mode of operation, channel access is determined by two settings in the terminal node controllers 32 and 38 PERSISTENCE and SLOTTIME. In the preferred embodiment of the present invention PERSISTENCE is calculated by the following expression:
PERSISTENCE=256/(number of sites+2) (1)
Thus, for example, if there are eight sites or stations in multiple unit tracking system 18, PERSISTENCE would be set at 26. SLOTTIME is a predetermined time period set at fifty milliseconds.
When the terminal node controller 32, for example, at each remote station 22 detects that the channel is clear and available, that is no carrier is detected, the terminal node controller starts an internal timer which is set at fifty milliseconds (SLOTTIME). When the timer expires the terminal node controller generates a random number between 0 and 255. If the generated number is equal to or less than the PERSISTENCE value, the terminal node controller 32 keys up the transceiver 34 and sends a data packet. With a setting of 26 the odds of this occurring after the first slottime are about 1 in 9 with the actual odds being the PERSISTENCE value plus 1 divided by 256. If the terminal node controller 32 generated random number is greater than PERSISTENCE value, the terminal node controller 32 restarts the timer and waits for the timer to expire again before generating a new random number. This procedure is repeated until terminal node controller 32 gains channel access and sends its packet of information.
Data received, for example, from transceiver 36 is converted into asynchronous format by terminal node controller 38 and sent to computer 40. The data actually sent over the serial port of the computer is formatted with special control information, allowing the computer to determine the type of data being received from the Terminal node controller.
All information flowing from the terminal node controller to the computer in the KISS mode of operation is data, special messages are not sent from the terminal node controller to the computer in the KISS mode of operation. The only data flowing from the terminal node controller to the computer is the data received through the radio transceiver link. Every "frame" of data sent from the terminal node controller will begin and end with a special FEND character which is the ASCII code $CO (hexadecimal) or 192 decimal. The second byte of the data will be the data type, and will always be a $00 hexadecimal which means that the following information is data. If the data actually contains the FEND character ($CO) it will be necessary to tell the computer that the $CO the computer receives is not the end of the frame, but simply is more data. This function is accomplished by replacing the $CO character with a special sequence consisting of a FESC ($DB hexadecimal) followed by a TFEND character $DC hexadecimal. One final special sequence which may be sent from the terminal node controller to the computer is a FESC ($DB hexadecimal) followed by TFESC ($DD hexadecimal) which is translated into $DB by the computer program.
When data flows from the computer to the terminal node controller, there are five possible commands in the KISS mode of operation that may be provided the terminal node controller from the computer which are setup parameters. These parameters are commands needed to set TXDELAY, PERSISTENCE, SLOTTIME, FULLDUP, and finally, a command to exit the KISS Mode of operation. The only other data which the computer may send to the terminal node controller in the KISS mode of operation is data which is to be transmitted over the radio transceiver (HDLC) channel. The data provided by the computer to the terminal node controller must also begin and end with the same FEND $CO hexadecimal character used for data coming from the terminal node controller to the computer. All special character sequences must also be used to send the FEND, and FESC characters as data.
Each of the commands is assigned a command type number in hexadecimal as follows: 00-Data is to be transmitted; 01-TXDELAY, second byte contains TXDELAY in ten millisecond increments; 02-PERSISTENCE, second byte contains persistence value; 03-SLOTTIME, second byte contains slot interval; 05-FULLDUP--if second byte is 0 sets fulldup mode, otherwise turns fulldup off; 255-KISS, causes exit from KISS Mode. For example, if it is desired to send a data packet in the KISS mode of operation, the computer sends the following bytes to the terminal node controller: C0, 00, 68, 65, 6C, 6C, 6F, C0. It is important to note that this data packet does not contain any addressing information, and therefore cannot be sent via the AX.25 protocol. All of the addressing and formatting of the addresses is programmed in the computer and sent as a data packet to the terminal node controller.
It should also be noted that only the PERSISTENCE and SLOTTIME commands are used in the preferred embodiment of the present invention.
Referring again to FIGS. 3 and 5 the Report Mode message directs each remote station 22 to begin sending position reports to base station 20. The control field 58 is 10 hexadecimal which indicates an information frame and a request for response. The first word of information field 62 is a message of 52 decimal which is a predetermined number selected to indicate Report Mode. The second word of the information field 62 is a value which is ten times the report interval of the remote station in seconds, that is the time required for each remote station 22 to transmit data to base station 20. The second word of the information field 62, in turn, indicates to each remote station 22 how often the remote station reports its position to base station 20.
The Position Report message informs base station 20 of the Latitude and Longitude position of the remote station 22. The control field 62 is either 0 or 10 hexadecimal depending upon whether a response is requested or not. The first word of the information field 62 is the message type of 49 decimal which is a predetermined number selected to indicate Position Report. The second, third, and fourth words or eight bit bytes, FIG. 6(a) of the information field 62 contain the Longitude position information. The least significant bit (LSB) values of the second, third and forth words are respectively 0.0001, 0.0256, and 6.5536 degrees. Bit seven of word four is set at a logic "1" state to indicate a negative or west Longitude and a logic "0" to indicate an east Longitude. In a similar manner the fifth, sixth and seventh words, FIG. 6(b), of information field 62 contain Latitude position information with the LSB values of the fifth, sixth and seventh words being respectively 0.0001, 0.0256, and 6.5536 degrees. Bit seven of word four is set at a logic "1" state to indicate a negative or south Latitude and a logic "0" to indicate a north Latitude. The eighth word contains the quality value of the position data provided by Loran 30 which is a number from 0-255. Quality numbers higher than 64 are considered suitable for navigation.
The Terminate message informs the remote station to enter the quiescent state. It is identical to the Report Mode message except the message type is 53 decimal.
There are two types of status messages used in multiple unit tracking system 18. When requested by base station 20, a 15 hexadecimal in control field 58 sent by a remote station indicates that the remote station is in a quiescent state. When requested by base station 20, a 11 hexadecimal in control field 58 sent by a remote station indicates that the remote station is in an operational mode. An 11 hexadecimal in control field 58 sent by base station 20 is an acknowledge to a remote stations request for a response.
Referring to FIG. 3 terminal node controllers 32 and 38 also provide a sixteen bit frame-check sequence field 64 which insures that the frame is not corrupted by the medium used to transmit the frame from the sender to the receiver. The frame-check sequence field 64 is a High Level Data Link Control (HDLC) type control procedure whereby the receiving station checks the incoming frames for transmission errors. In the KISS mode of operation messages with errors are not passed to computers 28 and 40.
Terminal node controllers 32 and 38 also determine proper timing for channel access to allow for the transmission of information between the base station 20 and each remote station 22.
In the preferred embodiment of the present invention the AX.25 Amateur Packet-Radio Link-Layer Protocol responsibility is off-loaded to computers 28 and 40 which use BAST2.BAS and REMS.BAS applications software to perform the AX.25 Protocol functions, that is the applications software is utilized to assemble and disassemble the "packets" or frames for transmission of positional data from each remote station 22 to base station 20. The program listing for this applications software is set forth below and is referred to by program listing line numbers in the following discussion of the operation of the multiple unit tracking station 18 of the present invention.
When each remote station 22 is powered up, the application software on remote station's computer 28 automatically loads and runs. The program loaded on computer 28 at each remote station 22 immediately jumps to an Initialization subroutine beginning at line 310. The base station software program is defined as BAST2.BAS and set forth at lines 10-4750, while the remote station software is defined as REMS.BAS and set forth at lines 10-5010.
The first section of the Initialization subroutine (lines 310-470) REMS.BAS closes all files, and initializes the user table, and the input buffers.
Referring to FIG. 7, the user table is an integer array of eight nineteen byte columns which is the maximum number of participants used in the preferred embodiment of the present invention, that is seven remote and/or relay stations and base station 20. Each nineteen byte column defines base station 20, a remote station 22 or a relay station 23 and contains a station address and other information used to set up and maintain data links. The user table of FIG. 7 is defined in both the base station 20 software and the software of each remote station 22 or relay station 23 though minor differences exist in table usage. It should be understood that the user table can be expanded to include more than eight remote and relay stations 23.
The structure of one column of the user table is shown in FIG. 7. The following discussion will be with reference to base station 22 software. Bytes five through ten, FIG. 7, contain the ASCII representation of the six character alphanumeric address of one remote station 22 or relay station 23. Bytes eleven through eighteen contain index numbers which reference other columns in the user table which, in turn, contain the addresses of relay stations 23 when relay stations 23 are utilized by multiple unit tracking system 18. Byte four is the byte number of the last relay station 23 index plus one. If byte four is zero, relay stations 23 are not used in the data link with the remote station. Byte zero contains the address of the output buffer holding a message to be sent to the remote station 22 identified by bytes 5-10. Byte one contains a number ten times the reporting period of the remote station 22. Bit zero of byte two identifies the participant as a reporting remote station, while bit one of byte two identifies the participant as a repeater/relay station 23 which may be either a stand alone relay station 23 or a remote station. Byte three is a retry counter and is used to identify nonresponsive participants.
FIG. 8 depicts an example setup of the contents of the user table for the base station software following completion of the Initialization subroutine. In the example of FIG. 8, base station 20 (PLP001, column 0, Bytes 5-10) sets up data communication links with three remote stations 22. The first link to a remote station PLP002 (column 1, Bytes 5-10) is a direct link without relay stations 23. The second link to a remote station PLP003 (column 2, Bytes 5-10) is through a stand alone relay station PLP005 (column 3, Bytes 5-10). The third link to remote station PLP004 (column 4, Bytes 5-10) is through both the stand alone relay station PLP005 and station PLP003. In this example, station PLP003 acts as both a reporting remote station and a relay station. Column zero of FIG. 8 is reserved for "own site" address and so contains the address of the base station (PLP001). Column one of FIG. 8 is set up for the PLP002 remote station. As bit zero of byte two is set to a logic "1", the remote station PLP002 is a reporting remote station. Byte four is zero indicating that no relay stations 23 are being used in this link.
Column two of FIG. 8 is set up for station PLP003. As byte two is a "3", bit zero and bit one are "ones", this station is used as both a reporting remote station and a relay station. Byte four is greater than zero indicating that relaying is used in this link. Byte eleven contains the index to the first relay station 23, in this case "3", therefore, column three holds the address of the relay station PLP005. Byte four of column two, FIG. 8, is "12". Since this is already one more than the location of the first index (byte eleven), only one relay station 23 is used in this link.
Column three of FIG. 8 contains the address of the stand alone relay station PLP005. Byte two is set to "2", bit one is "1", indicating that this site is a relay station only. Column four of FIG. 8 is set up for station PLP004. Byte two, bit zero, is one indicating that this is a reporting remote station. Byte four is greater than zero indicating that relaying is used in this link. Byte eleven of column 4 contains the index of the first relay station, in this case "3", therefore, the site reference in column three, relay station PLP005 will be used as the first relay. Byte twelve of column 4 contains the index of the second relay station in this case "2", therefore the site reference in column two, station PLP003 will be used as the second relay in this link. This is one more than the location of the second relay index (byte twelve), so only two relays are used in this link.
In the remote station software, the user table is also defined. Bytes four through eighteen of FIG. 7 serve the same purpose as in the base station software. Bytes zero, one and three of each column of FIG. 7 are not used in the remote station software and byte two serves a different purpose than in the base station software. When a remote station receives its first message from the base station, it must fill out its user table with any site addresses which were used to relay the message. This need only be done once, so byte two is used as a flag to indicate the relay address have been included in the remote station's user table.
FIG. 9 shows the user table of remote station PLP004 as it would look following receipt of the first message from the base station PLP001 in the previous example. Column zero of FIG. 9 is reserved for "own site" address information (PLP004). Column one of FIG. 9 is reserved for the base station address (PLP001) Byte four of column one is set to thirteen indicating that bytes eleven and twelve contain indexes to relay stations. Byte eleven of column one is "2", thus the first relay address is located in column two, bytes 5-10 (PLP003). Byte twelve of column one is "3", thus the second relay address is located in column three, bytes 5-10 (PLP005). It should be noted that the message to remote station PLP004 was transmitted from the base station, relayed through PLP005 and then relayed through PLP003, whereas any reply from remote station will be relayed in reverse order.
Data input from terminal node controller 34 at each remote station 22 or terminal node controller 38 at base station 20 to the computer software is accomplished through a set of input buffers in computer memory. Each input buffer of which there are eight for each computer in system 18 is 128 bytes long. The first byte of each buffer indicates the number of bytes that have been loaded into the buffer. If this byte is zero, the buffer is empty. During the software initialization routines for the base station and remote stations, the input buffers are cleared and the head and tail pointers are set to zero.
When the first message arrives from terminal node controller 32 or 38, the computer software selects the buffer indicated by a head pointer which is buffer "0" and loads the data. When the last byte of the message is loaded into buffer "0", the head pointer is incremented to one to direct the software to load the next message into buffer "1". A tail pointer which is still set to zero, thus being unequal to the head pointer, indicates that a buffer is full and ready for processing. When a processing subroutine of the computer software is called, the subroutine acts on the buffer indicated by the tail pointer, in this case buffer "0". Once buffer "0" has been processed, the first byte of the buffer is set to zero declaring buffer "0" empty, and the tail pointer is incremented. As the head and tail pointers are now both equal to one, no more buffers are ready to be processed.
The procedure of filling and processing input buffers continues as described above except when the seventh buffer is loaded or processed. In this case the head or tail pointer is not incremented to "8" but reset to "0". This creates the effect of a circle of buffers numbered zero through seven with the head pointer rotating as buffers are loaded and the tail pointer following the head pointer as buffers are processed and cleared.
The next section of the Initialization subroutine (lines 490-540) of REMS.BAS partially describes an array of constants which will be filled in by data from bas station 20 and loaded into the terminal node controller 38 of each remote station 22 to modify Slottime and Persistence timing parameters.
The next section (lines 560-660) of REMS.BAS initializes output buffers and sets certain flags and counters.
Output of messages, either information frames or status frames, from the computer software either at base station 20 or each remote station 22 to terminal node controller 32 or 38 is accomplished through a set of output buffers in computer memory. Unlike input buffers, processing of messages may require that an output buffer already loaded be cleared prior to use. This necessitates the use of a linked-list buffer scheme or buffer list for output buffers which is illustrated in FIG. 10.
The linked-list configuration as used in multiple unit tracking system 18, utilizes head and tail pointers to identify the first generated/oldest and last generated/newest output buffers in the link-list buffer scheme. In addition, forward and backward pointers associated with each buffer are used to identify the buffer immediately ahead and the buffer immediately behind a particular buffer. Each output buffer of which there are sixteen for each computer in system 18 is 128 bytes long. The first byte of each output buffer indicates the number of bytes that have been loaded into the buffer. If this byte is zero, the output buffer is empty. The second byte of each buffer is the forward pointer, which identifies the next oldest buffer. If the second byte is zero, the buffer is the first on the buffer list. If the second byte is set at a "-1" the buffer is not on the buffer list. The third byte of each buffer is the backward pointer, which identifies the next newest buffer. If this byte is zero, the buffer is the last buffer on the buffer list. During the software initialization routines for computers 22 and 40, the output buffers are cleared, the head and tail pointers are set to zero, and the forward pointers are set to "-1".
FIG. 10(A)-(D) is an example illustrating the status of head and tail pointers and forward and backward pointers as the pointers are being utilized. In this example, FIG. 10(A), four buffers numbered "1" through "4" are filled in order. The head pointer is set to "1" indicating that buffer one is the first buffer in the buffer list. The backward pointer in buffer one is set to "2" indicating that buffer two is the next buffer in the buffer list. Following the backward pointers of each successive buffer will lead to the buffer identified by the tail pointer which is buffer four. The forward pointer in buffer four is set to "3" indicating that buffer three is the previous buffer in the buffer list. Following the forward pointers of each successive buffer will lead to the buffer identified by the head pointer which is buffer one.
If a processing of information by computer 40 for example requires the removal of buffer three from the buffer list, the pointers would appear as shown in FIG. 10(B). The head and tail pointers would remain the same as in FIG. 10(A), but buffer three is no longer linked in the buffer list. The backward pointer in buffer two now points to buffer four, and the forward pointer in buffer four now points to buffer two. The forward pointer of buffer three is set to a "-1" indicating that this buffer is not currently linked.
Should a second message be generated for output by computer 40, the data would be loaded into buffer three and buffer three would be linked to the end of the list. The buffer pointers would then appear as in FIG. 10(C). The head pointer remains the same indicating buffer one, but the tail pointer is changed to reflect the new end of the buffer list which is buffer three. The backward pointer in buffer four now points to buffer three and the forward pointer in buffer three points to buffer four. The backward pointer in buffer three is set to zero to indicate that this is the last buffer in the buffer list.
When the "Print Output Buffer" subroutine (lines 5210-5420, BATS2.BAS and lines 3780-3960, REMS.BAS) is called, it processes the output buffer referenced by the head pointer which is buffer one. Once buffer one is output to the terminal node controller 32 or 38, the buffer is cleared and unlinked from the buffer list. The pointers would then appear as shown in FIG. 10(D). The head pointer is changed to indicate the next buffer in the list is buffer two, the forward pointer of buffer one is set to "-1" to indicate that the buffer is not linked to the buffer list and the forward pointer of buffer two is set to zero to indicate that this is the first buffer in the buffer list.
Referring to the REMS.BAS program listing, lines 680-800 of the REMS.BAS software program at each remote station 22 load the address of the remote station 22 (lines 680-730) and the base station 20 (lines 750-800) into the user table of FIG. 7.
The last section (lines 680-900) of the initialization routine of the REMS.BAS program sets up the input buffer for Loran-C receiver 30 at remote station 22 and opens the communications channel with terminal node controller 32. Due to the operational characteristics of the Loran-C receiver 30 used in the multiple unit tracking system 18, the communications channel to receiver 30 is not opened at this time.
The software at each remote station 22 then enters the Main Program Loop (lines 180-240) of the REMS.BAS program where checks are made for data from terminal node controller 32 at remote station 22, the status of the input and output buffers of the RAMS.BAS software in computer 28 and the status of the Loran-C 30. If any checks are true, that is if the input buffers, output buffers, Loran-C 30 or terminal node controller are ready to provide data, the appropriate subroutine is called. The loop also calls the Check Timers subroutine at lines 4540-4700 of the REMS.BAS program. At this time in the REMS.BAS program, all checks are false and the program will remain in the main loop until a command is received from base station 20.
When loaded and started the BAST2.BAS computer program on computer 35 at base station 30 jumps to the Initialization subroutine (lines 340-2500). The Initialization Subroutine first defines a set of error messages which will be displayed should the operator make an error in system setup (lines 340-410). The BAST2.BAS software then defines two arrays which contain information for the computer graphics to draw up to eight markers to indicate remote station 22 and/or relay station 23 positions [430-660]. The software then sets up an array used to initialize terminal node controller 38 (lines 680-750) which is a Kantronics Model KPC-2 terminal node controller. The BAST2.BAS computer software program next loads map data for the map of FIG. 4 from a disk 41 (lines 4360-4410); defines the eccentricity and semi-major axis of the geodetic spheroid used in reducing Latitude and Longitude positional data; and scale factors and offset values for the map data (lines 840-900).
Processing Loran-C 30 longitude and latitude positional data and displaying position and map data on computer screen 14 requires the use of four different coordinate systems. Latitude and Longitude Geodetic coordinates are provided by the Loran-C receiver 30 at each remote station 22. These Geodetic coordinates are converted in the base station software into East-North-Up Tangent Plane or Topocentric Cartesian coordinates for overlaying onto the range map of FIG. 4. The Range Map data is generated by a "bit-pad" with its own two dimensional coordinate system. For display, all map and position data are transformed into a computer screen coordinate system.
The world geodetic system was developed to provide a geocentric reference system to which different geodetic datums can be transformed to satisfy mapping and geodetic requirements. An equipotential ellipsoid of revolution, which is in the shape of a spheroid, is taken as the reference surface or geometric figure of the earth. The particular reference ellipsoid used in multiple unit tracking system 18 is designated Department of Defense WGS-72. The ellipsoid, in turn, has a semi-major axis of 20925640 feet and an ellipsoid eccentricity of 0.08181881.
The Topocentric Cartesian Coordinates System is located at any reference point desired where the geodetic coordinates are known. In multiple unit tracking system 18, the range origin selected was site 004008, Building. 53 at the Pacific Missile Test Center, Pt. Mugu, Cal. The xy plane is tangent to the ellipsoid, while the z axis is normal to the ellipsoid and directed upward. The positive axis is directed at an alpha angle from true North. The alpha angle is measured clockwise from true North and is set at ninety degrees. The positive y axis is ninety degrees counterclockwise from the positive x axis. The coordinate system is right handed. When the alpha angle is ninety degrees, the +x axis points East and the +y axis points to true North.
Referring to FIG. 11, the map data file for the map of FIG. 4 was generated by placing a printed map of the range on a "bit-pad" and manually designating points and line segments which when drawn on the computer screen 24 represent coastline and range area boundaries. For multiple unit tracking system 18, the range area digitized was approximately 120 nautical miles square. With a bit-pad range of 6000 points in the X and Y coordinates, each point converts to 119.683 feet. The X and Y values of the digitized points for the map of FIG. 4 are stored in a disc file 41 for use in computer 40. As is best illustrated by FIG. 11, a flag in bit 14 of the X coordinate indicates whether a particular set of coordinates represents a point or the endpoint of a line segment. For example, for the X 1 coordinate bit 14 is set at one thereby indicating the coordinates X 1 , Y 1 form a point designated as point 1. Since bit 14 of X 2 is set at zero the coordinates X 2 , Y 2 indicate a line drawn from coordinates X 1 , Y 1 . It should be noted that the coordinates for the range origin of FIG. 4 are X=3571 and Y=4397.
Additionally, a number pair is stored to indicate the color of subsequent line segments. For example, bit 13 of the X 0 coordinate is set to one and a number five which indicates the selected color is inserted in place of an X coordinate. The disk file containing map data is loaded into the base station computer 40 during the initialization routine.
The Latitude and Longitude Geodetic coordinates from the Loran-C receiver 30 after being received by base station 20 are first converted to geocentric coordinates XG, YG, and ZG by the following equations:
XG=(N+H)cosφcosλ Eq. 1
YG=(N+H)cosφsinλ Eq. 2
ZG=[N(1-e.sup.2)+H]sinφ Eq. 3
where: ##EQU2## a=ellipsoid semi-major axis (WGS-72=20925640 feet) e=ellipsoid eccentricity (WGS-72=0.08181881)
λ=Longitude
φ=Latitude
H=geodetic height (assumed zero in prototype system)
The geocentric coordinates are then converted to offset geocentric coordinates by subtracting the geocentric coordinates of the Range Origin which are X=-8440322 ft, Y=-15150850 ft and Z=11669280 ft (site 004008, Bldg. 53 at the Pacific Missile Test Center, Pt. Mugu, Cal.):
XO=XG-(-8440322) Eq. 4
YO=YG-(-15150850) Eq. 5
ZO=ZG-(11669280) Eq. 6
The offset geocentric coordinates are then converted into tangent plane coordinates XT, YT, and ZT by multiplication of a rotational matrix: ##EQU3## The elements of the rotational matrix are defined as follows: A=-sinλsinα-cosαcosλsinφ
B=cosλsinα-cosαsinλsinφ
C=cosφcosα
D=sinλcosα-sinαcosλsinφ
E=-cosλcosα-sinαsinλsinφ
F=cosφsinα
G=cosλcosφ
H=sinλcosφ
I=sinφ
For α=90 degrees, λ=-119.1214044 degrees (site 004008 Longitude) and φ=34.1129172 degrees (site 004008 Latitude):
A=-sinλ=0.8735892
B=cosλ=-0.4866641
C=0
D=-cosλsinφ=0.2729335
E=-sinλsinφ=0.4899308
F=cosφ=0.8279308
G=cosλcosφ=-0.4029259
H=sinλcosφ=-0.7232745
I=sinφ=0.5608253
This results in the following equations for calculating XT and YT since ZT is not used in system 18.
XT=0.8735892·XO+(-0.4866641)·YO Eq. 7
YT=0.2729335·XO+0.4899308·YO+0.8279308·ZOEq. 8
The XT and YT coordinates are then divided by 119.683 feet to make the XT and YT coordinates the same scale as the map data points.
The computer screen in graphics mode is resolved into 640 horizontal and 350 vertical lines. The map area of the screen is limited to horizontal lines 128 through 640. To plot the map on the screen, each set of coordinates read from the map file are first normalized by subtracting the "bit-pad" coordinates of the Range Origin (X=3571, Y=4397). The coordinates are then multiplied by X and Y scale factors. The scale factors (initialized at 0.08276 and 0.05985) respectively convert the map points to computer screen coordinates. In addition, X and Y offset values are added to the coordinates to center the map on the screen. The initial values of the scale factors and offset values will place the entire 120 nautical mile square range map onto the computer screen 24. The operator can change the scale factors during operation for the effect of "zooming" in or out on the range map of FIG. 4. The operator can also change the offset values for the effect of map "panning".
Position information from the remote station which has been converted as described above is multiplied by the same scale factors and adjusted by the offset values for overlaying the position marker over the map display.
The next section of the Initialization subroutine (lines 920-1060) of BAST2.BAS sets up the input buffers, the user table of FIG. 7 for base station 20 and a timer array which identifies time-out conditions with the remote stations. The next section of the Initialization subroutine (lines 1080-1150) of BAST2.BAS initializes the output buffers which are illustrated in FIG. 10. The address of base station 20 is loaded into the user table of FIG. 7 at lines 1170-1220 of the BAST2.BAS computer program. It should be noted that FIG. 8 is an example of the user table for base station 20. The remainder of the Initialization subroutine (lines 1240-2400) instructs the system operator to load the user table with remote station specific data as is best illustrated in FIGS. 7 and 8. Multiple unit tracking system 18, as currently configured, can accommodate up to seven reporting stations and/or relay stations 23 each identified by a unique six character alpha-numeric call sign.
After returning from the Initialization subroutine, the BATS2.BAS computer software then jumps to the Establish Links Subroutine (lines 2570-3030). The purpose of this subroutine is to send a request for status message to all of the remote stations identified in the Initialization subroutine and to wait until all stations have responded or have timed out. If all stations respond, the BATS2.BAS computer program continues. If one or more remote or relay stations 23 do not respond, the operator is given the option to continue the BATS2.BAS computer program, send another request for status message to all of the remote and/or relay stations 23 identified in the Initialization subroutine, or abort the program.
The Establish Links Subroutine first counts the number of remote stations entered by the operator (lines 2650-2730). For each participant in the user table of FIG. 7 which is identified as a reporting station, a status request message is generated and added to the output buffer list of computer 40 (lines 2650-2730). Included in this status request message is a timing parameter which includes the PERSISTENCE and SLOTTIME values and which is based on the number of remote stations and relay stations 23 in multiple unit tracking system 18. This timing parameter, which maximizes channel throughput, is loaded into the terminal node controller 32 at each remote station and relay station 23. The status request message is built by calling a Send Request for Status subroutine (lines 4230-4400) of the BAST2.BAS program. This subroutine calls the Find Output Buffer and Pack Address subroutine (lines 4460-4810) which locates an empty output buffer and loads the output buffer from the user table of FIG. 7 with the source address which is base station 20, the destination address of the remote station, the relay addresses if used, and various status bits as required by AX.25 protocol. After returning to the Send Request for Status subroutine (lines 4230-4400), the BAST2.BAS software appends to the buffer a pair of control bytes (the control field and the protocol identifier field), the message type number and the aforenoted timing parameter (lines 4260-4380). The Send Request for Status subroutine then calls or goes to the Link Output Buffer subroutine (lines 4880-4980) which links the filled output buffer onto the end of the output buffer list.
The BAST2.BAS software returns to the Establish Links subroutine and enters a status loop (lines 2760-2820) where control will remain until all remote stations have returned a status message or have timed out. The first line in the status loop checks for any input from terminal node controller 40. At this point in time, all remote stations 22 should be in the quiescent state so this check will be false. The next check is for input buffers full. Since data has not been transmitted from the remote stations 22 to the base station 20 there will be no input buffer full at this time and the check is false. The next check is for an output buffer full. Since output buffers have been loaded with request for status messages and linked to the output buffer list this check is true which results in the Print Output Buffer subroutine being called.
The Print Output Buffer subroutine (lines 5210-5420) takes the first buffer of the output buffer list, FIG. 10, as indicated by the output buffer head pointer and sends the data in this buffer to the Terminal node controller 38 for transmission. The output buffer is then taken off the buffer list and a check is made to determine if an acknowledge message was requested from the remote station. If an acknowledge message was requested, as in the case of a request for status message, a timer is set equal to twice the response time for the remote station. The first output buffer of the output buffer list is saved and if the timer expires before an acknowledgement is received by base station 22 as determined by the check timers subroutine (lines 6890-7040) of the BAST BAS program, the output buffer is once again linked to the output buffer list for retransmission to the remote station. If no acknowledge message was requested by base station 22, then the output buffer that was sent is cleared.
Referring to the status loop of the Establish Links subroutine (lines 2760-2820), the check timers subroutine is called at line 2790 of the BAST2.BAS program. This subroutine (lines 6890-7160) checks two timers associated with each remote station 22. The first timer is the remote station activity timer. This timer is not enabled until a remote station has begun transmitting longitude and latitude position reports. The timer is set up to a value of five times the reporting period for the remote station and is reset to this value whenever a message is received from the addressed remote station 22. If no messages are received causing the timer to decrement to zero, the operator is informed of a time out condition for the remote station, and an initiate message is periodically sent to the remote station automatically to reactivate the station.
The second timer associated with each remote station 22 is the acknowledge timer that is set in the print output buffer subroutine (lines 5210-5420). This timer is set if a message was sent to a remote station that required an acknowledge. The timer is cleared if an acknowledge is received from the addressed remote station. If the acknowledge timer expires, that is no acknowledge message is received from the remote station, then the output buffer that contained the message to the remote station is linked onto the output buffer list for retransmission. This cycle will occur five times before multiple unit tracking system 18 declares the remote station unresponsive. This, in turn, is the function of the retry counter of the base station user table of FIG. 7.
Referring again to the status loop of the Establish Links subroutine (lines 2760-2820), each remote station in the user table of FIG. 7 is checked to see if a response has been received or the remote station has been declared unresponsive. If neither of these conditions are true for any remote station 22, the status loop restarts at the check for terminal node controller 38 input.
Referring to REMS.BAS remote station software, the software at each remote station 22 has been cycling through the Main Loop waiting for a command from base station 22. The first check in the main loop is for input data from base station 22 which is provided from terminal node controller 32. Once a message from base station 22 is received by terminal node controller 32, the message is passed to computer 28 and this check will be true. The Main Loop at line 180 of REMS.BAS calls Holding Buffer Input subroutine (lines 960-1320) which loads one byte at a time into an input buffer within computer 28. The Holding Buffer Input subroutine first checks to see if the byte from terminal node controller 32 is the beginning of a new message from base station 20 or the next byte in a message already being provided by base station 20 and currently being reconstructed by REMS.BAS software.
If the byte from terminal node controller 32 is the first byte of a new message from base station 20, the next input buffer is flagged open and a check is made for the proper message header byte. If, however, an input buffer is open and the byte is a continuation of the current message, the byte is added onto the end of the buffer and a check is made to see if this is the last byte in the message. If the check is true, that is the byte is the last byte of the current message, the buffer is closed and the head pointer is adjusted. If the check is false, that is the byte is not the last byte of the current message, control is transferred back to the main loop.
When a complete message is received from base station 20, the check for input buffer full in the main loop of the REMS.BAS computer software program will be true and the Process Input Buffer subroutine (lines 1370-1510) is called. The first section of the Process Input Buffer subroutine (lines 1370-1510) checks the address fields of the message. If the destination address in the message does not match the remote station's address, the software jumps to check the relay addresses for a match (lines 1700-1930). If the remote station is identified as a relay station 23 for the message, REMS.BAS transfers the message to an output buffer and links the output buffer onto the output buffer list for transmission.
Referring again to the first section of the Process Input Buffer routine, if the destination address is the same as the remote station address, then the source address is checked to see if the source address matches the address for base station 20. A check is next made to see if this message was intended to be provided to the remote station through a relay station 23. If the message is provided from base station 20 to the remote station without the use of relay stations 23, the message is processed by computer 28. If relay stations 23 are used to transmit the message from base station 20 to the remote station 22, and relaying is complete, the relay addresses are stored in the user table of FIG. 9 (lines 1530-1680) so that return messages are relayed back in reverse order of the command messages from base station 20. The message is then processed by computer 28.
If the checks of the message address field indicate that this message is intended for the addressed remote station, the data in the message is decoded by the REMS.BAS (lines 1960-2260) to determine the nature of the message. For example, if the message is an acknowledge requested by the remote station from base station 20, then the counter that would reset the remote station to a quiescent state after twenty unanswered reports is reset. If the message is a request for status from base station 20, then the array of constants described in the Initialization subroutine (lines 490-540) of REMS.BAS computer program at each remote station 22 is filled in by data (Slottime and Persistence) from base station 20 and loaded into terminal node controller 38 to modify timing parameters. If the message is an initiate report mode command, then the appropriate flags are set in the REMS.BAS computer software to dictate that the software is in a report mode and an acknowledge is transmitted to base station 20. If the message is a terminate command, a response is transmitted to the base station 20 and remote station reinitializes to the quiescent state.
Referring again to the Process Input Buffer routine, when the message from base station 20 is a request for status the REMS.BAS software at the remote station will initialize terminal node controller 32 and call the Send Response subroutine (lines 2320-2420). The Send Response subroutine,in turn, calls the Find Output Buffer and Pack Address subroutine (lines 3030-3380) which locates an empty output buffer and loads the output buffer from the user table of FIG. 9 with the source address, the destination address of base station 20, the relay station addresses if used, and various status bits as required by the AX.25 protocol. After returning to the Send Response subroutine, the REMS.BAS software appends the control field to 11 hexadecimal or 15 hexadecimal. The Send Response subroutine next calls the Link Output Buffer subroutine (lines 3450-3530) which links the filled output buffer onto the end of the output buffer list, FIG. 10. After processing the input buffer, the REMS.BAS software clears the input buffer, adjusts the input tail pointer, and returns to the main loop of the program.
After the response message has been linked, the output buffer full check in the main loop will be true and the Print Output Buffer subroutine will be called. The Print Output Buffer subroutine (lines 3780-3960) takes the first buffer off the output buffer list as indicated by the output buffer head pointer and sends the data in this buffer to terminal node controller 32 for transmission to base station 20. The output buffer is then cleared and taken off the buffer list.
Referring now to BAST2.BAS program at base station 20, the software is operating in the status loop of the Establish Links subroutine (lines 2570-3030). As the responses from the remote stations 22 are received by terminal node controller 38 at base station 20, data is passed to the base station computer 40 and the check in the status loop for input data available will be true. At this time the Holding Buffer Input subroutine (lines 3250-3580) will be called to load one byte at a time into an input buffer. The Holding Buffer Input subroutine (lines 3250-3580) first checks to see if the next byte from terminal node controller 38 is the beginning of a new message or the next byte in a message already provided by one of the remote stations 22 and currently being reconstructed by the BAST2.BAS software. If the byte from terminal node controller 38 is the first byte of a new message from one of the remote stations 22, the next input buffer is flagged open and a check is made for the proper message header byte. If, however, an input buffer is open and the byte is a continuation of the current message, the byte is added onto the end of the buffer and a check is made to see if this is the last byte in the message. If the check is true, that is the byte is the last byte of the current message, the buffer is closed and the head pointer is adjusted. If the check is false, that is the byte is not the last byte of the current message, control is transferred to the status loop of the Establish Links subroutine (lines 2570-3030).
When a complete message has been received at base station 20, the status loop check for input buffer full will be true and the Process Input Buffer subroutine (lines 3630-4040) will be called. The first section of the Process Input Buffer subroutine (lines 3630-3810) checks the address fields of the message. In order for the message to be processed, the destination addresses in the message must match the address of base station 20, relaying must be complete if the message was intended to be received through a relay station 23 or more than one relay station 23, and the message source address must match one of the remote station 22 addresses in the user table of FIG. 8. If any of these checks fail, that is one of the checks is false, the message is discarded. If all the checks of the message address are true, the data in the message is decoded/processed at lines 3820-4040 of the Process Input Buffer subroutine.
If, for example, the message is a response from one of the remote stations 22 to a request by base station 20, then the validity of the response is checked at lines 3920-3950 of the BAST2.BAS program. If valid, then the output buffer that contained the request is cleared, and the response timer for that remote station 22 is disabled by the Unlink and Clear Buffer subroutine [5040-5150]. If the message were a position report from one of the remote stations 22, then the position report would be processed by computer 40 and if an acknowledge was requested by the remote station 22, an acknowledge would be sent by the BAST2.BAS computer program at lines 3850-3960. Following all processing of the message, the input buffer is cleared, the tail pointer is adjusted, and the remote station activity timer, if enabled, is reset at lines 4000-4040 the BAST2.BAS program. The software will return to the status loop in the Establish Links subroutine (lines 2570-3030) and remain there until all remote stations 22 have responded or have been flagged as unresponsive.
After exiting the status loop of BAST2.BAS, the operator of multiple unit tracking system 18 is informed of the status of the remote station links. If all remote station links are established, the program continues. If all remote station links are not established, the operator is given a choice of either continuing with those remote stations that responded, or to restart the Establish Links subroutine. If all links are established or the operator chooses to continue, the BAST2.BAS program calls the Initiate Report Mode subroutine. The Initiate Report Mode subroutine (lines 3100-3190) enables the remote station activity timer for all remote stations 22 and sends an initiate report mode message to each station 22 which includes the frequency at which the remote station should report its position to base station 20. The initiate report mode message is sent in the same manner and using the same subroutines as the request for status message that was sent to each remote station in the establish links subroutine. The Initiate Report Mode subroutine also opens a disk file that will save the remote station position report data when received for post operation analysis. The BAST2.BAT software now enters the Main Loop (lines 220-280) of the program. The main loop contains checks for keyboard entry, input data available from terminal node controller 38, input buffer full, and output buffer full. The Main Loop of the BAST2.BAT software are also calls to the check timers subroutine and the draw map line subroutine (lines 6470-6830).
The software utilized to write the BAST2.BAT and REMS.BAS program instructions for multiple unit tracking system 18 is conventional GW-Basic. The graphics limitations of GW-BASIC compiler used to generate the base station software presented two problems which are handled by the BATS2.BAS software. First, as the position markers for remote stations 22 move across the range map of FIG. 4 on monitor 24, the position markers will erase the part of the map the markers cross. To solve this problem the range map of FIG. 4 is continually redrawn by the BATS2.BAS software. The second problem arises due to reserving the left one quarter of the display screen for alpha-numeric data including remote station position coordinates and time-out messages. A "clipping" algorithm to prohibit drawing the map in the reserved area had to be implemented in the base station software.
The Draw Map Line subroutine (lines 6470-6670) is called on every pass through the main loop of the BATS2.BAT program in which input data from terminal node controller 38 is not available to computer 40. This routine will either plot a map point, draw a map line, change the color of the map lines to be drawn, or plot a circle on the map corresponding to the location of the range origin (site 004008, Bldg. 53 at the Pacific Missile Test Center, Pt. Mugu, Cal.). Which action is taken is dictated by the contents of the map array already loaded and the equations 1 thru 8 discussed previously. Points from the map array are normalized and scale and offset factors ar applied to generate display coordinates for the map of FIG. 4. If a map line is to be drawn, the clipping algorithm is called (lines 6700-6830). If both endpoints of the line fall within the right three-quarters of display screen 24 (map area of FIG. 4), the line is drawn without modification. If both endpoints of the line fall outside the map area, no draw commands are generated. If one endpoint of the line lies inside the map area and one point of the line lies outside the map area, a point is calculated which lies on the intersection of the map area boundary and the line if it were drawn. This point and the endpoint of the line which fell inside the map area are the new endpoints of the line.
The operator at base station 20 can effect changes in the map being viewed on display screen 24 by using keyboard 35. If the operator hits a key on keyboard 35, the keyboard entry check (line 230) in the main loop is true, then the Process Keyboard Entry subroutine (lines 5480-5780) is called. This routine (lines 5480-5780) inputs the keyboard character and performs one of the following: If a "1" is entered by the operator, the X and Y scale factors are modified to effect a zoom in on the map display appearing on monitor 24. If a "2" is entered by the operator, the X and Y scale factors are modified to effect a zoom out on the map display appearing on monitor 24. An entry of "3" or "4" by the operator modifies the X offset to effect a pan of the map display appearing on monitor 24 right or left, respectively. An entry of "5" or "6" by the operator modifies the X offset to effect a pan of the map display appearing on monitor 24 up or down, respectively. An entry of "0" or any non-numeric key via keyboard 35 will reset the map scale and offset to the initialized values. An entry of "9" by the operator will cause the termination of system operation.
The Initiate Report Mode messages that were linked to the output buffer by the Initiate Report Mode subroutine (lines 3100-3190) will be output to terminal node controller 38 from the main loop of BAST2.BAS by calling the Print Output Buffer subroutine (lines 5210-5420).
Referring to the REMS.BAS computer program, the software is cycling through the main loop waiting for a message from the base station 20. At this time, the software will receive the initiate report mode message that was sent by base station 20. This message is input and processed as described above.
Due to the operational characteristics of the Loran-C receiver 30 and Zenith 150 personal computer 28 used in multiple unit tracking system 18, the method of obtaining the position of each remote station 22 is complicated. The receiver continuously sends data packets at a fixed rate, thus providing more latitude and longitude position data then can be processed by computer 28. To resolve this problem, the data channel from computer 28 to receiver 30 is only opened when a position report is required by the REMS.BAS computer software and closed as soon as the position information is transferred to computer 28. Channel two of computer 28, which is used for data from Loran-C receiver 30 data, periodically quits functioning when both channel one and two serial interfaces of computer 28 are being used. To handle this situation, an interface time-out timer for channel two of computer 28 was added to the REMS.BAS software to identify and clear the channel problem.
When the initiate report mode message is received by the remote station 22, the time which identifies the frequency of reporting is saved and used to initialize the report timer for the remote station. At line 210 the main loop of the REMS.BAS program calls the Check Timers subroutine (lines 4540-4700) checks the report timer for the remote station and if the report timer has expired, that is the time to send a position report has expired, the channel to Loran-C receiver 30 is opened and a channel time-out timer is set. On subsequent passes through the Check Timers subroutine, the time-out timer is checked. If the channel time-out timer has expired because channel two quits functioning, channel two is cleared, reopened, and the time-out timer is reset. Once the channel to the Loran-C receiver 30 is opened, the main loop checks for input positional data from receiver 30. If this check is true, the LORAN Input subroutine is called.
The first section of the LORAN Input subroutine (lines 4020-4130) identifies and loads either of two data blocks from Loran-C receiver 30. The two data blocks used in multiple unit tracking system 18 are the Latitude/Longitude or "L" block and the SNR or "S" data block. The SNR data block provides an indication of the reliability of the position data being provided by Loran-C receiver 30. When a complete "L" data block is received, the data block is decoded and a flag is set (lines 4150-4280). When a complete "S" block is received from receiver 30, the three SNR values are decoded, the smallest of the three SNR values is stored, and another flag is set (lines 4300-4370). When both the "L" and "S" flags have been set, the Loran-C channel is closed and the Send Position subroutine is called (lines 4400-4480). The Send Position subroutine first resets the report timer for the remote station 22 and then calls the Find Output Buffer subroutine to locate an unused output buffer and pack the source, destination, and relay address's (lines 2490-2520) to allow for transmission of latitude and longitude positional data to base station 20. Control bytes are added to the buffer followed by the message type, the reformatted Latitude, Longitude, and SNR value (lines 2530-2920). The buffer is then linked to the output buffer list.
The remote station REMS.BAS software maintains a counter representing the number of position reports sent to base station 20. When the value of this counter is greater than nine, the position report includes a request for an acknowledge from base station 20. When an acknowledge is received from the base station 20, the counter is reset to zero. Should the counter ever reach a value of twenty, meaning the base station did not acknowledge position reports ten through nineteen, the remote station REMS.BAS software assumes the link with base station 20 has been disconnected and reinitializes to the quiescent state.
Referring to the base station BAST2.BAS software, the position report from each remote station 22 will be input by the Holding Buffer Input subroutine (lines 3250-3580) and decoded by the Process Input Buffer subroutine (lines 3630-4040) as previously described. When a position report is identified, the Process Position Data subroutine (lines 5850-6410) is called. The Process Position Data subroutine first decodes the Latitude and Longitude data and converts them to radian values in accordance with the following equation for further processing (lines 5850-5960). ##EQU4##
The latitude and longitude radian values, along with the SNR value and a time tag are then recorded onto a base station disk (lines 5980-6090). The next section of the routine (lines 6110-6210) uses the Latitude and Longitude data along with some geodetic data identified in the initialization routine to calculate the tangent plane coordinates of the remote station 22 using the aforenoted equations 1-8. The routine then applies the scale and offset values to convert the coordinates to display screen coordinates and plots the position of the remote site on the display screen 24. The tangent plane X and Y coordinates are printed on the left side of the screen.
The process of each remote station 22 sending position reports and base station 20 plotting positions on the map of FIG. 4 for viewing on screen 24 continues until such time as the operator terminates the links between base station 20 and remote stations 22 by entering a "9" from keyboard 35. When this entry is input by the Process Keyboard Entry subroutine, the Terminate subroutine is called. The Terminate subroutine (lines 7230-7450) of the BAST2.BAS program builds and links a terminate message to each remote station 22. A status loop is then entered which, like the status loop in the Establish Links subroutine, waits for all remote stations 22 to acknowledge the terminate message. When all remote stations 22 have responded or have been flagged unresponsive, the BAST2.BAS software program closes the disk file where data was recorded and ends the program.
Upon receiving a terminate message from base station 20, each remote station 22 sends an acknowledge message and reinitializes to the quiescent state. ##SPC1##
|
A stand alone multiple unit tracking system which utilizes a packet radio link to periodically transmit information identifying the geographic position of ships, aircraft and other land mobile vehicles. The stand alone multiple unit tracking system comprises a base station, relay stations and a plurality of remote stations placed on board ships, aircraft or the like. The remote stations transmit latitude and longitude position information to the base station through relay stations, if required, using packet radio techniques.
| 6
|
FIELD OF THE INVENTION
This invention relates to a method and apparatus for reducing feedback in acoustic systems, particularly hearing aids. More specifically, the invention relates to hearing aids that employ digital processing methods to implement hearing loss compensation and other forms of corrective processing, and is concerned with reduction of acoustic feedback in such hearing aids.
BACKGROUND OF THE INVENTION
Acoustic feedback in hearing aids occurs because the gain and phase of the acoustic path from the receiver to the microphone are such that a feedback signal arrives at the microphone in phase with the input signal and with a magnitude that is greater than or equal to the input signal. This problem is especially prevalent in high-power hearing aids. A number of methods have been developed in the past for acoustic feedback reduction in digital hearing aids. Recently, techniques that use digital signal processing have been proposed.
Kates, J. ( Feedback Cancellation in Hearing Aids: Results from a Computer Simulation, IEEE Trans. on Acoustics Speech and Signal Processing, 1991, 39:553-562) implemented a scheme where the open-loop transfer function of the hearing aid is estimated by opening the forward signal path of the hearing aid and injecting a short-duration (50 ms) noise probe signal. Because the probe signal is very short in duration, it is inaudible to the hearing aid user. (It may, however, reduce the intelligibility of the processed speech signal.) When acoustic feedback is detected, the forward path is opened, the noise signal is injected and an adaptive filter is adjusted to estimate the transfer function of the feedback path and eliminate the acoustic feedback. Computer simulations demonstrated that this scheme provides the potential for 17 dB of feedback cancellation. A more recent scheme proposed by Maxwell, J. and Zurek, P. ( Reducing Acoustic Feedback in Hearing Aids, IEEE Trans. on Speech and Audio Processing , Vol. 3, No. 4, pp. 304-313, July 1995) is similar in operation except that it adapts during the “quiet” intervals of the input speech signal, as well as adapting when feedback is detected.
Dyrlund, O. and Bisgaard, N. ( Acoustic Feedback Part 2: A Digital Feedback System for Suppression of Feedback, Hearing Instruments , Vol. 42, No. 10, pp. 44-25, 1991); and Dyrlund and Bisgaard ( Acoustic Feedback Margin Improvements in Hearing Instruments Using a Prototype DFS ( digital feedback suppression ) System, Scand Audiology , Vol. 20, No. 1, pp. 49-53, 1991) developed a scheme that was implemented in a commercial hearing aid, the Danavox DFS. This scheme continuously characterizes the acoustic feedback path with an injected noise signal. If feedback is detected, the DFS algorithm injects a cancellation signal into the hearing instrument signal path that is at the same frequency but has opposite phase to the feedback signal. This scheme can provide 8-15 dB higher gain than a hearing aid without feedback reduction. However, it has the disadvantages that the injected noise signal may be audible for some listeners and that the noise signal may mask some speech cues at higher frequencies.
BRIEF SUMMARY OF THE PRESENT INVENTION
The present invention provides a feedback scheme which uses a filtered noise source that is passed through a shaping filter whose frequency response is dependent on the spectrum of the input signal and a simplified model of the human auditory system. If the filter is adapted in a known manner [Jayant, N., Johnson J., and Safranek, R., Signal Compression Based on Models of Human Perception, Proc. of IEEE , Vol. 81, No. 10, pp. 1385-1422, October 1993] the shaped noise signal that is added to the hearing aid input signal (at a relatively low signal-to-noise ratio of 15 dB or greater) will be inaudible to the hearing aid wearer. This inaudibly shaped noise source is used continuously to characterize the acoustic feedback path. If feedback is detected, adjustments are made in the hearing aid frequency response to eliminate it.
In accordance with the present invention, there is provided a method of controlling feedback in an acoustic system having an input for an acoustic input signal and output signal that generates a potential feedback path between the output and the input, the method comprising the steps of:
(1) generating a first input signal from the acoustic input signal and making a spectral estimate of the first input signal;
(2) subjecting the spectral estimate to a psycho-acoustic model to generate a control signal;
(3) passing a noise signal through a shaping filter and controlling the shaping filter with the control signal, to generate frequency-shaped noise, which is inaudible to someone hearing the acoustic output signal;
(4) adding the frequency-shaped noise to the first input signal to form a combined signal;
(5) processing the combined signal in a forward signal path having a transfer function, to generate a first output signal;
(6) analyzing the first output signal and the frequency-shaped noise signal, to determine the presence of feedback at different frequencies;
(7) using the first output signal to generate the acoustic output signal; and
(8) modifying the transfer function of the forward signal path, to reduce the gain thereof at frequencies where feedback is detected.
Preferably, in step (2), the psycho-acoustic model selected from one of a normative psycho-acoustic model and a measured psycho-acoustic model representative of the hearing characteristics of an individual.
In a further embodiment of the present invention, step (6) comprises forming a cross-spectral estimate between the first output signal and the frequency-shaped noise and an auto-spectral estimate for the frequency-shaped noise, dividing the cross-spectral estimate by the auto-spectral estimate to obtain a spectral ratio, and determining when the frequency response of the spectral ratio varies from the frequency response of the forward path, indicative of feedback.
The method of the present invention can be applied to any suitable acoustic system, for example a digital hearing aid or a public address system.
In another embodiment of the present invention, steps (3) and (6) are based on maximum length sequence methods, such that step (3) comprises taking the fast Hadamard transform of the control signal to generate the frequency-shaped noise, and step (6) comprises taking the fast Hadamard transform of the first output signal from the forward path, generating the power spectrum of the fast Hadamard transform of the first output signal and the power spectrum of the fast Hadamard transform of the control signal, and dividing the two power spectrums to obtain a spectral ratio from which feedback can be detected.
The present invention also provides apparatus corresponding to the method aspects just defined. The apparatus is for processing an acoustic signal and generating an acoustic output, and the apparatus comprises:
an input means for receiving an acoustic input signal and for generating a first input signal;
an output transducer for generating an output acoustic signal;
a forward signal path within the apparatus connecting the input means to the receiver and having a main transfer function for generating a first output signal;
a feedback path between the receiver and the input means enabling at least a portion of the output acoustic signal to be received at the input means;
a spectral estimation means connected to the input means for receiving the first input signal and for generating a spectral estimate of the acoustic input signal;
a psycho-acoustic model means connected to the spectral estimation means for forming a control signal from the spectral estimate;
a noise generation means connected to the psycho-acoustic model means for generating a noise signal whose spectrum is dependent upon the control signal;
means for adding the noise signal to the first input electrical signal to form a combined signal, for processing in the forward signal path; and
means for analyzing the noise signal and the combined signal after processing in the forward signal path to determine the presence of feedback and for modifying the main transfer function of the forward path to eliminate any substantial acoustic feedback.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a schematic, block diagram of a first embodiment of the present invention; and
FIG. 2 is a schematic, block diagram of a second embodiment of the present invention.
FIG. 3 is a schematic, block diagram of a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a first embodiment of the hearing aid has an input 10 for an acoustic signal u(t). This input 10 and a feedback path 14 are connected to a summation unit 12 which represents the acoustic summation of the input and feedback signals. The output of the summation unit 12 is connected to block 16 representing a microphone transfer function H 1 (ƒ). At the output of the microphone block 16 , there is the basic input signal x(t).
In accordance with the present invention, the signal x(t) passes to a further summation unit 18 , where it is added to a shaped noise signal v(t). At the output of the summation unit 18 , the summed signal z(t) is subject to the forward path transfer function H 2 (ƒ), as indicated at block 20 .
The output of the forward path, a signal w(t) is fed to a transducer 22 , which applies the transfer function H 3 (ƒ), to yield an acoustic output y(t). The acoustic output signal, y(t), is fed back to the input via an acoustic transfer function which is represented by H 4 (ƒ), as indicated in the feedback path 14 .
Now, in accordance with the present invention, the input signal x(t) is also supplied to a spectral estimation unit 24 , which in turn is connected to a psycho-acoustic model unit 26 . The output of the psycho-acoustic model 26 controls a shaping filter H 5 (ƒ) 28 which receives an input from a noise source 30 and which is used to shape the frequency spectrum of the noise source 30 . In known manner, the noise source 30 generates a random noise signal which can then be used for test purposes. The output of the shaping filter 28 is the frequency shaped noise signal v(t).
As indicated at 32 , a cross-spectral estimate, S wv (ƒ), is made between shaped noise signal v(t) and the signal w(t) at the output of the forward path. Similarly, the shaped noise signal v(t) is supplied to unit 34 , to determine an auto-spectral estimate S vv (ƒ). These are divided at 36 , to give the ratio S wv (ƒ)/S vv (ƒ).
The frequency domain transfer functions H 1 (ƒ), H 2 (ƒ) and H 3 (ƒ) represent the “normal” forward electro-acoustic transfer function of the electro-acoustic system if acoustic feedback is at a negligible level. The acoustic feedback path transfer function is H 4 (ƒ).
The noise source n(t) is filtered with a digital shaping filter 28 , H 5 (ƒ), whose coefficients (and hence frequency response) are periodically updated (for example at 20 to 30 ms intervals) based on an estimate of the short-term input signal spectrum and a psycho-acoustic model. The shaping filter is adjusted so that the noise-to-signal ratio (where the “noise” is the shaped noise N(ƒ)H 5 (ƒ)) of the input signal in the “forward path” z(t) is maximized while ensuring that the injected frequency-shaped noise is inaudible to the hearing aid wearer when masked by the input signal. For a hearing aid application, the psycho-acoustic model may be generic (i.e., based on normative data for the general class of hearing characteristic) or specific (i.e., based on specific characteristics of the user's hearing characteristic).
The frequency domain transfer function from the input U to the output Y is: Y(1−H 1 H 2 H 3 H 4 )=H 2 H 3 H 5 N+H 1 H 2 H 3 U. If the noise source is set to zero, we arrive at the well-known transfer function: Y U = H 1 H 2 H 3 1 - H 1 H 2 H 3 H 4
whose form is characteristic of a feedback system.
The cross- and auto-spectral estimates S wv (ƒ) and S vv (ƒ) are computed in the frequency domain using well known fast Fourier transform (FFT) correlation methods:
S wv =H 2 ( H 5 N+H 1 ( U+H 4 Y ))( H 5 N )*
= H 2 (| H 5 | 2 S NN +H 1 ( H 5 *S NU +H 4 H 5 *S YN ))
where
S NN (ƒ)=is the auto-spectral density of the noise source,
S NU (ƒ)=is the cross-spectral density between the noise source and the input signal,
S YN (ƒ)=is the cross-spectral density between the output signal and the noise source, and
* indicates complex conjugation; and
S vv =|H 5 | 2 S NN
Because the shaped noise signal (v(t)) is uncorrelated with the input signal over multiple periods of the shaping filter update time (e.g., correlations are computed over 100 to 200 ms periods), S NU (ƒ) asymptomatically approaches zero, and S wv (ƒ) can be approximated as:
S wv ≅H 2 (| H 5 | 2 S NN +H 1 H 4 H 5 *S YN )
Thus, the ratio of these two spectra can be approximated as: S WV S VV ≃ H 2 ( H 5 2 S NN + H 1 H 4 H 5 * S YN ) H 5 2 S NN
If the gain of acoustic feedback path (H 4 (ƒ)) is small (i.e. there is very little or no acoustic feedback), then the ratio of these spectra will be approximately equal to H 2 (ƒ) which is known. Thus, the occurrence of feedback can be detected by finding the frequencies where the ratio of the spectra deviates significantly from the known frequency response, H 2 (ƒ).
Because the value of S wv (ƒ) may be very small for some input signal conditions, the adaptation at a given frequency will be disabled if S wv (ƒ) falls below a pre-specified level. This satisfies a condition known as persistent excitation which states that a system must be exited at a particular frequency before it can be characterized at that frequency.
Once feedback is detected, it can be eliminated by reducing the gain of H 2 (ƒ) at the frequency where the feedback has been detected. In operation, there is a continuous balance between the initial “target” setting of H 2 (ƒ) (i.e., the desired frequency response) and the “adjusted” H 2 (ƒ) that is required to keep the acoustic system out of the acoustic feedback condition. The algorithm used to adapt the frequency-gain characteristic that constitutes H 2 (ƒ) will slowly adapt towards the target setting and only reduce the gain at a particular frequency if feedback is likely to occur at that frequency. The algorithm used to adjust H 2 (ƒ) does not form part of the present invention, and any suitable algorithm can be used.
FIG. 2 shows a second embodiment of the present invention, and similar elements are given the same reference, and for simplicity, description of the common elements is not repeated. This second embodiment of the invention uses maximum length sequence (MLS) methods to characterize the transfer function feedback path.
Here, the psycho-acoustic model 26 supplies filter coefficients to the fast Hadamard transform (FHT) unit 40 which in known manner generates a shaped noise signal: see Borish, J., “An Efficient Algorithm for Generating Colored Noise Using a Pseudorandom Sequence”, J. Audio Engineering Society , Vol. 33, No. 3, pp. 141-144, (March 1985), which is incorporated herein by reference. The FHT algorithm is described in detail in “An Efficient Algorithm for Measuring the Impulse Response Using Pseudorandom Noise”, J. Audio Engineering Society , Vol. 31. No. 7, pp. 478-488 (July/August 1983) which is also incorporated herein by this reference. A similar unit 42 takes the fast Hadamard transform (FHT) of the signal W(ƒ) which generates the impulse response of the forward signal path. This operation is equivalent to cross-correlating the shaped input MLS signal with an unfiltered MLS signal. Because the MLS is deterministic and the measurement is synchronous, all components that are asynchronous with the MLS will be spread (more or less) uniformly across the entire impulse response, as disclosed in Rife, D. and Vanderkooy, J., “Transfer-Function Measurement with Maximum-Length Sequences”, J. Audio Engineering Society , Vol. 37, No. 6, pp. 419-444, (June 1989) and Schneider, T. and Jamieson, D., “Signal-Biased MLS-Based Hearing-Aid Frequency Response Measurement”, J. Audio Engineering Soc., Vol. 41, No. 12, pp. 987-997, (December 1993), both being incorporated herein by virtue of these references.
By taking only the initial portion of the impulse response and synchronously averaging a number of these segments in sequence, the components of the signal that are uncorrelated with the MLS (e.g. the acoustic input signal including any feedback) are rejected, and an estimate of H 2 (ƒ) can be obtained. The two fast Hadamard transform outputs are then processed by fast Fourier transforms in units 44 and 46 and the magnitude squared is computed (to generate the power spectrum), and then divided at 48 to give the ratio S wv (ƒ)/S vv (ƒ). Accordingly, in this realization the feedback is detected and reduced using the same methods that are described above.
FIG. 3 shows a third embodiment of the present invention in which similar elements are given the same reference numbers. For simplicity, the description of these common elements is not repeated here. This embodiment of the invention uses a stereo filterbank method (described in copending application Ser. No. 09/060,823) to generate the shaped noise signal. Each section of the stereo analysis filterbank 50 incorporates N channels.
One section 52 of the filterbank 50 is used, in combination with a multiplier unit 54 , to generate the forward path transfer function (H 2 (ƒ) in FIGS. 1 and 2 ). The N outputs of this filterbank section are also used to generate an N-channel spectral analysis that is used as the input to a psycho-acoustic model 26 . This spectral analysis replaces the spectral estimation carried out at 24 in the earlier Figures. In the embodiment of FIG. 3, the psycho-acoustic model generates N channel gains as an output. The shaped noise signal v(t) (or V(ƒ) in the frequency domain) is generated by applying a white noise source to the input of the other filterbank section 56 (which is equivalent to shaping filter 28 in FIG. 1) and applying N gains (generated by the psycho-acoustic model 26 ) to a multiplier unit 58 . The acoustic output y(t) is generated by first passing the output of the forward path transfer function, W(ƒ), through synthesis filterbank 51 and then providing that signal w(t) to transducer 22 .
Accordingly, in this realization the feedback is detected and reduced using the same methods that are described above.
|
There is provided a method of controlling feedback in an acoustic system, for example a digital hearing aid, in which there is a potential feedback path between the output and the input. The method comprises making a spectral estimate of the input signal spectrum, and then subjecting the spectral estimate to a psycho-acoustic model to generate a control signal. A noise source is passed through a shaping filter, which is controlled with the control signal, to generate frequency-shaped noise, which is inaudible to someone hearing the output. The frequency-shaped noise is then added to the input signal to form a combined signal, which is processed in a forward path, to generate a first output signal. The first output signal and the frequency-shaped noise signal are analyzed, to determine the presence of feedback at difference frequencies, and the characteristics of the forward path are modified to reduce the gain thereof at frequencies where feedback is detected.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates to enhanced, light weight energy absorbing materials and methods of making them. These materials have utility in the manufacture of ballistic vests, hard and soft armor, stab and knife protection systems, and anti-ballistic systems.
BACKGROUND OF THE INVENTION
[0002] Ballistic grade fibers, such as aramid fibers, and items made thereof are well known in the art. They are commonly used in aerospace and military applications, for ballistic body armor fabrics or as an asbestos substitute.
[0003] Needle felting, sometimes referred to herein as needle punching or simply needling, is a process used in the textile industry in which an element such as a barbed needle is passed into and out of a fabric to entangle the fibers to produce felts. Needle felting is well known in the art, and descriptions of this method can be found in these documents such as U.S. Pat. No. 5,989,375.
[0004] The use of felts in anti-ballistic systems is known. U.S. Pat. No. 7,101,818 discloses an article made of at least one woven layer of ballistic grade fiber and at least one nonwoven layer of fabric, wherein both layers are entangled with each other by needle felting process.
[0005] The combination of woven and nonwoven ballistic grade fibers allowed to manufacture anti-ballistic systems that offered better protection than comparable systems made solely with woven fibers.
[0006] The needle felting process stabilizes the individual layers and prevents the individual layers from separating in a ballistic event by intermingling the fibers of both layers and putting them into close contact, which is why the anti-ballistic system disclosed in U.S. Pat. No. 7,101,818 outperforms systems that consists solely of woven layer that are not needle felted.
[0007] However, in the anti-ballistic systems of U.S. Pat. No. 7,101,818, the felt is only used to stabilize the individual layers. In ballistic events, and especially in ballistic events where the angle of the incoming projectile trajectory is non-normal (non-90°) to the plane of the protective system, projectiles can bounce off the protective system and continue on a different trajectory. This is also called a ricochet.
[0008] Ricochets are a common danger of shooting because after bouncing off an object, the projectile that ricochets poses an ‘unpredictable’ and serious danger of causing collateral damage to bystanders, animals, objects or even the wearer of the hit personal protective system. When the deformed projectile does hit a bystander or wearer it can become very dangerous. Instead of cleanly traveling through the body, the bullet can behave more like a hollow point bullet, causing a larger wound cavity, or even fragmenting and causing multiple wounds.
[0009] The likelihood of a ricochet occurring becomes larger the smaller the angle of the incoming projectile trajectory is in respect to the plane of the protective system.
[0010] Projectiles are quite likely to ricochet off flat, hard surfaces such as concrete or steel, however a ricochet can occur on almost any surface including the ballistic pack of a personal protective system, given a flat enough angle when hit.
[0011] Materials that are soft, give away easily, or can absorb the impact have a lower incidence of ricochet. This is due to the fact that the kinetic energy that is partially absorbed by the soft material decelerates the projectile and flattens its angle of departure, thus redirecting the projectile into the material instead of ricocheting.
[0012] However, in cases where the incoming projectile trajectory is near the edges of the protective system and the angle shallow, the projectile can penetrate one or more layers of protective material and travel between adjacent layers of protective material to exit trough the flange of the protective system. Such an event can be fatal, if for example, the projectile exits on the upper flanges that surround the neck, resulting in severe cranio-maxillo-facial trauma.
[0013] In an effort to improve the protection against knife and needle attacks, ballistic packs are now commonly reinforced with polymeric resins. Such a technology is described in, for example, WO0137691A1.
[0014] The polymeric resins may be calendered, laminated or heat pressed onto the ballistic pack or each individual layer of protective tissue.
[0015] However, this stiffens and hardens the ballistic pack to a point where the likelihood of ricochet increases significantly.
[0016] In some cases, anti-ballistic vest manufacturers have resorted to use polymer foams to reduce ricochet likelihoods and to reduce backface trauma. These polymer foams, such as for example polyurethane foam, are used as inner lining in contact with the body of the wearer.
[0017] These polymer foams offer little or no ballistic protection in the sense that if a projectile penetrates the ballistic layer, the lining is not able to stop it because of its low protective property.
[0018] On the other hand, the use of felts as inner linings, especially of felts having ballistic protection properties, entails other disadvantages, such as the low resilience of ballistic felts.
[0019] By low resilience material it is meant a material that does not spring back in to its original shape when deformed or compressed several times.
[0020] While the felts have an original thickness and cushioning effect that provides protection against backface trauma and reduces the likelihood of ricochets, prolonged wearing of the anti-ballistic vest and the pressure of the fastening gradually compresses the thick felt layer into a thinner, more dense felt layer. This compressed thick layer will no more have the cushioning effect of the original layer and will therefore be less effective in preventing ricochets, thus exposing the wearer and bystanders to higher risk.
[0021] In addition, the felts tend to break open during a ballistic event because of the strain of deformation caused by a projectile impact.
[0022] Furthermore, the felts show problems when sewn onto another layer of fabric of the anti-ballistic vest. The wearing of the anti-ballistic vests as well as ballistic events themselves create clearances where the felt was stitched, resulting in loose stitches.
[0023] There is a need for an improved inner lining which not only has ballistic properties, but also reduces the likelihood of ricochets and does not lose said property during its use.
SUMMARY OF THE INVENTION
[0024] The present invention relates to fabric comprising at least one woven layer and at least one nonwoven layer, wherein the number ratio between the at least one woven layer and the at least one nonwoven layer is in the range of 0.1 to 1, and further wherein the at least one woven layer comprises fibers having a tenacity of from 180 centi-Newton(cN)/Tex to 320 cN/Tex and a tensile modulus of from 3600 cN/Tex to 10600 cN/Tex, and the at least one nonwoven layer comprises a blend of at least one aramid fiber and at least one polyester. The fabric according to the present invention can particularly be used in the manufacture of ballistic vests, hard and soft armor, stab and knife protection systems, and anti-ballistic systems, and they provide a highly reduction of likelihood of ricochets using such systems.
DETAILED DESCRIPTION
[0025] The fabric according to the present invention comprises at least one woven layer and at least one nonwoven layer, wherein the number ratio between the at least one woven layer and the at least one nonwoven layer is in the range of 0.1 to 1, and further wherein the at least one woven layer comprises fibers having a tenacity of from 180 cN/Tex to 320 cN/Tex and a tensile modulus of from 3600 cN/Tex to 10600 cN/Tex, and the at least one nonwoven layer comprises a blend of at least one aramid fiber and at least one polyester. Suitable fiber materials for the at least one woven layer of the fabric according to the invention may be ballistic grade fibers. The ballistic grade fibers can be chosen among para-aramid fibers (commercially available as Kevlar® from DuPont de Nemours), poly (p-phenylene-2,6-benzobisoxazole) (PBO), high molecular weight polyethylene fibers (HMPE), ballistic nylons and/or combinations thereof.
[0026] Weave styles useful in the at least one woven layer of the fabric according to the present invention include plain, basket, twill, satin and other complex weaves including, but not limited to, unidirectional, quasi unidirectional, multi-axial weaves described in EP0805332, and three dimensional materials, alone or in combination.
[0027] In a unidirectional fabric the yarns all run in the same direction. In a quasi-unidirectional fabric the yarns may be laid in more than one direction and some yarns are not totally flat. As used herein, “unidirectional” encompasses both unidirectional and quasi-unidirectional fabric, unless the context requires otherwise.
[0028] Suitable ballistic grade fibers for the at least one woven layer of the fabric according to the present invention are fibers having a tenacity of from 180 cN/Tex to 320 cN/Tex, and a tensile modulus of from 3600 cN/Tex to 10600 cN/Tex.
[0029] The terms tenacity and tensile modulus stated in the present description are known to the person skilled in the art.
[0030] The at least one woven layer of the fabric according to the present invention may be laminated, calendered, heatpressed, impregnated or otherwise reinforced with polymeric resins which may be thermoplastic resins or thermoset resins.
[0031] In the case where the polymeric resin is a thermoset resin, the thermoset resin may be hydrogenated nitrile butadiene (HNBR), styrene butadiene (SBR), ethylene propylene diene monomer (EPDM), fluoronated hydrocarbon (FKM), acrylic rubber (ACM), ethylene acrylic rubber (AEM), polybutadiene, chloro isobutylene isoprene (CIIR), isobutylene isoprene butyl (IIR), polyurethane acrylonitrile butadiene carboxy monomer (XNBR), polyvinyl butyral (PVB), phenolic resins and/or combinations thereof.
[0032] Preferably, the thermoset resin may be a polyvinyl butyral (PVB), phenolic resin and/or combinations thereof.
[0033] In the case where the polymeric resin is a thermoplastic resin, the thermoplastic resin may be an ionomer, polyolefin, polyamide, polyimide, polycarbonate, polyurethane, polyether etherketone, phenolic-modified resin, and/or mixtures thereof.
[0034] Preferably the thermoplastic resin may be a polyamide, a polyolefin, a ionomer and/or mixtures thereof.
[0035] More preferably, the thermoplastic resin is a ionomer.
[0036] Ionomers are thermoplastic resins that contain metal ions in addition to the organic backbone of the polymer.
[0037] In the case where the thermoplastic is a ionomer, the ionomer is a copolymer of an olefin monomer, such as for example ethylene, and a partially neutralized, unsaturated C3-C8 carboxylic acid monomer. Preferably, the carboxylic acid is acrylic acid (AA) or methacrylic acid (MAA). Preferred neutralizing agents are sodium ions, potassium ions, zinc ions, magnesium ions, lithium ions and combinations thereof.
[0038] The acid groups of the ionomers useful in the present invention are neutralized from 1.0 to 99.9% and preferably from 20 to 75%. lonomers can optionally comprise at least one softening comonomer that is co-polymerizable with ethylene.
[0039] Ionomers and their methods of manufacture are described in U.S. Pat. No. 3,264,272. Suitable ionomers for use in the present invention are commercially available under the trademark Surlyn® from E. I. du Pont de Nemours and Company, Wilmington, Del., USA.
[0040] The at least one nonwoven layer of the fabric according to the present invention can be obtained by a felting process.
[0041] The felting process can be any suitable felting process, such as for example needle felting, waterjet felting, airjet felting or glue felting.
[0042] Preferably, the felting process is needle felting process.
[0043] The needle felting process can be modified depending on the amount of woven and nonwoven layers that are desirable in the fabric according to the invention.
[0044] Modifications of the needling process may also include the amount of needle punches per unit area and/or the depth of those punches.
[0045] The optimal amount and type of needling, and the amount of nonwoven fiber can be determined by ballistic testing, preferably performed using standard ballistic testing procedures, such as Home Office Scientific Development Branch (HOSDB) HG1/A Standard, the standard as known at a person skilled in the art.
[0046] Suitable fiber materials for the at least one nonwoven layer according to the present invention may be high performance ballistic resistant fibers, especially ballistic grade fibers having a tenacity of from 180 cN/Tex to 320 cN/Tex, and a tensile modulus of from 3600 cN/Tex to 10600 cN/Tex (hereinafter “ballistic grade nonwoven fibers”).
[0047] The ballistic grade nonwoven fibers may be selected from aramid fibers, extended chain polyethylene fibers, PBO (poly (p-phenylene-2,6-benzobisoxazole) fibers, high molecular weight polyethylene fibers (HMPE), regenerated cellulose, rayon, polynosic rayon, cellulose esters, acrylics, modacrylic, polyamides, polyolefins, polyester such as poly(trimethylene) terephthalate or polyethylene terephthalate, rubber, synthetic rubber, saran, glass, polyacrylonitrile, acrylonitrile-vinyl chloride copolymers, polyhexamethylene adipamide, polycaproamide, polyundecanoamide, polyethylene and polypropylene.
[0048] Preferably, the ballistic grade nonwoven fibers are aramid fibers, extended chain polyethylene fibers or PBO fibers.
[0049] Most preferably, the ballistic grade nonwoven fibers are aramid fibers.
[0050] In the case where the ballistic grade nonwoven fibers are aramid fibers, the aramid fibers can be a para-aramid fibers or a meta-aramid fibers. Preferably, the aramid are para-aramid fibers.
[0051] In a further embodiment, the at least one nonwoven layer comprises a blend of at least one aramid fiber and at least one polyester. Preferably, the polyester can be selected from the group consisting of polyethylene terephthalate and poly(trimethylene) terephthalate.
[0052] Preferably, the blend comprises from 70 to 99% by weight of aramid fibers and from 1 to 30% by weight of polyester, relative to the total weight of the at least one nonwoven layer.
[0053] More preferably, the blend comprises from 75 to 90% by weight of aramid fibers and from 10 to 25% by weight of polyester, relative to the total weight of the at least one nonwoven layer.
[0054] Most preferably, the blend comprises 75% by weight of aramid fibers, relative to the total weight of the nonwoven fabric, and 25% by weight of polyester, relative to the total weight of the at least one nonwoven layer.
[0055] One advantage of this embodiment is that the at least one nonwoven layer according to the present invention has a high mechanical resiliency. The high mechanical resiliency is warranted by the polyester fibers that are blended into the nonwoven layer.
[0056] The polyester fibers allow prolonged use of the fabric according to the present invention, because the nonwoven layer will not flatten and decrease in thickness over time. This, in turn, will maintain the cushioning effect of the nonwoven layer that effectively reduces the ricochet likelihood.
[0057] It is possible according to this invention to use more than 25% by weight of the polyester fiber, based on the total weight of the blend of the at least one aramid fiber and at least one polyester fiber.
[0058] However, amounts in excess of 30% by weight of polyester fiber are not desirable because of the flammability and heat sensitivity of polyester fiber. Flammability may be reduced by methods known in the art, such as the addition of flame retardants, additives, fillers and/or combinations thereof. Flame retardants will reduce the flammability of the polyester fiber, but will not prevent the melting and softening of the polyester fiber when heated by flames. Softened and molten polyester fibers will be compacted and will no longer confer the desirable properties to the fabric according to the present invention, and, therefore, the likelihood of ricochets will rise unfavorably.
[0059] In a preferred embodiment, the at least one nonwoven layer comprises fibers having non-uniform length, such as for example two-cut fibers or multiple-cut fibers.
[0060] The term two-cut fibers stated in the present description are fibers which are of two different lengths, and the term multiple-cut fibers stated in the present description are fibers which are of more than two different lengths.
[0061] The use of two-cut fiber blends or multiple-cut fiber blends allows a better level of entanglement between the nonwoven layer and the woven layer, because longer fibers will be pushed deeper into the woven layer during the felting process described below.
[0062] In another preferred embodiment, the nonwoven layer comprises fibers having non-uniform length, wherein the fibers having non-uniform length have different linear mass densities, depending on the length of the fiber.
[0063] Fine fibers, such as for example 1.7 dtex fibers having a reduced cut length of 38 mm, can be blended with coarser fibers, such as for example 2.5 dtex fibers having a larger cut length of 63 mm to form the nonwoven batting layer wherein batting layer means the unfelted layer that will form the at least one nonwoven layer upon entanglement by felting.
[0064] The term dtex stated in the present description are known to the person skilled in the art.
[0065] It is believed that the better level of entanglement results from the fine and short fibers of the nonwoven batting layer being directed into the woven layer during the felting process, thereby extensively contacting the woven layer and providing high levels of entanglement.
[0066] On the other hand, the coarse fibers provide for the thickness and resilience properties of the nonwoven layer.
[0067] Prior to the felting process, the at least one woven layer is combined with at least one nonwoven batting layer in a felting loom to form a stack.
[0068] The resulting stack is then subjected to a felting process, which combines the woven layers and nonwoven batting layers into the fabric according to the present invention.
[0069] The stack may be felted by needle felting, waterjet felting, airjet felting or glue felting, thereby felting the at least one nonwoven batting layer to become the at least one nonwoven layer of the fabric according to the invention.
[0070] The felting process is a process known to the person skilled in the textile arts, and shall not be discussed in further detail for the sake of brevity.
[0071] Preferably, the number ratio between the at least one woven layer and the at least one nonwoven layers is in the range of 0.1 to 1.
[0072] More preferably, the number ratio between the at least one woven layer and the at least one nonwoven layers in the range of 0.1 to 0.9.
[0073] Most preferably, the number ratio between the at least one woven layer and the at least one nonwoven layers is smaller than 2/3 or 0.66, particularly is in the range of 0.1 to 0.66
[0074] The weight ratio between the at least one woven layer and the at least one nonwoven layer may be between 0.1 and 5.
[0075] Preferably, the weight ratio between the at least one woven layer and the at least one nonwoven layer may be between 0.1 and 3.
[0076] More preferably, the weight ratio between the at least one woven layer and the at least one nonwoven layer may be between 0.3 and 1.5.
[0077] Most preferably, the weight ratio between the at least one woven layer and the at least one nonwoven layer may be between 0.3 and 1.
[0078] The total amount of layers, consisting of the sum of the number of woven layers and the number of nonwoven layers, can be from 2 to 10, preferably from 2 to 6 and more preferably from 2 to 4.
[0079] Most preferably, the total amount of layers, consisting of the sum of the number of woven layers and the number of nonwoven layers is 2, while at the same time having a number ratio of 1/2 or 0.5.
[0080] The woven layers of the fabric according to the present invention enable the fabric to be sewn into or between ballistic packs or at the backface of an anti-ballistic systems. One advantage of the fabric according to the present invention is that during extensive periods of wearing, the woven fabric layer holds finished material tightly in place, because the woven fabric layer has an regular structure that prevents the formation of clearances.
[0081] If the fabric would only be made of a nonwoven felt layer and were subsequently sewn to the back-face of or into an anti-ballistic system, the nonwoven layer would give way around the stitches and form clearances that would negatively affect the function of the felt.
[0082] The fabric according to the present invention provides multiple advantages over previously used solutions for reducing the likelihood of ricochets which are commonly used as inner lining material in anti-ballistic systems, such as polyurethane foams.
[0083] The fabric according to the present invention confers the benefits of a polyurethane foam layer, which are resilience and a cushioning effect that reduce the likelihood of ricochets, but without suffering from its shortcomings.
[0084] A disadvantage of polyurethane foams is that they get easily damaged when subjected to the deformation that occurs during a ballistic event.
[0085] During a ballistic event, the material surrounding the point of impact is pushed back into a cone shape by the projectile. Depending on the velocity and caliber of the projectile, the depth of the cone deformation can be considerable.
[0086] The deformation rips the polyurethane foams apart and/or causes cracks to form in the polyurethane foam.
[0087] However, the fabric according to the present invention does not rip apart easily as it comprises ballistic grade fibers.
[0088] The presence of ballistic grade fibers in the fabric according to the present invention confers anti-ballistic properties to the fabric.
[0089] Polyurethane foams, on the contrary, offer no ballistic protection.
[0090] When a projectile such as a fragmenting bullet enters the protective layer of an anti-ballistic system, the fragmenting bullet forms a multitude of small, irregularly shaped fragments that are usually stopped by the anti-ballistic layer (the pack) of the anti-ballistic system. However, some of these fragments can penetrate the anti-ballistic layer (the pack) and cause considerable damage to the wearer.
[0091] The fibers used in the fabric according to the present invention have a high tensile modulus and a high tenacity that confer ballistic protection to the fabric in addition to the cushioning effect that reduces the likelihood of ricochets.
[0092] In general, the protective action of a given fabric depends on how much fibers contact a projectile. The felts of the present invention have a high areal density of fibers. They are thus able to considerably slow down or even stop fragments of projectiles that may pass through the actual ballistic pack.
[0093] In a further embodiment, the fabric according to the present invention can be affixed in between the individual layers of a ballistic pack to reduce the occurrence of ricochets in ballistic events.
[0094] The fabric according to the present invention can be affixed by sewing, crimping, clinching, glueing, nailing and/or combinations therof.
[0095] Preferably, the fabric according to the present invention is affixed by sewing.
[0096] The fabric according to the present invention can be affixed in between an equal or nonequal number of individual layers of the ballistic pack.
EXAMPLES
[0097] Example 1
Preparation of a Laminated Para-aramid Woven Layer
[0098] Poly-p-phenylene terephtalamide yarns having a linear density of 1100 dtex were woven into a plain weave fabric having 8.5 ends/cm (warp) and 8.5 ends/cm (weft) and were subsequently laminated with a ionomer film having a thickness of 55 μm.
[0099] The ionomer was a copolymer of ethylene and 19 wt-% MAA (methacrylic acid), wherein 45% of the available carboxylic acid moieties were neutralized with sodium cations (product supplied by E. I. du Pont de Nemours and Company, Wilmington, Del. under the trademark Surlyn®).
[0100] Poly-p-phenylene terephtalamide yarns are commercially available from E.I. du Pont de Nemours and Company (Wilmington, USA) under the trade name Kevlar® 1K1533.
[0101] The laminated para-aramid woven layer is commercially available from E.I. du Pont de Nemours and Company (Wilmington, USA) under the trade name Kevlar® AS 400 S 802.
Example 2
Preparation of a Fabric According to the Invention and Assembly Into a Ballistic Pack
[0102] A layer of a nonwoven fabric batting consisting of 75% by weight of poly-p-phenylene terephtalamide fibers, relative to the total weight of the nonwoven fabric, and 25% by weight of polyethylene terephthalate, relative to the total weight of the nonwoven fabric, having a total areal weight of 335 g/m2 was superposed on a layer of a plain weave para-aramid fabric, having an areal weight of 185 g/m2, to form a stack. The stack was then subjected to needle felting consolidation to obtain a thickness of about 2.72 mm, measured according to ISO 9073:2. The resulting felted material was tested according EN 29073-3 for tensile strength and according to DIN 53859-4 for tear strength. The results are summarized in Table 1.
[0103] The resulting fabric according to the present invention was then positioned between 16 layers of para-aramid laminated fabric (AS 400 S 802) and then 14 layers of para-aramid laminated fabric (AS 400 S 802) to form a multilayered ballistic pack having a core layer consisting of the fabric according to the present invention and a total areal weight of 7.756 kg/m2. The obtained multilayered ballistic pack was then conditioned at room temperature for 24 hours before being subjected to several tests
[0104] During the tests, the multilayered ballistic pack was oriented such as to position the 16 layers of the para-aramid laminated fabric (AS 400 S 802) on the strike face.
[0105] The plain weave para-aramid woven layer is commercially available from E.I. du Pont de Nemours and Company (Wilmington, USA) under the trade name Kevlar® ST 802.
Example 3
Knife and Spike Resistance Test
[0106] The stack manufactured according to example 2 was subjected to knife and spike resistance according to the HOSDB Body armour Standards for UK Police (2007) Part 3 from the United Kingdom Home Office, Scientific Development Branch, using a P1 B test blade having 24 and 36 joules of attacking energy, a backing material made of foam and a number of 5 drops of the same blade.
[0107] Results were recorded and are summarized in Table 2.
Example 4
Ballistic Test
[0108] Ricochet occurrence was tested on the stack manufactured according to example 2, according to HOSDB HG2 using 0.357 Magnum SJHP Remington cartridges for both 0° shots and 30° angle shots. A ricochet was considered not to have occurred when the bullet remained stuck in the multilayered ballistic pack, instead of being redirected. The projectiles 0.357 Magnum, Remington SPFN, R357M3 had a velocity of about 455 m/s. The occurrence of ricochets was recorded and results are summarized in Table 3.
Comparative Example 1
Preparation of the Comparative Fabric of Prior Art and Assembly Into Pack
[0109] The comparative stack was a 33-layer multilayer ballistic pack, consisting of 33 layers of laminated para-aramid fabric (AS 400 S 802). The 33 layers were assembled together to obtain a multilayer ballistic pack having essentially the same areal weight (7.965 kg/m2) as the pack according to Example 2.
[0110] The obtained multilayered ballistic pack was then conditioned at room temperature for 24 hours before being subjected to several tests.
[0111] Poly-p-phenylene terephtalamide yarns are commercially available from E.I. du Pont de Nemours and Company (Wilmington, USA) under the trade name Kevlar® 1K1533.
[0112] The laminated para-aramid fabric is commercially available from E.I. du Pont de Nemours and Company (Wilmington, USA) under the trade name Kevlar® AS 400 S 802.
Comparative Example 2
Knife and Spike Resistance Test
[0113] The comparative stack manufactured according to comparative example 1 was subjected to knife and spike resistance tests according to example 3. Results were recorded and are summarized in Table 2.
Comparative Example 3
Ballistic Test
[0114] The comparative stack manufactured according to comparative example 1 was subjected to ballistic tests according to example 4.
[0115] The occurrence of ricochets was recorded and results are summarized in Table 3.
[0000]
TABLE 1
Test method
Unit
Value
Weight
DIN EN
g/m2
521
29073P1
Thickness
DIN EN ISO
mm
2.72
9073P2
Tensile
DIN EN
long.
N/5 cm
963
strength
29073P3
cross
N/5 cm
1655
Tearing
DIN
long
N
250
strength
53859T4
cross
N
362
[0116] Table 1 shows results of tests for determining mechanical properties of the felted fabric. As can be seen the felt has good mechanical properties. The woven layer that is felted together with the batting layer during the felting process confers additional mechanical stability to the felted fabric according to the present invention.
[0000]
TABLE 2
Pack
Energy
Blade
density
Protection
Level
penetration
Pack description
(kg/m 2 )
Backing
level
(Joule)
Blade
(mm)
33*AS400S
7.956
Foam
KR1/E1
24
P1B
0, 0, 0, 0, 0
16*AS400S +
7.756
Foam
KR1/E1
24
P1B
0, 0, 0, 0, 0
FF520 + 14*AS400S
33*AS400S
7.956
Foam
KR1/E2
36
P1B
10, 10, 8, 9, 9
16*AS400S +
7.756
Foam
KR1/E2
36
P1B
9, 12, 11, 10, 9
FF520 + 14*AS400S
[0117] Table 2 shows the results of tests according to the HOSDB Body armour Standards for UK Police (2007) Part 3 from the United Kingdom Home Office, Scientific Development Branch, using a P1 B test blade having 24 and 36 joules, respectively. 5 knive drops were performed and recorded on the comparative fabric (33*AS400S) and the fabric according to the invention (16*AS400S+FF520+14*AS400S). The blade penetration corresponding to each knife drop is shown in millimeters, separated by commas. Both fabrics comply with requirements of the KR1/E1 and KR2/E2 protection levels.
[0000]
TABLE 3
Pack
Pack
Complete,
weight
density
Angle
Trauma
Average
partial or
(g)
(kg/m 2 )
Backing
Bullet
(°)
(mm)
(mm)
slip′out
33*AS400S
1273
7956
Plastiline
357
30
14
13.5
slip′out
Roma
Remington
SJHP
33*AS400S
1273
7956
Plastiline
357
30
13
13.5
slip′out
Roma
Remington
SJHP
16*AS400S +
1241
7756
Plastiline
357
30
12
13
Held
FF520 + 14*AS400S
Roma
Remington
SJHP
16*AS400S +
1241
7756
Plastiline
357
30
14
13
Held
FF520 + 14*AS400S
Roma
Remington
SJHP
[0118] Table 3 shows the results of the HOSDB HG2 test s using 0.357 Magnum SJHP Remington cartridges for two 30° angle shots. The control fabric (33*AS400S) did not retain the bullet, which means that a ricochet occurred in 2 out of 2 cases. The fabric according to the invention (16*AS400S+FF520+14*AS400S) did hold the bullet inside, so there was no ricochet that occurred in 2 out of 2 cases.
[0119] As can be seen from Table 3, the fabric according to the present invention offers a higher degree of protection against ricochet occurrence. However, it still offers a comparable degree of protection against projectiles at 0° when compared to a control fabric having about the same weight (data not shown). It is believed that the higher degree of protection against ricochets arises from the core layer made of a felt fabric.
[0120] The mechanical properties of the felted fabric allow the fabric to maintain its structural integrity in the case of a ballistic event. The mechanical properties derive at least in part from the woven layer that is felted into the batting during the felting process and which prevents the felted fabric to rip or give way in the case of a ballistic event.
|
The present invention relates to a fabric comprising at least one woven layer and at least one nonwoven layer, wherein the number ratio between the at least one woven layer and the at least one nonwoven layer is in the range of 0.1 to 1. The fabric according to the present invention can particularly be used in the manufacture of ballistic vests, hard and soft armor, stab and knife protection systems, and anti-ballistic systems, and they provide a highly reduction of likelihood of ricochets using such systems.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns an asynchronous digital correlator and demodulators having a correlator of this type.
This correlator enables the processing of a complex signal formed by a first carrier and a second carrier, I and Q, modulated by a pseudo-random function to spread the spectrum and modulate it by an M-ary orthogonal code. A complex signal of this type results, for example, from a PSK, MSK or APSK type modulation with spectrum spreading, and modulation by Walsh codes. The demodulation of a signal of this type makes it necessary to compress its spectrum by means of a pseudo-random function identical to the one thathas been used to spread this spectrum, and then consists in recognizing a transmitted item of data in identifying the modulating among M possible codes. These two operations can be done by means of a correlator.
2. Description of the Prior Art
At present, there are no correlators that can be used to correlate a complex signal with a reference signal on a great length, such as one of 256 chips, while having, at the same time, a structure that is simple enough to enable the making of a demodulator which can be integrated in a single integrated circuit. Prior art types of correlators are designed for frame recognition rather than for demodulation. A first type of prior art correlator device, commercially available in the form of an integrated circuit, works only on 64 chips. A second known type of correlator, commercially available in integrated circuit form, works on 256 chips and has no intermediate outputs giving partial correlation values relating to a smaller number of chips.
Known correlators have a large number of 64-chip or 256-chip correlators: they have a chain of four 64-chip correlators, or one 256-chip correlator for the carrier I; and a chain of four 64-chip correlators or one 256-chip correlator for the carrier Q, for each of the M-ary codes. Since number M may be equal to 16, the number of integrated circuits may reach 128.
SUMMARY OF THE INVENTION
An aim of the invention, therefore, is to propose an asynchronous digital correlator that enables the making, notably, of simpler demodulators which may possibly be integrated in a small number of integrated circuits or even in a single integrated circuit. An object of the invention is a correlator with a systolic structure wherein the computations for the carrier I and the carrier Q are temporally multiplexed, said structure being divided in such a way that it gives values of the modulus of a partial correlation function computed on far smaller lengths than the total correlation length, to enable recognition of the codes by means of a relatively simple arithmetic code computing linear combinations of these moduluses.
According to the invention, there is proposed an asynchronous, digital correlator to correlate a binary reference signal (REF) with a complex signal formed by a first carrier and second carrier (I, Q), modulated by a pseudo-random function and by an M-ary orthogonal encoding, said two carriers being sampled and digitized, said correlator comprising:
a multiplexer to transmit, alternately, a value (I) of the first carrier, and a value (Q) of the second carrier, with a period equal to half their sampling period;
a first digital filter adapted to the pseudo-random function (PN), comprising a chain of registers to store L consecutive bits of the reference signal (REF) and a chain of M correlation macro-cells receiving the sequence of multiplexed values of the first carrier and the second carrier (I and Q), each macro-cell computing the value (CPI0,..., CPI15) of a first function, called a partial correlation function, between N bits of the reference signal and N values of the first carrier (I), and then computing the value (CPQ0,..., CPQ15) of a second function, called a partial correlation function, betweenn N bits of the reference signal and N values of the second carrier (Q), N being equal to L/M;
a second digital filter adapted to at least one of the M-ary encoding codes and having computation means to determine the value of at least one linear combination of the values of the first functions of partial correlation (CPI0,... CPI15); and then to determine the value of a linear combination of the values of the second functions of partial correlation (CPQ0,..., CPQ15), the coefficients of the linear combination being unchanged and being equal to ±1; and having means to demultiplex the values of the two linear combinations (FIi, FQi), and to determine the modulus (Fi) of a vector having, as its components, the values of these two linear combinations (FIi, FQi).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and other details will emerge from the following description and the accompanying figures, of which:
FIG. 1 is a block diagram of an exemplary embodiment of a prior art demodulator;
FIG. 2 is a block diagram of an exemplary embodiment of a first type of demodulator including a correlator according to the invention;
FIG. 3 shows a more detailed block diagram of a correlation macro-cell constituting this exemplary embodiment;
FIGS. 4 and 5 are partial diagrams of this macro-cell;
FIG. 6 is a block diagram of a computing device belonging to this exemplary embodiment;
FIG. 7 shows a block diagram of an exemplary embodiment of a second type of demodulator including a correlator according to the invention;
FIG. 8 shows a block diagram of a computing device belonging to this embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The prior art demodulator, shown in FIG. 1, has:
two input terminals 1 and 2, respectively receiving the digital values of two carriers, I and Q, which are modulated by a pseudo-random function and by an M-ary orthogonal code, and which are sampled and digitized;
a Walsh codes generator 13, having 16 outputs, respectively giving 16 binary signals corresponding to 16 Walsh codes, and referenced W0, ...W15;
a generator 14 giving a pseudo-random binary signal PN, identical to the one that has been used to spread the spectrum of the two carrier waves I and Q;
sixteen chains of correlators 100 to 115 to correlate the carrier I with the sixteen reference signals, each chain such as the chain 100 having four correlators 5 to 8, each operating on 64 chips and being formed by an integrating circuit;
sixteen chains of correlators, 200 to 215, to correlate the carrier Q with the 16 reference signals, each chain being identical to the chain 100;
a set 9 of sixteen devices of the modulus of a two-component vector;
a device 10 for the detection of the maximum among 16 values.
It is also possible to form each of the chains 100 to 115 and 200 to 215 by means of a single correlator integrated circuit working on 256 chips.
The chains of correlators 100 to 115 respectively give digital values F10 to F115, which are the values of the functions of correlation of the carrier 1, respectively with the sixteen reference signals, on 256 chips. The outputs of the chains of correlators, 200 to 215, respectively give values FQ0 to FQ15 which are the values of the functions of correlation of the carrier Q, respectively with the sixteen reference signals on 256 chips. Each of the computing devices of the set 9 computes the modulus of a vector having, as its components, a value of the function of correlation of the carrier 1 with a reference signal corresponding to a code and a value of the function of correlation of the carrier Q with the same reference signal. For example, a computing device of the set 9 computes the square root of F10 2 +FQ0 2 .
The set 9 gives the sixteen values, F0 to F15 of the moduluses of the functions of correlation of the complex signal formed by the carrier I and the carrier Q, correlated with the sixteen reference signals. The sixteen vales F0 to F15 are compared with one another by the device 10. This device 10 gives an output terminal 19 the index j of the correlation function with the greatest modulus. This index j designates the code that modulates the carriers I and Q. The device 10 also gives the value Fj of the modulus to a output terminal 20.
This prior art demodulator is complex and bulky because there are 32 correlation chains in parallel.
FIG. 2 is a block diagram of an exemplary embodiment of a demodulator of a first type, having a correlator according to the invention. This demodulator has five sub-units:
a multiplexer 33 to transmit, alternately, a value of the carrier I and a value of the carrier Q, at a rate which is twice their sampling frequency;
a first digital filter 31, adapted to the pseudo-random function, which spreads the spectrum of the carriers I and Q;
a second digital filter 35, matched to the sixteen Walsh codes which can modulate the carriers I and Q to transmit a piece of data; this latter filter computes sixteen values of moduluses of correlation functions, F0 to F15, corresponding to sixteen Walsh codes;
a device 34 selecting the maximum among these sixteen values, and giving the maximum value Fj to an output terminal 28 and giving the index j, which identifies the modulating code, at an output terminal 25.
The first digital filter 31 has:
a generator 24 giving a pseudo-random signal PN, identical to the one used to spread the spectrum of the complex signal to be demodulated;
a chain of shift registers 40, having a total of 256 stages;
a set 41 of sixteen independent registers, each giving, in parallel, sixteen bits and their complements;
a chain 42 of sixteen correlation macro-cells, each computing a value of a partial correlation function on sixteen bits;
a multiplexer 23 having two data inputs, one output and one control input.
The pseudo-random signal PN is a reference signal, REF, for demodulation. The bits of the signal REF are stored and shifted, one by one, in the chain of registers 40 under the control of a clock signal CKR, at the rate at which they are created by the generator 24. The signal CKR is given to an input terminal 25 by a standard generator of clock signals, not shown in the figure. The chain of registers 40 stores 256 bits of the reference signal. The content of these registers is transferred as a block into the chain of registers 40, under the control of a clock signal, LOAD, in synchronism with the clock signal CKS. The period of the signal LOAD is, for example, 10 mS, while that of CKR is, for example, 30 nS. The clock signal LOAD is given to an input terminal 26 by a standard generator of clock signals, not shown in the figure.
The multiplexer 23 is a multiplexer with two inputs and one output. Its inputs are respectively connected to input terminals 21 and 22, receiving the carriers I and Q to be demodulated, in the form of digital values encoded on four bits, the negative values being encoded in the two's complement system. The output of the multiplexer 23 gives a value formed by four bits: X0, ..., X3 to an input of the chain 43, with sixteen correlation macro-cells. The multiplexer 23 and the correlation macro-cells are controlled by a clock signal CKS at a rate which is twice the sampling rate of the carriers I and Q. The clock signal CKS is given to an input terminal 27 by a standard generator of clock signals, not shown in FIG. 2.
The first correlation cell in the chain 42 is a cell 43 which receives the four bits X0, ..., X3, alternately representing a value of the carrier I and a value of the carrier Q, and which receives 32 bits R0, ..., R15, R0 ..., R15, representing sixteen bits of the reference signal stored in a register of the chain 41. The macro-cell 43 retransmits the four bits X0, X3 to a following macro-cell, with a delay respectively equal to 16, 17, 18, 19 periods of the clock signal CKS, and respectively gives a value CPI0 of the partial correlation function corresponding to the signal I, then a value CPQ0 of the partial correlation function corresponding to the signal Q.
Each macro-cell is identical to the macro-cell 43 and has: a sixteen bit input receiving sixteen successive bits of the reference signal and sixteen complementary bits; a four bit input receiving a value of the sequence of multiplexed values of the carriers I and Q; an output retransmitting the four bits of this value to the following macro-cell, with a delay respectively equal to 16, 17, 18, 19 periods of the clock signal CKS; and an eight bit output successively giving the value of a first partial correlation function, corresponding to the carrier I, then the value of a second partial correlation function corresponding to the carrier Q, said output being connected to an input of the linear combinations computing device 32.
The chain of correlators 42 has 16 eight-bit outputs respectively giving sixteen values of partial correlation functions: CPI0, CPI15, corresponding to the carrier I; and then respectively giving sixteen values of partial correlation functions: CPQ0, CPQ15, correspondig to the carrier Q.
The filter 35 has: a device 32 for the computation of linear combinations and a demultiplexing and modulus computing device 33. The device 32 computes, on 256 chips, the value FIi of the function of correlation of the carrier I with the pseudo-random signal PN and with each Walsh code Wi, for i=0 to 15; and then computes, on 256 chips, the value FQi of the function of correlation of the carrier Q with the pseudo-random signal PN and each Walsh code Wi for i=0 to 15, in combining the values CO10, ..., CPI15., respectively CPQ0, CPQ15 of the partial functions of correlation, on sixteen chips of the carrier I and the carrier Q respectively, with the reference signal REF. It must be noted that, in this demodulator, the reference signal REF is formed solely by the pseudo-random signal PN, contrary to the reference signals used in the prior art device shown in FIG. 1.
The device 32 is a "pipeline" structure device controlled by the clock signal CKS. It has two eight-bit outputs, respectively giving values FI0, ..., FI15 which are values of the function of correlation of the signal I with the reference signal and with the sixteen Walsh codes respectively; then respectively giving values FQ0, ..., FQ15 which are values of the function of correlation of the signal Q with the reference signal and with sixteen Walsh codes respectively.
The device 33 computes the modulus Fi of the function of correlation, on 256 chips, of the complex signal to be modulated wth the pseudo-random signal and with each Walsh code Wi for i=0 to 15.
The device 33 receives and then demultiplexes the values FIi and FQi, for i=0 to 15, and computes the modulus Fi of a vector having, as its component, FIi and FQi, in determining the square root of FIi 2 +FQi 2 . The device 33 has sixteen outputs giving, respectively, the values F0, F15, to sixteen inputs of the device 34. The device 34 selects the greatest value, marked Fj, among the values Fi for i=0 to 15, and selects the corresponding index j. This index j designates the Walsh code which is detected by the demodulator. In other words, it designates the piece of data which is transmitted by the signals I and Q. The devices 32, 33 and 34 are also controlled by the clock signal CKS.
FIG. 3 shows a block diagram of the macro-cell 43. The other macro-cells of the chain 42 are identical to the macro-cell 43. Each macro-cell has a systolic structure formed by a matrix of 128 identical cells working on a single bit. This matrix has eight rows of sixteen cells. The first cell 49, of the first row of cells, receives a bit X0 of a first value from the carrier I or Q. This bit X0 is propagated from one cell to another of the first row, each delay being equal to a clock signal CKS period. The first cell of the second row of the matrix receves the bit Xl with a delay equal to the clock signal CKS period, with reference to the bit X0. This delay is got by a D-type flip-flop 57. The cells of the second row retransmit the bit Xl, each with a delay equal to a clock signal CKS period.
The first cell of the third row receives the bit X2 with a delay equal to two clock signal CKS periods: this delay is obtained by a set 58 formed by two D-type flip-flops. The cells of the third row retransmit the bit X2, each with a delay equal to one clock signal CKS period. The first cell of the third row receives the bit X3 with a delay equal to three clock signal CKS periods. This delay is got by a set 59 of three D-type flip-flops. The cells of the third line retransmit the bit X3,. each with a delay equal to a clock signal CKS period.
The first cell of the fourth row receives the bit X3 with a delay equal to three clock signal CKS periods: this delay is got by a set 59 of three D-type flip-flops. Each cell of the fourth row retransmits the bit X3 with a delay equal to a clock signal CKS period.
The first cell of the fifth line receives the bit X3 with a delay equal to four clock signal CKS periods. This delay is got by a set 60 of four D-type flip-flops. Each cell of the fifth line retransmits the X3 with a delay equal to a clock signal CKS period. The first cell of the eighth row receives the bit X3 with a delay equal to seven periods of the clock signal CKS. This delay is obtained by a set 63 of seven D-type flip-flops. Each cell of the eighth row retransmits the bit X3 with a delay equal to a clock signal CKS period. The first cell of the sixth line receives the bit X3 with a delay equal to five clock signal CKS periods. The delay is got by a set 61 of five D-type flip-flops. Each cell of the sixth row retransmits the bit X3 with a delay equal to a clock signal CKS period. The first cell of the seventh row receives the bit X3 with a delay equal to six periods of the clock signal CKS. This delay is got by a set 62 of six D-type flip-flops. Each cell of the seventh row retransmits the bit X3 with a delay equal to one clock signal CKS period. The last cell of each line therefore gives one of the bits X0, Xl, X2, X3, with a delay which depends on the order of the row, to an input of the following macro-cell in the chain 42.
Each cell has an input receiving one partial correlation result bit, given by an output, called a partial correlation result output, belonging to the next cell. In this example, the capacity of a macro-cell is never exceeded. Consequently, there is no provision for transmitting result bits from one macro-cell to another. The inputs of the partial correlation result bits of the last cells respectively receive bits C0,..., C7 having null value.
All the cells of the first column, all the cells of the second column, etc., respectively receive the bits R15 and R15,..., RO and RO, of the reference signal. A carry-over input, of the first cell of the first column, receives the bit R15, and gives a carry-over bit to the next cell in the same column. The next cell, in turn, gives a carry-over bit to a next cell, each time with a delay equal to a clock signal CKS period. Similarly, in the following columns, a carry-over input of the first cell respectively receives R14, ..., RO, and the cells of the following rows give carry-over bits to the cells of the following row.
The partial correlation result output of each cell of the first column gives a correlation result bit on 16 chips. The first cell of the first row gives a bit SO, through a set 50 of seven D-type flip-flops giving a delay equal to seven clock signal CKS periods. The first cell of the second row gives a bit S1 through a set 51 of six D-type flip-flops giving a delay equal to six periods of the clock signal CKS. The first cell of the third row gives a bit S2, through a set 52 of five D-type flip-flops giving a delay equal to five clock signal CKS periods. The first cell of the fourth row gives a bit S3 through a set 53 of four D-type flip-flops, giving a delay equal to four periods of the clock signal CKS. The first cell of the fifth row gives a bit S4 through a set 54 of three D-type flip-flops giving a delay equal to three clock signal CKS periods. The first cell of the sixth row gives a bit S5 through a set 55 of two D-type flip-flops giving a delay equal to two clock signal CKS periods. The first cell of the seventh row gives a bit S6 through a D-type flip-flop 56 giving a delay equal to one clock signal CKS period. The first cell of the eighth row directly gives a bit S7.
FIG. 4 is a more detailed block diagram of one of the cells 50 of the correlation macro-cell 43. The cell 50 has:
an exclusive-NOR gate 70 with a first bit receiving reference signal bit R, said bit being further transmitted without modification to the next cell in the same column, and having a second input receiving a bit Xin with a value of carrier I or carrier Q;
an adder 71 having a first input which receives a bit Sin which is a partial correlation result given by the following cell on the same row and having a second input connected to the output of the gate 70;
a first D-type flip-flop 72, having an input receiving the bit Xin; having a control input receiving the clock signal CKS; and having an output giving a bit Xout which is the preceding value of the bit Xin to the next flip-flop on the same row;
a second D-type flip-flop 73 having an input connected to the output of the adder 71; having a control input receiving the clock signal CKS; and having an output giving a bit Sout which is a partial correlation result constituting a bit of the value of one of the functions of partial correlation of the carriers I and Q;
a third D-type flip-flop 74 having an input connected to a carry-over output of the adder 71; having a control input receiving the clock signal CKS and having an output giving a bit Cout which is the carry-over for the next cell in the same column;
FIG. 5 illustrates the operation of a row of the matrix of cells of the macro-cell 43 for the computation of the value of the bit S5 of the function of partial correlation of the carrier I or Q. This row consists of sixteen cells 79, 78, 77,..., 76. At the instant considered, the first cell 79 receives the bit X (20) given by the output of the set 60 of four D-type flip-flops. At the same instant, this set 60 receives a bit X (24) at its input. The bits X are successively retransmitted by each of the cells of the row in adding, each time, a delay equal to a clock signal CKS period. Consequently, the cells of the row respectively receive the bits X(20), X(19), X(18), X(17) X(5), at the instant considered. These values are respectively applied to the exclusive-NOR gates of each of the cells to obtain the product of these bits with the bits R15,..., R0 of the reference signal. In each cell, the result of the product is applied to the first input of the adder which adds to it the value of a carry-over bit given by the homologous cell in the preceding row and which also adds to it the partial correlation result bit given by the next cell on the same row. For example, in the cell 79, the carry-over bit C15 is added to the result of the product X(20).R15 and to the bit Sout 14.
The second input of each adder receives a partial correlation result bit given by the output of the adder of the following cell through a D-type flip-flop. Each flip-flop further gives a carry-over bit, C15',..., C0' respectively, to the cells of the following row. The output of the adder of the first cell 79 gives the value of the bit S5 through a D-type flip-flop that its cell has, and through the set 54 of three D-type flip-flops giving a delay equal to two periods of the clock signal CKS. The value of the bit S5 is thus equal to the sum of Ri X(i+5)+Ci, for i=0 to 15.
FIG. 6 shows a block diagram of the linear combinations computing device 32, successively determining a value of a first partial correlation function for the signal I, and then a value of a second partial correlation function for the signal Q, for the 16 Walsh codes. The device 32 has 16 inputs, respectively receiving CPI0,..., CPI15 in this order; then CPQ0,..., CPQ15 in this order. This device 32 has a "pipeline" structure comprising four rows of operators, each operator computing a linear combination of two intermediate values determined by two operators of the preceding row. Each operator is: either an adder followed by a register or a subtractor followed by a register. The registers are controlled by the clock signal CKS.
The first row is formed by pairs of operators: an adder and a subtractor, taken in this order, and respectively computing the sum and the difference of two values, applied respectively to two neighbouring inputs of the device 32.
The operators of the second row form four identical groups, each having two adders and then two subtractors. Each of the adders adds the value given by the operator located on top of it and the intermediate value given by the operator located two ranks further on in the row above. Each subtractor computes the difference between the intermediate value given by the operator located on top of it and the intermediate value given by the operator located two ranks before it on the previous row.
The operators of the third row form two identical groups, each having four adders and then four subtractors. Each adder computes the sum of the intermediate value given by the operator located on top of it and the intermediate value given by the operator located four ranks further on in the previous row. Each subtractor computes the difference between the intermediate value given by the operator on top of it, and the intermediate value given by the operator located four ranks before it on the previous row.
The fourth row of operators is formed by eight adders and then eight subtractors. Each adder computs the sum of the intermediate value given by the operator located on top of it and the intermediate value given by the operator located eight ranks further on in the previous row. Each substractor computes the difference between the intermediate value given by the operator on top of it, and the intermediate value given by the operator located eight ranks before it on the previous row. The outputs of the eight adders and eight subtractors of the fourth line respectively give the values FI0, FI15, FI7, FI8, FI3, FI12, FI4, FI11, FI1, FI14, FI6, FI9, FI2, FI13, F15, FI10 of the function of correlation of the carrier I, and then give the values FQ0, FQ15, FQ7, FQ8, FQ3, FQ12, FQ4, FQ11, FQ1, FQ14, FQ6, FQ9, FQ2, FQ13, FQ5, FQ10 of the function of correlation of the carrier Q.
FIG. 7 shows a block diagram of an exemplary embodiment of a second type of demodulator which also has a correlator according to the invention. The elements identical to the elements of the first exemplary embodiment carry the same reference but have the index '. This exemplary embodiment includes a first digital filter 88 including, notably: two chains of registers 40 and 41', a multiplexer 23'and a chain 32'of correlation macro-cells identical to the above-described elements.
The reference signal REF' is different from the signal REF. It is given by the output of an exclusive-OR gate 82, which achieves the product of a pseudo-random signal PN and a Walsh code signal Wi. A generator 80 gives the pseudo-random signal PN which is identical to the one that has been used to modulate the signals I and Q to be demodulated. A generator 81 gives the Walsh code signal Wi. In this latter type of demodulator, the reference signal REF' is thus adapted to a Walsh code chosen from among the M possible codes. This particular feature enables the second filter adapted to the Walsh encoding.
The filtering adapted to the Walsh encoding is achieved by an adapted filter 89 comprising:
a linear combinations computing device 83,
a device 85 for demultiplexing, and for computing the function of correlation for the Walsh code Wi; and a device 84 for demultiplexing and for the computing of the function of correlation for another Walsh code Wh, which is related to the code Wi. The index h is related to the index i by the following relationship: h=M-i.
For example, if the generator 81 gives the Walsh code W0, the devices 85 and 84 respectively give the values F0 and F15 of the function of correlation, respectively for the Walsh code W0 and for the Walsh code W15. If the generator 81 gives the Walsh code W1, the outputs of the devices 85 and 84 respectively give the correlation functions F1 and F14, respectively corresponding to the Walsh code W1 and the Walsh code W14. The demodulator, therefore, at a given instant, can only detect two of the sixteen Walsh codes, but this is enough for certain applications and, at the same time, enables great simplification of the computing device 83 as will be seen further below.
The computing device 83 has 16 eight-bit inputs respectively connected to 16 outputs of the chain 42' of correlation macro-cells. These inputs respectively receive the values CPI0',..., CPI15' of the functions of partial correlation of the carrier I with the reference signal and then the values CPQ0',..., CPQ15', of the functions of partial correlation of the carrier Q with the reference signal. The device 83 has two eight-bit outputs, respectively connected to an input of the device 85 to give it a value FIi, then a value FQi of the function of correlation of the carrier I and the carrier Q, respectively for the Walsh code Wi; and a second output connected to an input of the device 84 to give it a value FIh then a value FQh of the function of correlation of the carrier I and the carrier Q respectively for the Walsh code Wh.
The device 85 demultiplexes the values FIi and FQi, and then computes the modulus of a vector having these values as components. This modulus constitutes the value Fi of the function of correlation of the complex signal to be demodulated. The value Fi is given at an input of a device 90 for the detection of a maximum.
The device 84 demultiplexes the values FIh and FQh, then computes the modulus of a vector having these values as components. The value Fh of this modulus constitutes the value of the correlation function of the complex signal to be demodulated for the Walsh code Wh. The value Fh is applied to a second input of the device 90. The device 90 has two outputs, respectively connected to two output terminals 86 and 87 of the demodulator, to respectively give two values j and Fj which are, respectively, the index and the value of the greater of the two values Fi and Fh. The value j which can be equal only to i or h, represents a transmitted piece of data. The devices 83, 84, and 85 are controlled by a clock signal CKS', at a rate which is twice the sampling rate of each of the carriers I and Q. The clock signal CKS' is given by a standard generator of clock signals, not shown in FIG. 7.
FIG. 8 is a block diagram of the linear combinations computing device 83. It has a pipeline structure comprising four lines of operators which are all adders, except one which is a subtractor. Each operator is followed by a register which is controlled by the clock signal CKS' and is not shown in the figure.
The first row of operators has four adders, 91 to 94, each achieving the sum of two values of partial correlation functions of even rank, and has four adders 98 to 101 each achieving the sum of two values of partial correlation functions of odd rank.
The second row of operators has an adder 95 that adds up the intermediate values given by the operators 91 and 92, an operator 96 adding up the intermediate values given by the adders 93 and 94, an adder 102 adding up the intermediate values given by the adders 98 and 99, and an adder 103 computing the sum of the intermediate values given by the adders 100 and 101.
The third row has an adder 97 which computes the sum of the intermediate values given by the adders 95 and 96; and includes an adder 104 which computes the sum of the intermediate values given by the adders 102 and 103.
The fourth row has an adder 105 which computes the sum of the intermediate values given by the adder 97 and by the adder 104; and has a subtractor 106 which computes the difference between the intermediate value given by the adder 97 and the intermediate value given by the adder 104.
It can be easily verified that the adder 105 thus gives a value equal to the sum of all the values of functions of partial correlation applied to the inputs of the device 83, while the substractor 106 gives the value of the difference between the sum of the values of the functions of partial correlation having a even rank and the sum of the functions of partial correlation having an odd rank. The output of the adder 105 is the output of the device 83 which gives the value FIi, then the value FQi, of the function of correlation of the carrier I and the carrier Q, respectively, for the Walsh code Wi. The output of the subtractor 106 forms the output of the device 83 which gives the value FIh, then the value FQh, of the function of correlation of the carrier I and the carrier Q, respectively, for the Walsh code Wh.
As can be seen in the diagram of FIG. 8, the computing device 83 is simpler to make than the computing device 32 shown in FIG. 6. The second type of demodulator has a diagram which is simple enough for it to be integrated
entirely in a single integrated circuit, using a known technology enabling the etching of lines with a width of 1.25 microns. It therefore provides for far simpler making than is the case with the standard correlating devices described above.
The invention can be applied, in particular, to the making of MSK, PSK or OQPSK modulators, with spread spectrum and and M-ary orthogonal coding for aeronautical on-board equipment which has to be has compact as possible.
|
A demodulator to demodulate a complex signal formed by two carriers, in quadrature, the spectrum of which is spread by a pseudo-random signal, and which are modulated by an M-ary, Walsh, code comprises:
a chain of registers to store 256 bits of a pseudo-random signal;
a multiplexer to temporally multiplex the processing of the two carriers;
a chain of correlation macro-cells having a systolic structure enabling temporal multiplexing and having intermediate outputs providing for partial correlation values on 16 chips;
a device for the computation of linear combinations of the functions of partial correlation, to compute two functions of correlation corresponding to two carriers for each M-ary code;
a demultiplexing and computation device to compute the module of the function of correlation for each of the Walsh codes which may modulate the signal to be demodulated;
a device for the selection of the greatest value of the correlation functions and for the selection of the corresponding piece of data.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application No. PCT/HU01/00077 filed Jul. 9, 2001, designating the United States and claiming priority with respect to Hungarian Application No. P0002588 filed Jul. 7, 2000. The disclosures of both of the foregoing applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to integrated optical devices controllable fully by light comprising a protein as a material of non-linear optical property, and to complex integrated optical modules comprising the optical devices of the invention. The invention further relates to methods for carrying out logical operations and methods for the preparation of the ad-layer of the optical devices.
The optical device of the invention can be used in particular in the field of integrated optics, e.g. as a logical element, as an optical switch or as a sensor.
In the field of data processing or sensor technology optical systems (as opposed to the presently used type where the working basis is electrical) are generally believed to constitute the next generation with the promise of vastly improved performance in practically every aspect. The development of fundamental scientific knowledge and the required technology in the necessary fields forecasts the advent of revolutionary new devices either with direct applications or as building blocks of more complex systems.
At present, however, the level of the development of purely optical data processing devices is in its infancy; consequently, the development of highly complex systems seems not to be a task for the immediate future. Rather, the state of the art suggests a need for the testing of basic ideas, and finding the possibilities of basic classes of approaches.
Since the start of integrated electronics the expansion of development has been described by “Moore's law”: the density (performance) of integrated electronic circuits doubles about every 1.8 years. While this “law” has remained proven valid for a remarkable period of 30 years, there is a general perception that the evolutionary development has reached a limit. Molecular electronics combined with optical data processing is regarded as being among the most promising emerging alternative technologies.
Key solutions are expected to emerge on a new field of optics, called integrated optics. New type of logical circuits may be created from integrated optical devices (IOD) integrated on a small substrate as various optomodules. The fundamental unit of an integrated optical device is an optical waveguide. Via a prism or a grating coupler, light may be confined to a high refractive index, thin waveguide layer, the totally reflecting walls of which result in a phenomenon analogous to the quantum mechanical particle in a box. Here the walls are of finite height and thickness, hence the field is a standing wave within the box and evanescent beyond the walls, dying away exponentially. Only certain discrete modes (transversal electronic, TE and transversal magnetic, TM modes) can exist within the box that can be characterized by the Maxwell equations.
If the waveguide is coated with an applied medium (ad-medium) or preferably a thin film (or ad-layer) comprising a nonlinear optical (NLO) material, which (interacting with the evanescent part of the light beam) are capable of manipulating the light by changing one or more of their optical properties under the influence of an applied voltage or another light beam, the so obtained device can be utilized in integrated optics.
Intensive research is going on to seek the most suitable NLO materials that could meet the demanding requirements of applications, in particular high sensitivity accompanied with high stability [Service, R. F., (1995)].
The basis of operation is that the refractive index of the ad-layer changes according to an external perturbation.
Since the theory and measuring techniques for integrated optics are well-developed [see e.g. K. Lizuka: Engineering Optics (Springer-Verlag, Berlin, Heidelberg, 1987)], the main limitations are of a technical nature, namely to find the proper NLO materials for the particular applications envisaged.
In the field of integrated optics most frequently liquid crystals are used as NLO materials. Nevertheless, usually their electrooptical effect is utilized, that is light-control is carried out indirectly via photoelectronic converters (e.g. photodiodes) [see K. Lizuka: Engineering Optics (1987), above]. Up to the present, the art does not teach nor suggest fully light driven, integrated optical devices comprising protein as photochromic material. In particular, the art does not disclose the use of such photochromic proteins in ad-medium of integrated optical devices. Further, according to the art no disclosure of the manipulation of the propagating light in the waveguide by light controlled change of the refractive index of such ad-layers can be found. There exists a need, however, for such devices in the pertinent field of art.
The invention is based on the finding that a simple and reliable integrated optical device can be provided if an appropriate protein is used as an NLO material and an appropriate setup (arrangement), disclosed herein, is used.
An optical switch for optical fibres and working on a basis different from integrated optics is disclosed by Kobayashi Y. and Matsuda Y in EPA 0,433,901, wherein the use of a fulgide combined with a macromolecular polymer in optical fibres [mainly used in the field of telecommunication and having a significantly larger thickness than integrated optical (IO) waveguides] is described. Furthermore, in their device, though it works on the basis of changing the refractive index of the medium coating the fibre, a modulation event can take place only if the refractive index of the whole medium is nearly the same as that of the light coupling region. In EPA 0,532,014 [Hosoya, T. (1993)] an improved version of said switch is disclosed, in which the photosensitive material is placed between two waveguides. Again, precise setting of the refractive index of the medium carrying the photosensitive material is crucial.
Up until now the relating field of art has remained silent regarding the combination of photosensitive proteins and integrated optics.
During the past 10 years, several laboratories in the USA, Europe and Japan have worked on the development of parallel-processing devices, three-dimensional data-storage hardware and neural networks based on photosensitive proteins, in particular on bacteriorhodopsin (bR) [see, e.g., Parthenopoulos, D. A. and Rentzepis, P. M. (1989), Oesterhelt, D., Brauchle, C. and Hampp, N. (1991), Birge, R. R. (1992), Birge, R. R. (1994)]. The suggested applications so far have concentrated on optical data storage [Lewis A. et al, (1995), U.S. Pat. No. 5,470,690], sensor technology [Sakai T et al (1989) U.S. Pat. No. 4,804,834] and holography [Trantolo, D. (2000), WO 00/30084].
An optical switch utilizing the proton pump property of bR is disclosed in JP2310538 [Watanabe T., (1990)]. In U.S. Pat. No. 5,757,525 [Devulapalli V. G. L. N. R. et al., (1998)] an all optical device is described, in which three input radiation fields spatially overlapping on a bR sample are applied in a special geometry. Irradiation of the sample by a modulating radiation field results in a change in the bR state and consequently in the signal. No waveguides, so important in integrated optics, are used in either of the above solutions. In U.S. Pat. No. 5,618,64 [Hiroyuki T. and Norio S. (1997)] well defined partially permeable mirrors are used to control light transmission on the bR layer placed between the mirrors.
Neither of the above applications aimed and is not appears to be applicable in the field of integrated optics.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to provide a useful integrated optical device fully controllable by light, the device comprising protein as an NLO material.
The inventors found that if a film of photochromic (photosensitive) protein, is deposited on the surface of a waveguide the light having been coupled into the waveguide can be modulated by changing the molecular state (and thereby the refractive index) of the protein using a modulating light beam of an appropriate wavelength.
In an embodiment, if the light is coupled into the waveguide by a grating, the angle at which efficient coupling takes place largely depends on the refractive index of the material around the grating. Thus, if the layer of the protein is deposited directly above the grating the intensity of the coupled light is modulated by the light-induced molecular reactions, at a given coupling angle. Furthermore, the light beam traveling in the waveguide can be coupled out using a grating created in the layer comprising the photosensitive protein.
Thus, the invention relates to an integrated optical device fully controllable by light comprising protein as a material of non linear optical property. Preferably, the device is fully light driven.
Preferably, the integrated optical device of the invention comprises a waveguide, a coupling unit and, in contact with the waveguide, an ad-medium, preferably an ad-layer. The ad-layer comprises a photochromic protein and, preferably, a transparent, inert, film-forming material.
More preferably, the waveguide comprises a thin layer wave-carrying medium on a substrate (support) and the photochromic protein is a member of the bacteriorhodopsin family. As a coupling unit the waveguide may comprise a grating and, optionally, a prism. The grating can be a grating formed at the boundary interface of the waveguide and/or can be located in the ad-medium. The grating located in the ad-medium can be a transient grating or a permanent grating, the latter preferably being formed by holographic exposition.
In a further aspect, the invention relates to a use of any of the above integrated optical devices as an optically controlled optical switch or as an integrated optical logical element or any other integrated optical device.
The invention also relates to a complex integrated optical module comprising any optical devices of the invention as a logical element.
In a further aspect, the invention relates to a method for carrying out a simple logical operation using a fully light controllable integrated optical device comprising a protein as a material of non linear optical property, comprising
i) coupling light, into a waveguide
ii) changing an optical property of the protein located in an ad-medium of the waveguide by using a modulating or control light, preferably a modulating laser, and thereby affecting the propagation of light in the waveguide.
Preferably, the integrated optical device is any of the devices disclosed herein.
Preferably the refractive index of the protein in the ad-medium is changed by inducing a transition between at least two molecular states of the protein, e.g. by switching the protein from one stable or metastable state to another.
The protein preferably is a member of the rhodopsin family, highly preferably bacteriorhodopsin.
The incoupled light is preferably a monochromatic light, more preferably a laser beam.
In a further embodiment
i) in the resting state light is not coupled in, then
ii) coupling in is achieved by changing the refractive index the ad-layer by using a modulating or control light.
A further possibility is coupling out the light traveling in the waveguide.
Thus, in a further preferred embodiment for coupling light in and/or out a grating at the boundary surface of the ad-layer and/or a transient grating in the ad-medium and/or a permanent grating in the ad-medium, preferably prepared by holographic exposition, is used. The holographic exposition is preferably holographic bleaching.
For coupling light in and/or out a prism also can be used.
In a highly preferred embodiment
i) the monochromatic light is coupled into the waveguide using a grating in a well defined angle and
ii) the light is modulated in the waveguide by changing the refractive index in the part of the ad-layer covering the grating.
In a further aspect the invention relates to a method for the preparation of an integrated optical device of the invention, comprising
i) coating the surface of a waveguide with an ad-medium, preferably an ad-layer, comprising a protein of non linear optical property, preferably of the bacteriorhodopsin family, and, optionally
ii) preparing, within the ad-layer, either a transient, holographic grating by the interference of two identical laser beams or a permanent grating by holographic exposition, e.g. by bleaching.
Preferably, the coating is carried out by
preparing a water suspension of bacteriorhodopsin,
mixing the suspension with an inert, film-forming material, preferably gelatine, whose final concentration is 0.1 to 0.6% preferably 0.5% and
applying the obtained medium, preferably as an ad-layer, to the waveguide, and
drying, e.g. under air flow, preferably laminar air flow, the ad-medium.
DEFINITIONS
The term “optical waveguide” refers to a device in which light propagates in a confined geometry via multiple total reflections, and which comprises a “wave-carrying medium” and, if desired, a substrate for supporting the “wave-carrying medium”. The “wave-carrying medium” is a thin layer (preferably less than 100 nm) or fibre of a material of a sufficiently high index of refraction to achieve totally reflecting boundaries of the medium, analogously to the quantum mechanical particle in a box. The walls are of finite height and thickness, hence the field is evanescent beyond the walls, dying away exponentially.
A “non linear optical” (NLO) material can change its optical property/properties (e.g. index of refraction, absorption etc.) on external influences (electric field, temperature, pH, reagents etc.), preferably upon excitation by light.
“Integrated optics” is a field of optics aiming to integrate various optomodules on a small substrate The slab geometry is one of the most fundamental configurations in integrated optical technology, consequently the optomodules usually contain thin film devices. Such an integrated optical device can be e.g. an optical switch, a logical gate, an optical modulator, a sensor etc. or a more complex device, e.g. a logical circuit using the above basic devices as building blocks. An optical device can be all optical (fully light driven), or electrooptical.
An “ad-medium”, preferably a thin layer (“ad-layer”), is a medium comprising the NLO material and being in close contact with the wave carrying medium.
“Light is meant herein as an electromagnetic radiation in the infrared, visible or ultraviolet range. According to a preferable embodiment of the invention, e.g. for delivering or processing information, monochromatic light, more preferably laser is applied.
“Modulating radiation” or “modulating light” is understood as a radiation or light capable of changing an optical property of an NLO material. According to the invention when a modulating light is used the wavelength of said light is defined by the energy level differences between molecular states of the photochromic protein. When bacteriorhodopsin (bR) is used the modulating light is a visible laser beam capable of exciting the bR-molecule from its ground state (bR) to the M state.
A “photochromic protein” is a protein the absorption spectrum and/or the refractive index of which changes upon effect of an appropriate wavelength light.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is as schematic representation of a three-layer waveguide.
FIG. 2 is a sketch of an experimental setup disclosed in the description.
FIG. 3 is diagram showing light intensity at the edge of the waveguide versus the angle of incidence without (a) and with (b) a bacteriorhodopsin ad-layer.
FIG. 4 is a diagram showing intensity changes of the guided light following the flash-excitation versus time at selected positions of the rotational turntable (8).
FIG. 5 is a diagram showing angular dependence of the baseline (I 0 ) and the amplitudes of the two exponential components (ΔI 1 , ΔI 2 ) fitted to the curves in FIG. 4 . (ΔΦ 1 and ΔΦ 2 are the angular shifts in degrees).
FIG. 6 is a diagram showing a demonstration of the refractive index change during the bR to M transition. The spectra span from 350 nm to 680 nm. The red and blue lines depict the spectra/refractive indices of the ground state (bR) and the M intermediate, respectively, while the black line shows the shape of refractive index change calculated from the Kramers-Kronig relation. (The amplitudes are given in arbitrary units.)
FIG. 7 is a schematic showing a scheme of the holographic setup for providing a holographic grating.
FIG. 8 is a diagram showing measured traces of refractive index change upon quasi-stationary illumination.
FIG. 9 is a diagram showing light-induced shift of the resonance incoupling curve from the data in FIG. 8 , wherein the reference position is at the maximal incoupling of the sample without illumination.
DETAILED DESCRIPTION OF THE INVENTION
The technology used in the invention is based upon the modulation of light conductivity in optical waveguides utilizing nonlinear optical (NLO) properties of photochromic proteins (photosensitive proteins or chromoproteins), e.g. bacteriorhodopsin. Since optical transitions of such proteins can be initiated in a number of ways, light modulation in the waveguides can be achieved actually not only by an external light, but also by various external factors. Consequently, optical switching devices with significantly different properties can be constructed.
Some embodiments of the invention are explained below and illustrated by the examples. Nevertheless, a person skilled in the art will understand that in the knowledge of the present disclosure many other embodiments of the invention can be carried out without undue burden and within the scope of the invention.
Grating Coupling Modulated by the Refractive Index of Bacteriorhodopsin
In this scheme light is coupled into the waveguide by a diffraction grating formed in the waveguide. FIG. 1 illustrates an integrated optical device designed for that purpose. The waveguide comprises a substrate ( 1 ) and a wave carrying medium ( 2 ). The ad-medium ( 3 ) [in this case an ad-layer ( 3 . a ), e.g. a layer of Bacteriorhodopsin] is deposited directly above the grating ( 4 ).
Efficient coupling is a very sensitive function of the coupling angle. The angle at which efficient coupling takes place largely depends on the refractive index of the material around the grating. Consequently, the change of the index of refraction of the ad-layer can be very sensitively followed by measuring the coupling angle. Alternatively, at a given coupling angle the intensity of the coupled light is modulated by the reactions effecting the refractive index.
In a suitable angle an incident light beam ( 5 ) is sent to grating ( 4 ) in the waveguide. Said light beam, provided that the above-mentioned conditions are met, is coupled into wave carrying medium ( 2 ). By changing the refractive index of ad-medium ( 3 ), carried out in this embodiment by exciting the bacteriorhodopsin molecule, the conditions of successful coupling change too. Thereby the propagation of the guided light beam ( 6 ) can be arrested. Alternatively, the light beam to be coupled into the waveguide can be sent to the grating ( 4 ) in an angle defined by the refractive index of the excited state of the bacteriorhodopsin, and coupling in is allowed by the excitation of the bacteriorhodopsin molecules in the ad-layer.
Coupling Light Into and Out of the Waveguide by a Transient Grating Formed in the Ad-Layer by Holographic Excitation
Here the grating for coupling is formed within the ad-layer by appropriate light excitation: light excitation by two uniform laser beams interfering in the ad-layer produces a holographic grating within the ad-layer. This transient grating can act as a coupling grating, achieving a grating for the duration of the photoreactions in bacteriorhodopsin. The transient grating can be used both as a phase-grating (by coupling light where there is no absorption change during the photoreaction) or as an absorption grating (where absorption at the wavelength of the coupled light changes during the photoreaction).
This arrangement is clearly useful for coupling light both in and out. In the second case, i.e. when a transient grating is used for coupling out, light can be coupled in by a prism and the light beam coupled in this way can be removed from the waveguide controlled by the transient grating. Note that in this case, due to the use of prism, high light intensities can be handled. When a grating is used to couple the light in, only a small portion of the light is transferred into the waveguide. This can be an important point when selecting layouts for switching applications.
A holographic grating can be created e.g. by the experimental setup shown on FIG. 7. A laser beam from a He—Cd laser source reflected by mirror ( 14 ) to variable beam splitter ( 15 ) sending the light to further mirrors ( 14 ′). The two light beams, having passed beam expanders ( 16 ) meet each other in the bacteriorhodopsin film ( 17 ) creating an interference pattern. Scattering of laser beam ( 7 ) by the holographic grating can be detected by photodiode ( 10 ).
Coupling Light Into and Out of the Waveguide by a Grating Formed in the Ad-Layer by Holographic Bleaching
In the presence of certain chemicals (e.g. hydroxylamine) bacteriorhodopsin just as other proteins of the Rhodopsin family is bleached by light. This phenomenon can be used to burn permanent gratings into the bacteriorhodopsin ad-layer by applying holographic excitation as described in the previous paragraph. When the photocycle is initiated in bacteriorhodopsin, this grating changes its efficiency at different wavelengths, according to the changes in the absorption spectrum.
Optically Controlled Optical Switch
Each above-mentioned way for modulating light transfer in the waveguide by photochromic proteins, e.g. bacteriorhodopsin can be applied for building optically driven light switch. As a consequence a number of suitable method can be provided The inventors' present knowledge suggests that in highly preferred embodiments the light is coupled into the waveguide by a prism and outcoupling is achieved by a grating created in the ad-medium. The advantage of this embodiment is the high intensity of the handled light. Namely, a highly preferred switch allows output light intensities which are sufficient to operate further switches. This is particularly useful when complex logical circuits are designed.
Controlling of Optical Switches
In a preferred embodiment of the invention systems with different time characteristics can be built using different chromoproteins or protein mutants either with characteristic reactions following different kinetics or with different colors, etc. Many mutant variant of bR is known in the art. Using these protein variants the timing of the transients, which can be important for the application of optical switches, becomes controllable. Such mutant proteins are e.g. the following mutants; Asp85→Asn and Asp85→Thr.
In all the following examples, the timing of the changes can be varied arbitrarily: it can be dynamic with characteristic times from picoseconds to infinity, static, also bistable (switching between two stable states by illumination with lights of different colors). Operation in all modes can be verified in detailed kinetic experiments with an appropriate time resolution, e.g. following the exemplary methods disclosed herein.
Besides using different proteins or protein variants, a further possibility is to utilize the different states of the reaction cycle of the photochromic protein, e.g. bacteriorhodopsin.
By these methods switches or other integrated optical devices, e.g. sensors of various reaction time, of various sign/noise ratio or sensible for light of various wavelengths can be created. This versatility can be efficiently utilized in integrated optical logical circuits.
From these mutant or variant proteins sequentially connected switches, gates or other elements of various property can be formed, which can be advantageously used in simple logical circuits. A person skilled in the art of integrated optics will know a number of various logical elements.
For experiments where short excitation pulses with different wavelengths are needed e.g. a tunable pulsed laser (e.g. flashlamp pumped Nd:YAG laser with Optical Parametric Oscillator) can be applied.
Complex Logical Optoelectronic Devices
Once efficient optical switches are developed, complex devices using them as building blocks can be constructed.
It should be recalled that the above-mentioned devices can form the elements of optical computing. Here the logical circuits necessary for realizing functions of a computer may be created. The finally aimed product is a model computer that operates fully by light.
The methodology used in the described exemplary embodiments of the invention is explained below both in theory and from a practical view.
Relevant Properties of the Chromoproteins Applicable in the Invention
On the basis of the description it is assumed that in principal any protein of NLO property, in particular proteins which change their refractive index upon an appropriate wavelength light, can be used in the invention.
Such proteins are e.g. proteins involved in photosynthesis and sensation of light. In a preferred embodiment proteins of the rhodopsin family are used, e.g. visual rhodopsins such as rhodopsins comprising retinal-1 or retinal-2 as a chromophore or rhodopsins of the bacteriorhodopsin type such as halorhodopsins, phoborhodopsins, chlamyrhodopsins or sensory rhodopsins. In a particularly preferred embodiment bacteriorhodopsin is used.
Bacteriorhodopsin is a protein-pigment complex from the cell membrane of Halobacterium salinarium . It is a biological light energy converter: upon absorption of a photon it pumps a proton across the cell membrane, i.e. it converts the energy of light into the electrochemical energy of the created transmembrane proton concentration difference. This is its biological function, which is, however, actually irrelevant in respect of many bio-electronics applications.
Bacteriorhodopsin is very easy and cheap to produce in practically unlimited quantities. The bacteria are easy to grow and the pigment is easy to separate. The isolated bacteriorhodopsin (unlike most biological samples) is extremely stable: solutions, or dried films with practically unlimited activity (in time) can be produced.
Genetic engineering techniques to produce modified proteins are well established. According to the art, species with advantageously modified kinetic parameters can be prepared.
The function of bacteriorhodopsin is based upon a sequence of photochemical reactions, the photocycle, [Der, A. and Ormos, P. (1995)] Following light excitation during the photocycle the bacteriorhodopsin molecule changes its optical absorption, refractive index and charge distribution (Tkachenko, N. V., Savransky, V. V. and Sharonov, A. Y. (1989)); these properties can be used separately or simultaneously in opto-electronic devices. Gels and thin films containing oriented bR molecules [Der, A., Hargittai, P. and Simon, J. (1985), Varo, G. and Keszthelyi, L. (1983)] are extremely stable, they maintain their photoelectric activity at the same level for several years. On the other hand, the photocycle of bacteriorhodopsin can be controlled in many different ways. For example, the population states of the intermediates can be manipulated by a combination of orange and blue light illumination in situ [Ormos, P., Dancshazy, Z. and Keszthelyi, L. (1980)], while special site-directed mutant bacteriorhodopsins with drastically altered optical properties and photocycle kinetics created by genetic engineering techniques are available (for a review, see [Lanyi, J. K. (1993)]).
There have been numerous attempts to design devices to utilize one or more of these properties. However, to our knowledge up till now the combination of bacteriorhodopsin and integrated optics has not been attempted.
Thin Films of Native and Mutant bR
In all applications described below the key to effective function is a film of good optical quality. Thin films of native and mutant bacteriorhodopsin can be prepared e.g. on a glass surface by one or more of the following methods: gel-formation [(Der, A., Hargittai, P. and Simon, J. (1985)], vacuum-drying [Varo, G. and Keszthelyi, L. (1983)], and the Langmuir-Blodgett (LB) technique [Niemi, H., Ikonen, M., Levlin, J. M., Lemmetyinen H. (1993)]. Lb-films of pure all-trans and 13-cis retinal (the chromophores of bacteriorhodopsin) are also considered in practical applications for two purposes: retinal, as a carotenoid, is a voltage-sensitive dye: its optical density and, consequently, its refractive index are strongly dependent on the local electric field; on the other hand, because of a specific reaction with the free radical 1 O 2 , it undergoes a cis-trans isomerisation change [Krinsky, N. I. (1971) ] which also alters its optical and electrical properties. Any of these methods can be appropriate for the preparation of suitable films.
In the exemplary method described herein we prepared a water suspension of bacteriorhodopsin and mixed with gelatine, whose final concentration was 0.5%. Upon drying under laminar air flow, a film of optical quality was developed. Instead of gelatine any transparent, inert (regarding bacteriorhodopsin), film-forming material can be applied. Preferably, the upper limit of gelatine concentration is defined by the fact that the photochromic protein should not be extremely diluted (i.e. evidently a sufficient amount is required), and the lower limit is defined by the occurance of cracks in the bacteriorhodopsin film. The concentration of gelatine is preferably 0.1 to 0.6%, more preferably 0.4 to 0.55%, e.g. about 0.5%.
Optical Waveguides
A basic element of integrated optical devices is the optical waveguide. Herein, on top of a glass substrate a thin (preferably less than 200 nm, more preferably less than 100 nm thick) layer of a material of very high (e.g. about 2) index of refraction is acting as an optical waveguide: light travels along the layer within it. Note that the thickness of the wave-carrying layer is preferably significantly smaller than the wavelength of the light. The evanescent character of the travelling light is therefore very pronounced (a large part of the light wave extends out of the layer).
Light is coupled into the waveguide usually by a diffraction grating formed at the interface of the waveguide layer. The geometrical conditions for effective coupling in this case are very strict: only light coming at a very well defined angle with respect to the grating is coupled into the waveguide. By changing the refractive index adjacent to the grating the coupling can be arbitrarily modulated. Thus, optical switching can be established. Analogously, outcoupling can be carried out in the opposite way.
EXAMPLES
Example 1
Provision for Waveguides
The waveguide used in the examples consists of a planar glass support plate (substrate) and a layer of material of high index of refraction, typically a SiO 2 —TiO 2 solid solution. The thickness of the layer is small (e.g. about 100 nm), much smaller than the wavelength of the guided light. The efficiency of the waveguide is determined by the layer thickness (by influencing the evanescent character of the light) and the consistency of the material of the layer (depending on the method of producing the layer—evaporation, SOL-GEL technique). The waveguide parameters optimal for stable light guide properties and effective modulation by bacteriorhodopsin were determined.
Grating-coupled optical waveguides [Tiefenthaler, K. and Lukosz, W. (1989) J. Opt. Soc. Am. B 6:209-219] made by sputtering a thin film of Si(Ti)O2 (refractive index, n=1.77) onto a Corning C7059 glass substrate (n=1.53) were obtained from Artificial Sensing Instruments (ASI), Zurich, or prepared in the KFKI ATKI, Budapest with modifications of the standard technique. As an ad-layer, a bacteriorhodopsin film was deposited on the surface of the waveguide (FIG. 1 ). Water suspensions of wild type (or point-mutated) bR (OD=40 at 570 nm) were prepared by the standard technique [Oesterhelt, D. and Stoeckenius, W. (1971) Nature 233:149-152], and mixed with gelatine (Sigma), whose final concentration was 0.5%. Upon drying under laminar air flow, a film of optical quality was developed.
Example 2
Measurement of the bR-Refractive Index by the Waveguide Technique
The experimental setup consisted of a laser beam source ( 7 ) (10 mW He—Ne Laser; Melles Griot, Carlsbad, Calif., USA), a computer ( 12 ) controlled rotational turntable ( 8 ) (Ealing Electro-Optics) so as to vary the angle of incidence, and a pair of photodiodes ( 10 ) measuring the intensity of the guided light at the edges of the waveguide ( 9 ) (FIG. 2 ). The obtained sign was analyzed using amplifier ( 11 ). Computer records of guided light intensity versus the angle of incidence are depicted in FIGS. 3 a and b . Peaks measured at 1.1 and 9.8 degrees in FIG. 3 a represent the TE (transversal electronic) and TM (transversal magnetic) modes of a bare waveguide, respectively [Ramsden, J. J. (1994)].
The large shift of these peaks (6.8 and 12.5 degrees) in FIG. 3 b is due to the effect of the bR refractive index. In order to evaluate the results, the solution of the grating equation for the incoupling conditions and the mode equation for a three-layer planar waveguide [Tiefenthaler, K. and Lukosz, W. (1989)]. As a result, n=1.52 is given for refractive index of a dried bacteriorhodopsin film.
For the measurement of light-induced refractive index changes of the bacteriorhodopsin film, the waveguide ( 9 ) was tuned to the resonance maximum of the incoupled light by the help of the rotational turntable ( 8 ). Short (≅20 ns) flashes of 590 nm from an excimer-laser-driven dye laser (here Rhodamine 6G), were used to trigger the bacteriorhodopsin photocycle. Intensity changes of the guided light (and also those corresponding to absorption changes during the photocycle) were detected by a photodiode, and recorded by a digital storage oscilloscope (LeCroy 9310L). Traces measured with 50 μs time resolution were fitted by 2 exponentials (FIG. 4 ). FIG. 5 shows the angular dependence of the amplitudes of the exponential components. The angular distribution of the components can be interpreted as a result of both refractive index and absorption changes. In order to decompose the signals in terms of the two effects, the angular dependence of the fast component was fitted with two Gaussians. From their angular shifts (ΔΦ 1 and ΔΦ 2 as compared to the resonance curve), taking into account the absorption kinetics, we calculated the refractive index changes during the photocycle. The amplitude (i.e. the maximum of the refractive index change during the photocicle) (5×10 −3 ) and the sign of this change is consistent with the refractive index shift calculated by the help of the Kramers-Kronig relations from the absorption change in the M→bR transition of the photocycle (FIG. 6 ). The measurements undoubtedly proved the feasibility of optical switching based on the light-induced refractive index changes of bacteriorhodopsin.
To give a further, preferred example for switching, light-induced refractive index changes were measured also by quasi-stationary excitation. The experimental setup was similar to that in FIG. 2 , except that the photocycle was initiated via stepwise illumination by a 10 mW He—Ne laser (wavelength=637 nm) (Melles Griot), and refractive index changes were measured at 677 nm, with the light of a solid-state laser (Lasiris Inc., Ashby, Canada, 8 mW). The humidity of the sample was controlled by a closed chamber containing saturated salt solutions so as to buffer relative humidity. Optimal results (i.e. biggest refractive index changes) were found between 30 and 50% relative humidities. Traces measured at 30% relative humidity, detected at incoupling angles on different sides of the resonance peak (position 1 and position 2 ) are depicted in FIG. 8 . The amplitude of the refractive index changes is 5×10 −3 , corresponding to the light-induced bR-M transition. In this case, the kinetics of the signals is limited by the intensity of the exciting light. The resonance curves of incoupling determined for the TE mode are shown, with and without illumination of the sample, in FIG. 9 . As it can he estimated from the figure, the maximal relative light-induced intensity change of the incoupled light is about 2 (at position 0.05). This effect is expected to be optimized by chemical or genetic modifications of bacteriorhodopsin.
A further, alternative way of creating fast switching effects can be manifested in the future via double excitation. In such cases those properties of the bR photocycle can be utilized, that most of the intermediates may be driven back to the ground state by light [Balashov, S. P. (1995)]. By this method the bacteriorhodopsin is transferred (via excitation by a green or red light) to a state in which it is unsusceptible to excitation by the additional red light used more often in optical (switching) applications. By applying a blue flesh in this state a fast M to bR transition is generated. Thereby, a more efficient and rapid switching can be achieved.
Example 3
Creation of bR-Based Dynamic Holographic Grating
By the help of a further experiment we demonstrated that an NLO material in an ad-medium ( 3 ) (e.g. a bacteriorhodopsin film) can serve as a material for dynamic holographic grating, and as such, an incoupling device for optical waveguides (FIG. 7 ). Using the blue line of a He—Cd laser, we induced a 2400 line pair/mm grating in the glass-supported bacteriorhodopsin film ( 17 ) fixed by ultra-low-melting-point agarose of high optical purity. Light beam of a red He—Ne laser beam source ( 7 ) was incident on the grating, and the first-order diffraction beam was monitored. The time for development and release of the grating corresponded to the rate-limiting steps of the photocycle of a dried bR film (not shown). The latter experiment proved that bacteriorhodopsin can serve as an optically switchable, dynamic incoupling (or outcoupling) grating.
The outcoupled light beam can be detected as described above.
By using proteins as NLO materials and applying waveguide technology, the invention renders possible to solve a number of problems (and opens a path for the solution of many more), which occurred in the field of integrated optics, such as building easy to use, stable devices, achieving a reliable switching and creating a sufficient versatility due to many possibilities in modifying parameters such as wavelength, design or in mutating the proteins, connecting several optical elements, and thereby creating simple logical circuits.
The invention has been described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art, that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the appended claims, is intended to cover all such changes and modifications that fall within the true spirit of the invention.
List of Abbreviations
NLO
nonlinear optical
LB
Langmuir-Blodgett (film)
bR
bacteriorhodopsin (ground state)
IOD
integrated optical device
1 O 2
singlet oxygen
SiO 2
silicon oxyde
TiO 2
titanium oxyde
Nd: YAG
neodymium yttrium aluminum garnet
He—Cd
helium-cadmium
EPR
electron paramagnetic resonance
|
A fully light-controllable integrated optical switch applicable in a slab geometry configuration includes a waveguide and an ad-medium in contact with the waveguide. The the ad-medium comprises a photochromic protein as a material of non-linear optical property, wherein switching of a light propagating in the waveguide is effected by a change of an optical property of the ad-medium caused by a light-induced transition of the photochromic protein from one defined molecular state to another.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/847,719, filed Jul. 30, 2010, now U.S. Pat. No. 8,288,515, which claims the benefit of U.S. Provisional Application No. 61/230,557, filed Jul. 31, 2009, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to processes for the synthesis of the Factor Xa anticoagulent Fondaparinux, and related compounds. The invention also relates to protected pentasaccharide intermediates and to an efficient and scalable process for the industrial scale production of Fondaparinux sodium by conversion of the protected pentasaccharide intermediates via a sequence of deprotection and sulfonation reactions.
BACKGROUND OF THE INVENTION
[0003] In U.S. Pat. No. 7,468,358, Fondaparinux sodium is described as the “only anticoagulant thought to be completely free of risk from HIT-2 induction.” The biochemical and pharmacologic rationale for the development of a heparin pentasaccharide in Thromb. Res., 86(1), 1-36, 1997 by Walenga et al. cited the recently approved synthetic pentasaccharide Factor Xa inhibitor Fondaparinux sodium. Fondaparinux has also been described in Walenga et al., Expert Opin. Investig. Drugs , Vol. 11, 397-407, 2002 and Bauer, Best Practice & Research Clinical Hematology , Vol. 17, No. 1, 89-104, 2004.
[0004] Fondaparinux sodium is a linear octasulfated pentasaccharide (oligosaccharide with five monosaccharide units) molecule having five sulfate esters on oxygen (O-sulfated moieties) and three sulfates on a nitrogen (N-sulfated moieties). In addition, Fondaparinux contains five hydroxyl groups in the molecule that are not sulfated and two sodium carboxylates. Out of five saccharides, there are three glucosamine derivatives and one glucuronic and one L-iduronic acid. The five saccharides are connected to each other in alternate cc and 13 glycosylated linkages (see FIG. 1 ).
[0005] Fondaparinux sodium is a chemically synthesized methoxy derivative of the natural pentasaccharide sequence, which is the active site of heparin that mediates the interaction with antithrombin (Casu et al., J. Biochem., 197, 59, 1981). It has a challenging pattern of O- and N-sulfates, specific glycosidic stereochemistry, and repeating units of glucosamines and uronic acids (Petitou et al., Progress in the Chemistry of Organic Natural Product, 60, 144-209, 1992).
[0006] The monosaccharide units comprising the Fondaparinux molecule are labeled as per the convention in FIG. 1 , with the glucosamine unit on the right referred to as monosaccharide A and the next, an uronic acid unit to its left as B and subsequent units, C, D and E respectively. The chemical synthesis of Fondaparinux starts with monosaccharides of defined structures that are themselves referred to as Monomers A2, B1, C, D and E, for differentiation and convenience, and they become the corresponding monosaccharides in fondaparinux sodium.
[0007] Due to this complex mixture of free and sulfated hydroxyl groups, and the presence of N-sulfated moieties, the design of a synthetic route to Fondaparinux requires a careful strategy of protection and de-protection of reactive functional groups during synthesis of the molecule. Previously described syntheses of Fondaparinux all adopted a similar strategy to complete the synthesis of this molecule. This strategy can be envisioned as having four stages. The strategy in the first stage requires selective de-protection of five out of ten hydroxyl groups. During the second stage these five hydroxyls are selectively sulfonated. The third stage of the process involves the de-protection of the remaining five hydroxyl groups. The fourth stage of the process is the selective sulfonation of the 3 amino groups, in the presence of five hydroxyl groups that are not sulfated in the final molecule. This strategy can be envisioned from the following fully protected pentasaccharide, also referred to as the late-stage intermediate.
[0000]
[0008] In this strategy, all of the hydroxyl groups that are to be sulfated are protected with an acyl protective group, for example, as acetates (R═CH 3 ) or benzoates (R=aryl) (Stages 1 and 2) All of the hydroxyl groups that are to remain as such are protected with benzyl group as benzyl ethers (Stage 3). The amino group, which is subsequently sulfonated, is masked as an azide (N 3 ) moiety (Stage 4). R 1 and R 2 are typically sodium in the active pharmaceutical compound (e.g., Fondaparinux sodium).
[0009] This strategy allows the final product to be prepared by following the synthetic operations as outlined below:
[0010] a) Treatment of the late-stage intermediate with base to hydrolyze (deprotect) the acyl ester groups to reveal the five hydroxyl groups. The two R 1 and R 2 ester groups are hydrolyzed in this step as well.
[0000]
[0011] b) Sulfonation of the newly revealed hydroxyl groups.
[0000]
[0012] c) Hydrogenation of the O-sulfated pentasaccharide to de-benzylate the five benzyl-protected hydroxyls, and at the same time, unmask the three azides to the corresponding amino groups.
[0000]
[0013] d) On the last step of the operation, the amino groups are sulfated selectively at a high pH, in the presence of the five free hydroxyls to give Fondaparinux ( FIG. 1 ).
[0014] While the above strategy has been shown to be viable, it is not without major drawbacks. One drawback lies in the procedure leading to the fully protected pentasaccharide (late stage intermediate), especially during the coupling of the D-glucuronic acid to the next adjacent glucose ring (the D-monomer to C-monomer in the EDCBA nomenclature shown in FIG. 1 ). Sugar oligomers or oligosaccharides, such as Fondaparinux, are assembled using coupling reactions, also known as glycosylation reactions, to “link” sugar monomers together. The difficulty of this linking step arises because of the required stereochemical relationship between the D-sugar and the C-sugar, as shown in FIG. 2 .
[0015] The stereochemical arrangement illustrated in FIG. 2 is described as having a 13-configuration at the anomeric carbon of the D-sugar (denoted by the arrow). The linkage between the D and C units in Fondaparinux has this specific stereochemistry. There are, however, competing β- and α-glycosylation reactions.
[0016] The difficulties of the glycosylation reaction in the synthesis of Fondaparinux is well known. In 1991 Sanofi reported a preparation of a disaccharide intermediate in 51% yield having a 12/1 ratio of β/α stereochemistry at the anomeric position (Duchaussoy et al., Bioorg . & Med. Chem. Lett., 1(2), 99-102, 1991). In another publication (Sinay et al., Carbohydrate Research, 132, C5-C9, 1984) yields on the order of 50% with coupling times on the order of 6-days are reported. U.S. Pat. No. 4,818,816 (see e.g., column 31, lines 50-56) discloses a 50% yield for the β-glycosylation.
[0017] Alchemia's U.S. Pat. No. 7,541,445 is even less specific as to the details of the synthesis of this late-stage Fondaparinux synthetic intermediate. The '445 patent discloses several strategies for the assembly of the pentasaccharide (1+4, 3+2 or 2+3) using a 2-acylated D-sugar (specifically 2-allyloxycarbonyl) for the glycosylation coupling reactions. However, Alchemia's strategy involves late-stage pentasaccharides that all incorporate a 2-benzylated D-sugar. The transformation of acyl to benzyl is performed either under acidic or basic conditions. Furthermore, these transformations, using benzyl bromide or benzyl trichloroacetimidate, typically result in extensive decomposition and the procedure suffers from poor yields. Thus, such transformations (at a disaccharide, trisaccharide, and pentasaccharide level) are typically not acceptable for industrial scale production.
[0018] Examples of fully protected pentasaccharides are described in Duchaussoy et al., Bioorg. Med. Chem. Lett., 1 (2), 99-102, 1991; Petitou et al., Carbohydr. Res., 167, 67-75, 1987; Sinay et al., Carbohydr. Res., 132, C5-C9, 1984; Petitou et al., Carbohydr. Res., 1147, 221-236, 1986; Lei et al., Bioorg. Med. Chem., 6, 1337-1346, 1998; Ichikawa et al., Tet. Lett., 27(5), 611-614, 1986; Kovensky et al., Bioorg. Med. Chem., 1999, 7, 1567-1580, 1999. These fully protected pentasaccharides may be converted to the O- and N-sulfated pentasaccharides using the four steps (described earlier) of: a) saponification with LiOH/H 2 O 2 /NaOH, b) O-sulfation by an Et 3 N—SO 3 complex; c) de-benzylation and azide reduction via H 2 /Pd hydrogenation; and d) N-sulfation with a pyridine-SO 3 complex.
[0019] Even though many diverse analogs of the fully protected pentasaccharide have been prepared, none use any protective group at the 2-position of the D unit other than a benzyl group. Furthermore, none of the fully protected pentasaccharide analogs offer a practical, scaleable and economical method for re-introduction of the benzyl moiety at the 2-position of the D unit after removal of any participating group that promotes β-glycosylation.
[0020] Furthermore, the coupling of benzyl protected sugars proves to be a sluggish, low yielding and problematic process, typically resulting in substantial decomposition of the pentasaccharide (prepared over 50 synthetic steps), thus making it unsuitable for a large [kilogram] scale production process.
[0000]
[0021] It has been a general strategy for carbohydrate chemists to use base-labile ester-protecting group at 2-position of the D unit to build an efficient and stereoselective β-glycosidic linkage. To construct the β-linkage carbohydrate chemists have previously acetate and benzoate ester groups, as described, for example, in the review by Poletti et al., Eur. J. Chem., 2999-3024, 2003.
[0022] The ester group at the 2-position of D needs to be differentiated from the acetate and benzoates at other positions in the pentasaccharide. These ester groups are hydrolyzed and sulfated later in the process and, unlike these ester groups, the 2-hydroxyl group of the D unit needs to remain as the hydroxyl group in the final product, Fondaparinux sodium.
[0023] Some of the current ester choices for the synthetic chemists in the field include methyl chloro acetyl and chloro methyl acetate [MCA or CMA]. The mild procedures for the selective removal of theses groups in the presence of acetates and benzoates makes them ideal candidates. However, MCA/CMA groups have been shown to produce unwanted and serious side products during the glycosylation and therefore have not been favored in the synthesis of Fondaparinux sodium and its analogs. For by-product formation observed in acetate derivatives see Seeberger et al., J. Org. Chem., 2004, 69, 4081-93. Similar by-product formation is also observed using chloroacetate derivatives. See Orgueira et al., Eur. J. Chem., 9(1), 140-169, 2003.
[0024] Therefore, as will be appreciated, there are several limitations to current processes used for the synthesis of fondaparinux sodium. Thus, there is a need in the art for new synthetic procedures that produce fondaparinux and related compounds in high yield and with high stereoselectivity. The processes of the present invention address the limitations known in the art and provide a unique, reliable and scalable synthesis of compounds such as Fondaparinux sodium.
[0025] Additional advantages will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the aspects described below. The advantages described below will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.
SUMMARY OF THE INVENTION
[0026] Applicants have surprisingly found that in the synthesis of Fondaparinux, the use of a unique levulinate-protected 2-glucuronic acid-anhydro sugar coupling methodology allows for a highly efficient glycosylation reaction, thereby providing late stage intermediates or oligosaccharides (and Fondaparinux related oligomers) in high yield and in high β/α ratios. In particular, glycosylation of the 2-levulinate-protected glucuronic acid can occur with high coupling yields (>65%) of the β-isomer, rapidly (for example, in an hour reaction time), and with no detectable α-isomer upon column chromatography purification. The levulinate protecting group may be efficiently and selectively removed from the glycosylated product in the presence of potential competing moieties (such as two acetate and two benzoate groups) to generate a free 2-hydroxyl group. The newly generated hydroxyl group may be efficiently and quantitatively re-protected with a tetrahydropyran (THP) group to provide a fully protected 2-THP containing pentasaccharide that may be selectively and consequentially O-sulfated, hydrogenated and N-sulfated to produce the desired pentasaccharide, such as Fondaparinux, in excellent yields. The inventors have surprisingly found that the THP group remains intact and protected through all of the subsequent operations and is efficiently removed during work-up, after the final N-sulfonation step.
[0027] The present invention includes certain intermediate compounds identified below, including those of Formula I.
[0028] One embodiment of the invention is a process for making Fonadparinux sodium by converting at least one compound selected from
[0000]
[0000] where R 2 is Ac or Bz,
[0000]
[0000] where R 2 is Ac or Bz,
[0000]
[0000] where R 2 is Ac or Bz,
[0000]
[0000] to Fonadaparinux sodium.
[0029] Yet another embodiment is a method of preparing an oligosaccharide having a β-glucosamine glycosidic linkage by reacting a 1,6-anhydro glucopyranosyl acceptor (e.g., 1,6-anhydro-β-D-glucopyranose) having an azide functional group at C2 and a hydroxyl group at C4 with a uronic acid glycopyranosyl donor having an activated anomeric carbon, a levulinate group at C2, and a protected acid group at C5 to form an oligosaccharide having a β-glycosidic linkage between the hydroxyl group of the glucopyranosyl acceptor and the anomeric carbon of the glycopyranosyl donor.
BRIEF DESCRIPTION OF THE FIGURES
[0030] FIG. 1 depicts the structure of Fondaparinux sodium.
[0031] FIG. 2 depicts the stereochemical relationship between the D-sugar and the C-sugar in Fondaparinux sodium.
[0032] FIG. 3 is a 1 H NMR spectrum of the EDC trimer.
[0033] FIG. 4 is a 1 H NMR spectrum of the EDC-1 trimer.
[0034] FIG. 5 is a 1 H NMR spectrum of the EDC-2 trimer.
[0035] FIG. 6 is a 1 H NMR spectrum of the EDC-3 trimer.
[0036] FIG. 7 is a 1 H NMR spectrum of the EDCBA-1 pentamer.
[0037] FIG. 8 is a 1 H NMR spectrum of the EDCBA-2 pentamer.
[0038] FIG. 9 is a 1 H NMR spectrum of the EDCBA pentamer.
[0039] FIG. 10 is a 1 H NMR spectrum of API-2 pentamer.
[0040] FIG. 11 is a 1 H NMR spectrum of API-3 pentamer.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Applicants have surprisingly found that in the synthesis of Fondaparinux, the use of a unique levulinate-protected 2-glucuronic acid-anhydro sugar coupling methodology allows for an highly efficient glycosylation reaction, thereby providing late stage intermediates or oligosaccharides (and Fondaparinux related oligomers) in high yield and in high β/α ratios. In particular, glycosylation of the 2-levulinate-protected glucuronic acid with an anhydro sugar occurs quickly (for example, with a reaction time of about an hour), with high coupling yields (>65%) of the β-isomer, and with high selectivity (for example, with no detectable α-isomer upon column chromatography purification). The levulinate protecting group may be efficiently and selectively removed from the glycosylated product in the presence of potential competing moieties (such as two acetate and two benzoate groups) to generate a free 2-hydroxyl group. The newly generated hydroxyl group may be efficiently and quantitatively re-protected with a tetrahydropyran (THP) group to provide a fully protected 2-THP containing pentasaccharide that may be selectively and consequentially O-Sulfated, hydrogenated and N-sulfated to produce the desired pentasaccharide, such as Fondaparinux, in excellent yields. The THP group remains intact and protected through all of the subsequent operations and is efficiently removed during work-up, after the final N-sulfonation step.
[0042] The levulinyl group can be rapidly and almost quantitatively removed by treatment with hydrazine hydrate as the deprotection reagent as illustrated in the example below. Under the same reaction conditions primary and secondary acetate and benzoate esters are hardly affected by hydrazine hydrate. See, e.g., Seeberger et al., J. Org. Chem., 69, 4081-4093, 2004.
[0000]
[0043] The syntheses of Fondaparinux sodium described herein takes advantage of the levulinyl group in efficient construction of the trisaccharide EDC with improved β-selectivity for the coupling under milder conditions and increased yields.
[0000]
[0044] Substitution of the benzyl protecting group with a THP moiety provides its enhanced ability to be incorporated quantitatively in position-2 of the unit D of the pentasaccharide. Also, the THP group behaves in a similar manner to a benzyl ether in terms of function and stability. In the processes described herein, the THP group is incorporated at the 2-position of the D unit at this late stage of the synthesis (i.e., after the D and C units have been coupled through a 1,2-trans glycosidic (β-) linkage). The THP protective group typically does not promote an efficient β-glycosylation and therefore is preferably incorporated in the molecule after the construction of the β-linkage.
[0045] The scheme below exemplifies some of the processes of the present invention disclosed herein.
[0000]
[0046] The tetrahydropyranyl (THP) protective group and the benzyl ether protective group are suitable hydroxyl protective groups and can survive the last four synthetic steps (described above) in the synthesis of Fondaparinux sodium, even under harsh reaction conditions. Certain other protecting groups do not survive the last four synthetic steps in high yield.
[0047] Thus, in one aspect, the present invention relates to novel levulinyl and tetrahydropyran pentasaccharides. Such compounds are useful as intermediates in the synthesis of Fondaparinux.
[0048] In one embodiment, the present invention relates to a compound of Formula I:
[0000]
[0000] wherein
[0049] R 1 is levulinyl (Lev) or tetrahydropyran (THP);
[0050] R 2 is —O − or a salt thereof, —OH, —OAcyl, or —OSO 3 − or a salt thereof;
[0051] R 3 is H, benzyl or a protecting group removable by hydrogenation (a hydroxyl protecting group) (for example, —CO 2 − or a salt thereof);
[0052] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 − or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0053] R 5 is C 1 -C 6 alkyl; and
[0054] R 6 and R 7 are independently selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe); and
[0000] wherein said compound has alpha (α) stereochemistry at the carbon bearing the —OR 5 group.
[0055] In one embodiment, R 2 is —O-Acetyl or —O-Benzoyl. In another embodiment, R 2 is —O − , —ONa, —OLi, —OK or —OCs. In a further embodiment, R 2 is —OSO 3 − , —OSO 3 Na, —OSO 3 Li, —OSO 3 K or —OSO 3 Cs.
[0056] In another embodiment, R 5 is methyl.
[0057] In a further embodiment, R 3 is benzyl or p-methoxybenzyl. In yet a further embodiment, R 3 is —CO 2 − , —CO 2 Na, —CO 2 Li, —CO 2 K or —CO 2 Cs.
[0058] In one embodiment of the compound of Formula (I), R 1 is levulinyl (Lev), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me.
[0059] In another embodiment of the compound of Formula (I), R 1 is tetrahydropyran (THP), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me.
[0060] In yet another embodiment of the compound of Formula (I), R 1 is tetrahydropyran (THP), R 2 is —O − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0061] In a further embodiment of the compound of Formula (I), R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0062] In another embodiment of the compound of Formula (I), R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is H, R 4 is NH 2 , R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0063] In another embodiment of the compound of Formula (I), R 1 is tetrahydropyran (THP), R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na.
[0064] In yet a further embodiment, the present invention relates to a compound of Formula I:
[0000]
[0065] wherein R 1 is H, R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me.
Synthetic Processes
[0066] In another aspect, the present invention relates to processes for the preparation of fondaparinux. The invention also relates to processes for the preparation of novel intermediates useful in the synthesis of fondaparinux. The processes described herein proceed in an efficient manner, thereby providing the desired compounds in good yield and in a manner that is scalable and reproducible on an industrial scale.
Selective Coupling Strategy
[0067] The present invention provides a procedure for the selective formation of a β-anomer product from a glycosylation coupling reaction. Without wishing to be bound by theory, the applicants believe that the β/α ratio observed during the processes described herein is due to the levulinate-directed glycosylation exemplified below:
[0000]
[0068] The 2-levulinate-mediated glycosylation reactions described herein provide a surprisingly high β/α ratio of coupled products. In the present invention, a high β-selectivity is obtained when the present, conformationally restricted, anhydro acceptor C is used. The high β-selectivity is unexpected and may be due the conformationally locked anhydroglucose.
[0069] Thus, in certain aspects, the present invention provides a levulinate ester/tetrahydropyranyl ether (Lev/THP) strategy for the protection, deprotection and re-protection of the 2-position of a glucuronic saccharide, which is useful for the synthesis of Fondaparinux and related compounds.
[0070] In one embodiment, the present invention relates to a process for preparing fondaparinux sodium:
[0000]
[0000] In certain embodiments, the process includes (a) at least one of:
[0071] (i) deprotecting and then THP protecting a levulinate pentamer of the formula:
[0000]
[0000] where R 2 is Ac or Bz to obtain a THP pentamer of the formula:
[0000]
[0072] (ii) hydrolyzing a THP pentamer of the formula:
[0000]
[0000] where R 2 is Ac or Bz to obtain a hydrolyzed pentamer of the formula:
[0000]
[0073] (iii) sulfating a hydrolyzed pentamer of the formula:
[0000]
[0000] to obtain an O-sulfated pentamer of the formula:
[0000]
[0074] (iv) hydrogenating an O-sulfated pentamer of the formula:
[0000]
[0000] to obtain a hydrogenated pentamer of the formula:
[0000]
[0075] (vi) N-sulfating a hydrogenated pentamer of the formula:
[0000]
[0000] to obtain Fondaparinux-THP of the formula:
[0000]
[0000] (b) optionally, converting the product of step (a) to Fondaparinux sodium. For instance, the Fondaparinux-THP intermediate shown above can be deprotected (i.e., the THP protecting group can be removed) to obtain Fondaparinux.
[0076] In another aspect, the present invention relates to a process for preparing a compound of Formula I:
[0000]
[0077] wherein R 1 is H, R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na, the process including:
[0078] (a) deprotecting a compound of Formula I wherein R 1 is levulinyl (Lev), R 2 is —OAcetyl or -Obenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me, to provide a compound of Formula I wherein R 1 is H, R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me;
[0079] (b) protecting the product of step (a) to provide a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me;
[0080] (c) hydrolyzing the product of step (b) to provide a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —O − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof;
[0081] (d) sulfating the product of step (c) to provide a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof;
[0082] (e) hydrogenating the product of step (d) to provide a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is H, R 4 is NH 2 , R 5 is methyl, and R 6 and R 7 are —CO 2 or a salt thereof;
[0083] (f) sulfating the product of step (e) to provide a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na; and
[0084] (g) deprotecting the product of step (f) to provide a compound of Formula I wherein R 1 is H, R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na.
[0085] In one embodiment, deprotecting step (a) includes treatment with a reagent selected from hydrazine, hydrazine hydrate, hydrazine acetate and R 8 NH—NH 2 where R 8 is aryl, heteroaryl or alkyl.
[0086] In one embodiment, deprotecting step (a) includes treatment with hydrazine
[0087] In another embodiment, protecting step (b) includes treatment with dihydropyran or a dihydropyran derivative and an acid selected from camphor sulfonic acid (CSA), hydrochloric acid (HCl), p-toluenesulfonic acid (pTsOH) and Lewis acids.
[0088] In one embodiment protecting step (b) includes treatment with dihydropyran and an acid selected from hydrochloric acid and p-toluenesulfonic acid.
[0089] In another aspect, the present invention relates to a process for preparing a THP pentamer of the formula:
[0000]
[0000] wherein R 2 is Ac or Bz;
the process including deprotecting and then THP protecting a compound of the formula:
[0000]
[0090] In a further embodiment of this aspect, the process further includes hydrolyzing the THP pentamer to produce a hydrolyzed pentamer of the formula:
[0000]
[0091] In a further embodiment of this aspect, the process further includes sulfating the hydrolyzed pentamer to obtain an O-sulfated pentamer of the formula:
[0000]
[0092] In a further embodiment of this aspect, the process further includes hydrogenating the O-sulfated pentamer to obtain a hydrogenated pentamer of the formula:
[0000]
[0093] In a further embodiment of this aspect, the process further includes N-sulfating the hydrogenated pentamer to obtain fondaparinux-THP of the formula:
[0000]
[0094] In a further embodiment of this aspect, the process further includes converting the Fondaparinux-THP to Fondaparinux sodium. In one embodiment, the conversion includes deprotecting the Fondaparinux-THP.
[0095] In another aspect, the present invention relates to a process for preparing a compound of Formula I:
[0000]
[0096] wherein R 1 is levulinyl (Lev), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me;
[0097] the process including linking a compound of Formula EDC
[0000]
[0000] wherein R 1 is levulinyl (Lev), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide) and R 6 is —CO 2 CH 2 C 6 H 5 ;
[0098] with a compound of Formula BA
[0000]
[0099] wherein R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl and R 7 is —CO 2 Me.
[0100] In one embodiment of this aspect, the process further includes converting the resulting product to fondaparinux sodium.
[0101] In yet another aspect, the present invention relates to a process for preparing a compound of Formula I:
[0000]
[0000] wherein
[0102] R 1 is H, levulinyl (Lev) or tetrahydropyran (THP);
[0103] R 2 is —O − or a salt thereof, —OH, —OAcyl, or —OSO 3 − or a salt thereof;
[0104] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0105] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0106] R 5 is C 1 -C 6 alkyl; and
[0107] R 6 and R 7 are independently selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe); and
[0000] wherein said compound has alpha (α) stereochemistry at the carbon bearing the —OR 5 group;
said process including linking a compound of Formula II:
[0000]
[0000] wherein,
[0108] R 1 is H, levulinyl (Lev) or tetrahydropyran (THP);
[0109] R 2 is —O − or a salt thereof, —OH, —OAcyl, —OSO 3 − or a salt thereof;
[0110] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0111] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0112] R 6 and R 7 are independently selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe); and
[0113] R 9 is R 1 or R 2 ,
[0000] with a compound of Formula III
[0000]
[0000] wherein
[0114] R 2 is —O − or a salt thereof, —OH, —OAcyl, —OSO 3 − or a salt thereof;
[0115] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0116] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0117] R 5 is C 1 -C 6 alkyl.
[0118] In certain embodiments of this aspect, the compound of Formula II is
[0000]
[0119] and the compound of Formula III is
[0000]
[0120] In yet another aspect, the present invention relates to a process for preparing a compound of Formula I:
[0000]
[0000] wherein,
[0121] R 1 is H, levulinyl (Lev) or tetrahydropyran (THP);
[0122] R 2 is —O − or a salt thereof, —OH, —OAcyl, or —OSO 3 − or a salt thereof;
[0123] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0124] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0125] R 5 is C 1 -C 6 alkyl; and
[0126] R 6 and R 7 are independently selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe); and
[0000] wherein said compound has alpha (α) stereochemistry at the carbon bearing the —OR 5 group;
the process including linking a compound of Formula IV:
[0000]
[0000] wherein,
[0127] R 1 is H, levulinyl (Lev) or tetrahydropyran (THP);
[0128] R 2 is —O − or a salt thereof, —OH, —OAcyl, —OSO 3 − or a salt thereof;
[0129] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0130] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 ); and
[0131] R 6 is selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe), with a compound of Formula V:
[0000]
[0000] wherein,
[0132] R 1 is H, levulinyl (Lev) or tetrahydropyran (THP);
[0133] R 2 is —O − or a salt thereof, —OH, —OAcyl, —OSO 3 − or a salt thereof;
[0134] R 3 is H, benzyl or a protecting group removable by hydrogenation;
[0135] R 4 is N 3 (azide), NH 2 , NH-protecting group (i.e., —NH—R where R is an amino protecting group), or NHSO 3 or a salt thereof (e.g., NHSO 3 Na, NHSO 3 Li, NHSO 3 K, and NHSO 3 NH 4 );
[0136] R 5 is C 1 -C 6 alkyl; and
[0137] R 7 is selected from —CO 2 − or a salt thereof, —CO 2 H, and —CO 2 R x (where R x is a C 1 -C 6 alkyl, aryl, C 1 -C 4 alkoxy(aryl), aryl(C 1 -C 6 alkyl), or C 1 -C 4 alkoxy(aryl)(C 1 -C 6 alkyl)) (e.g., —CO 2 Me, —CO 2 CH 2 C 6 H 5 and —CO 2 CH 2 C 6 H 4 OMe); and
[0138] R 9 is R 1 or R 2 .
[0139] In certain embodiments of this aspect, the compound of Formula IV is
[0000]
[0140] and the compound of Formula V is
[0000]
[0141] In another aspect, the present invention relates to a process for preparing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me, the process including:
[0142] (a) deprotecting a compound of Formula I wherein R 1 is levulinyl (Lev), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 and R 7 is —CO 2 Me to afford a compound of Formula I wherein R 1 is H, R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl,
[0143] R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 , and R 7 is —CO 2 Me; and
[0144] (b) THP protecting the product of step (a).
[0145] In one embodiment, deprotecting step (a) includes treatment with a reagent selected from hydrazine, hydrazine hydrate, hydrazine acetate and R 8 NH—NH 2 where R 8 is aryl, heteroaryl or alkyl. In one embodiment deprotecting step (a) comprises treatment with hydrazine.
[0146] In one embodiment, protecting step (b) comprises treatment with dihydropyran or a dihydropyran derivative and an acid selected from camphor sulfonic acid (CSA), hydrochloric acid (HCl), p-toluenesulfonic acid (pTsOH) and Lewis acids. In one embodiment, protecting step (b) comprises treatment with dihydropyran and an acid selected from hydrochloric acid and p-toluenesulfonic acid.
[0147] In another aspect, the present invention relates to a process for preparing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —O − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof, comprising hydrolyzing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OAcetyl or —OBenzoyl, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, R 6 is —CO 2 CH 2 C 6 H 5 , and R 7 is —CO 2 Me.
[0148] In another aspect, the present invention relates to a process for preparing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof, comprising sulfating a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —O − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0149] In another aspect, the present invention relates to a process for preparing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is H, R 4 is NH 2 , R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof, comprising the step of hydrogenating a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is benzyl, R 4 is N 3 (azide), R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0150] In another aspect, the present invention relates to a process for preparing a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na, comprising the step of sulfating a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 − or a salt thereof, R 3 is H, R 4 is NH 2 , R 5 is methyl, and R 6 and R 7 are —CO 2 − or a salt thereof.
[0151] In a further aspect, the present invention relates to a process for making a compound of Formula I:
[0000]
[0152] wherein R 1 is H, R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na;
[0153] the process including deprotecting a compound of Formula I wherein R 1 is tetrahydropyran (THP), R 2 is —OSO 3 Na, R 3 is H, R 4 is NHSO 3 Na, R 5 is methyl, and R 6 and R 7 are —CO 2 Na.
[0154] In yet a further aspect, the present invention relates to a process for making a compound of Formula 8:
[0000]
[0000] comprising reacting a compound of Formula 9:
[0000]
[0000] with a compound of Formula 10:
[0000]
Fondaparinux Sodium
[0155] In a further aspect, the present invention relates to Fondaparinux, or a salt thereof (e.g., Fondaparinux sodium) containing a compound selected from P2, P3, P4, and combinations thereof.
Compound P2 (Methylated Nitrogen on the E Ring):
[0156]
Compound P3 (Methylated Nitrogen on the A Ring):
[0157]
Compound P4 (N-Formyl Group on the C Ring):
[0158]
[0159] In additional embodiments, the present invention relates to a composition (such as a pharmaceutical composition) that includes Fondaparinux, or a salt thereof (e.g., Fondaparinux sodium) and a compound selected from P2, P3, P4, and combinations thereof.
[0160] In certain embodiments, the Fondaparinux, or a salt thereof (e.g., Fondaparinux sodium), or composition contains at least 90, 95, 98, 99 or 99.5% Fondaparinux, or salt thereof, based on the total weight of Fondaparinux or composition.
[0161] In certain embodiments, Compound P2 is present in an amount of greater than 0% and less than about 0.5%, such as greater than 0% and less than about 0.4%, greater than 0% and less than about 0.3%, greater than 0% and less than about 0.2% and greater than 0% and less than about 0.1%, based on the total weight of Fondaparinux or composition.
[0162] In certain embodiments, Compound P3 is present in an amount of greater than 0% and less than about 0.5%, such as greater than 0% and less than about 0.4%, greater than 0% and less than about 0.3%, greater than 0% and less than about 0.2% and greater than 0% and less than about 0.1%, based on the total weight of Fondaparinux or composition.
[0163] In certain embodiments, Compound P4 is present in an amount of greater than 0% and less than about 0.5%, such as greater than 0% and less than about 0.4%, greater than 0% and less than about 0.3%, greater than 0% and less than about 0.2% and greater than 0% and less than about 0.1%, based on the total weight of Fondaparinux or composition.
[0164] In additional embodiments, the Fondaparinux, or a salt thereof (e.g., Fondaparinux sodium) (or composition that includes Fondaparinux, or a salt thereof (e.g., Fondaparinux sodium)) may also contain Compound P1 (in addition to containing a compound selected from P2, P3, P4, and combinations thereof).
Compound P1 (Beta-Anomer of Fondaparinux Sodium)
[0165]
[0166] In certain embodiments, Compound P1 is present in an amount of greater than 0% and less than about 0.5%, such as greater than 0% and less than about 0.4%, greater than 0% and less than about 0.3%, greater than 0% and less than about 0.2% and greater than 0% and less than about 0.1%, based on the total weight of Fondaparinux or composition.
[0167] In additional embodiments, the present invention relates to a composition (such as a pharmaceutical composition) that includes Fondaparinux or a salt thereof (e.g., Fondaparinux sodium) and one or more tetrahydropyran protected pentasaccharides. In additional embodiments, the tetrahydropyran protected pentasaccharide is any of the tetrahydropyran protected pentasaccharides as described in any of the embodiments herein.
[0168] In certain embodiments, the tetrahydropyran protected pentasaccharide is present in an amount of greater than 0% and less than about 0.5%, such as greater than 0% and less than about 0.4%, greater than 0% and less than about 0.3%, greater than 0% and less than about 0.2%, greater than 0% and less than about 0.1%, based on the total weight of Fondaparinux or composition.
[0169] Any of the aforementioned forms of Fondaparinux (or a salt thereof) or compositions containing Fondaparinux (or a salt thereof) may be administered (e.g., 2.5 mg, 5 mg, 7.5 mg, 10 mg, solution for injection) for the prophylaxis of deep vein thrombosis (DVT) which may lead to pulmonary embolism (PE) in patients undergoing (i) hip fracture surgery (including extended prophylaxis), (ii) hip replacement surgery, (iii) knee replacement surgery and (iv) abdominal surgery (who are at risk for thromboembolic complications). The forms and compositions described herein may also be administered in conjunction with warfarin sodium for the treatment of acute DVT and PE.
DEFINITIONS
[0170] Examples of alkyl groups having one to six carbon atoms, are methyl, ethyl, propyl, butyl, pentyl, hexyl, and all isomeric forms and straight and branched thereof.
[0171] The term “acyl” unless otherwise defined refers to the chemical group —C(O)R. R can be, for example, aryl (e.g., phenyl) or alkyl (e.g., C 1 -C 6 alkyl).
[0172] The term “aryl” refers to an aromatic group having 6 to 14 carbon atoms such as, for example, phenyl, naphthyl, tetrahydronaphthyl, indanyl, and biphenyl. The term “heteroaryl” refers to an aromatic group having 5 to 14 atoms where at least one of the carbons has been replaced by N, O or S. Suitable examples include, for example, pyridyl, quinolinyl, dihydroquinolinyl, isoquinolinyl, quinazolinyl, dihydroquinazolyl, and tetrahydroquinazolyl.
[0173] It will be apparent to those skilled in the art that sensitive functional groups may need to be protected and deprotected during synthesis of a compound of the invention. This may be achieved by conventional methods, for example as described in “Protective Groups in Organic Synthesis” by Greene and Wuts, John Wiley & Sons Inc (1999), and references therein which can be added or removed using the procedures set forth therein. Examples of protected hydroxyl groups (i.e., hydroxyl protecting groups) include silyl ethers such as those obtained by reaction of a hydroxyl group with a reagent such as, but not limited to, t-butyldimethyl-chlorosilane, trimethylchlorosilane, triisopropylchlorosilane, triethylchlorosilane; substituted methyl and ethyl ethers such as, but not limited to, methoxymethyl ether, methythiomethyl ether, benzyloxymethyl ether, t-butoxymethyl ether, 2-methoxyethoxymethyl ether, tetrahydropyranyl ethers, 1-ethoxyethyl ether, allyl ether, benzyl ether; esters such as, but not limited to, benzoylformate, formate, acetate, trichloroacetate, and trifluoracetate. Examples of protected amine groups (i.e., amino protecting groups) include, but are not limited to, amides such as, formamide, acetamide, trifluoroacetamide, and benzamide; imides, such as phthalimide, and dithiosuccinimide; and others. Examples of protected sulfhydryl groups include, but are not limited to, thioethers such as S-benzyl thioether, and S-4-picolyl thioether; substituted S-methyl derivatives such as hemithio, dithio and aminothio acetals; and the like.
[0174] A protecting group that can be removed by hydrogenation is, by way of example, benzyl or a substituted benzyl group, for example benzyl ethers, benzylidene acetals. While the benzyl group itself is a commonly used protecting group that can be removed by hydrogenation, one example of a substituted benzyl protecting group is p-methoxy benzyl.
[0175] A number of hydrazine and hydrazine derivative are available for the deprotection (removal) of tetrahydropyran (THP) protecting group, including, but not limited to, hydrazine [NH 2 —NH 2 ], hydrazine hydrate [NH 2 —NH 2 .H 2 O] and hydrazine acetate [NH 2 —NH 2 .AcOH] and alkyl and aryl hydrazine derivatives such as R 8 NH—NH 2 where R 8 is aryl, heteroaryl or alkyl.
[0176] Lewis acids known in the art include, for example, magnesium chloride, aluminum chloride, zinc chloride, boron trifluoride dimethyl etherate, titanium(IV) chloride and ferric chloride.
[0177] Throughout the description and claims of this specification the word “comprise” and other forms of the word, such as “comprising” and “comprises,” means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps.
[0178] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component” includes mixtures of two or more components.
[0179] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.
[0180] Throughout this specification, 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 the disclosed matter pertains. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon.
[0181] The following examples are merely illustrative of the present invention and should not be construed as limiting the scope of the invention in any way as many variations and equivalents that are encompassed by the present invention will become apparent to those skilled in the art upon reading the present disclosure.
EXAMPLES
[0182] In the synthesis of Fondaparinux sodium, the monomers A2, B1, C, D and E described herein may be made either by processes described in the art or, e.g., in the case of the D monomer, by a process as described herein. The B1 and A2 monomers may then linked to form a disaccharide, BA dimer. The E, D and C monomers may be linked to form a trisaccharide, EDC trimer. The EDC trimer may be derivatized to form an intermediate suitable for coupling with the BA dimer, thereby forming a pentasaccharides (EDCBA) pentamer. The EDCBA pentamer is an intermediate that may be converted through a series of reactions to Fondaparinux sodium. This strategy described herein provides an efficient method for multi kilograms preparation of Fondaparinux in high yields and high stereoselectivity.
Synthetic Procedures
[0183] The following abbreviations are used herein: Ac is acetyl; ACN is acetonitrile; MS is molecular sieves; DMF is dimethyl formamide; PMB is p-methoxybenzyl; Bn is benzyl; DCM is dichloromethane; THF is tetrahydrofuran; TFA is trifluoro acetic acid; CSA is camphor sulfonic acid; TEA is triethylamine; MeOH is methanol; DMAP is dimethylaminopyridine; RT is room temperature; CAN is ceric ammonium nitrate; Ac 2 O is acetic anhydride; HBr is hydrogen bromide; TEMPO is tetramethylpiperidine-N-oxide; TBACl is tetrabutyl ammonium chloride; EtOAc is ethyl acetate; HOBT is hydroxybenzotriazole; DCC is dicyclohexylcarbodiimide; Lev is levunlinyl; TBDPS is tertiary-butyl diphenylsilyl; TCA is trichloroacetonitrile; O-TCA is O-trichloroacetimidate; Lev 2 O is levulinic anhydride; DIPEA is diisopropylethylamine; Bz is benzoyl; TBAF is tetrabutylammonium fluoride; DBU is diazabicycloundecane; BF 3 .Et 2 O is boron trifluoride etherate; TMSI is trimethylsilyl iodide; TBAI is tetrabutylammonium iodide; TES-Tf is triethylsilyl trifluoromethanesulfonate (triethylsilyl triflate); DHP is dihydropyran; PTS is p-toluenesulfonic acid.
[0184] The monomers used in the processes described herein may be prepared as described in the art, or can be prepared using the methods described herein.
Monomer A-2
[0185]
[0186] The synthesis of Monomer A-2 (CAS Registry Number 134221-42-4) has been described in the following references: Arndt et al., Organic Letters, 5(22), 4179-4182, 2003; Sakairi et al., Bulletin of the Chemical Society of Japan, 67(6), 1756-8, 1994; and Sakairi et al., Journal of the Chemical Society, Chemical Communications , (5), 289-90, 1991, and the references cited therein, which are hereby incorporated by reference in their entireties.
Monomer C
[0187]
[0188] Monomer C(CAS Registry Number 87326-68-9) can be synthesized using the methods described in the following references: Ganguli et al., Tetrahedron: Asymmetry, 16(2), 411-424, 2005; Izumi et al., Journal of Organic Chemistry, 62(4), 992-998, 1997; Van Boeckel et al., Recueil: Journal of the Royal Netherlands Chemical Society, 102(9), 415-16, 1983; Wessel et al., Helvetica Chimica Acta, 72(6), 1268-77, 1989; Petitou et al., U.S. Pat. No. 4,818,816 and references cited therein, which are hereby incorporated by reference in their entireties.
Monomer E
[0189]
[0190] Monomer E (CAS Registry Number 55682-48-9) can be synthesized using the methods described in the following literature references: Hawley et al., European Journal of Organic Chemistry , (12), 1925-1936, 2002; Dondoni et al., Journal of Organic Chemistry, 67(13), 4475-4486, 2002; Van der Klein et al., Tetrahedron, 48(22), 4649-58, 1992; Hori et al., Journal of Organic Chemistry, 54(6), 1346-53, 1989; Sakairi et al., Bulletin of the Chemical Society of Japan, 67(6), 1756-8, 1994; Tailler et al., Journal of the Chemical Society, Perkin Transactions 1 : Organic and Bio - Organic Chemistry , (23), 3163-4, (1972-1999) (1992); Paulsen et al., Chemische Berichte, 111(6), 2334-47, 1978; Dasgupta et al., Synthesis , (8), 626-8, 1988; Paulsen et al., Angewandte Chemie, 87(15), 547-8, 1975; and references cited therein, which are hereby incorporated by reference in their entireties.
Monomer B-1
[0191]
[0192] Monomer B-1 (CAS Registry Number 444118-44-9) can be synthesized using the methods described in the following literature references: Lohman et al., Journal of Organic Chemistry, 68(19), 7559-7561, 2003; Orgueira et al., Chemistry—A European Journal, 9(1), 140-169, 2003; Manabe et al., Journal of the American Chemical Society, 128(33), 10666-10667, 2006; Orgueira et al., Angewandte Chemie, International Edition, 41(12), 2128-2131, 2002; and references cited therein, which are hereby incorporated by reference in their entireties.
Synthesis of Monomer D
[0193] Monomer D was prepared in 8 synthetic steps from glucose pentaacetate using the following procedure:
[0000]
[0194] Pentaacetate SM-B was brominated at the anomeric carbon using HBr in acetic acid to give bromide derivative IntD1. This step was carried out using the reactants SM-B, 33% hydrogen bromide, acetic acid and dichloromethane, stirring in an ice water bath for about 3 hours and evaporating at room temperature. IntD1 was reductively cyclized with sodium borohydride and tetrabutylammonium iodide in acetonitrile using 3 Å molecular sieves as dehydrating agent and stirring at 40° C. for 16 hours to give the acetal derivative, IntD2. The three acetyl groups in IntD2 were hydrolyzed by heating with sodium methoxide in methanol at 50° C. for 3 hours and the reaction mixture was neutralized using Dowex 50WX8-100 resin (Aldrich) in the acid form to give the trihydroxy acetal derivative IntD3.
[0195] The C4 and C6 hydroxyls of IntD3 were protected by mixing with benzaldehyde dimethyl acetate and camphor sulphonic acid at 50° C. for 2 hours to give the benzylidene-acetal derivative IntD4. The free hydroxyl at the C3 position of IntD4 was deprotonated with sodium hydride in THF as solvent at 0° C. and alkylated with benzyl bromide in THF, and allowing the reaction mixture to warm to room temperature with stirring to give the benzyl ether IntD5. The benzylidene moiety of IntD5 was deprotected by adding trifluoroacetic acid in dichloromethane at 0° C. and allowing it to warm to room temperature for 16 hours to give IntD6 with a primary hydroxyl group. IntD6 was then oxidized with TEMPO (2,2,6,6-tetramethyl-1-piperidine-N-oxide) in the presence of tetrabutylammonium chloride, sodium bromide, ethyl acetate, sodium chlorate and sodium bicarbonate, with stirring at room temperature for 16 hours to form the carboxylic acid derivative IntD7. The acid IntD7 was esterified with benzyl alcohol and dicyclohexylcarbodiimide (other reactants being hydroxybenzotriazole and triethylamine) with stirring at room temperature for 16 hours to give Monomer D.
Synthesis of the BA Dimer
[0196] The BA Dimer was prepared in 12 synthetic steps from Monomer B1 and Monomer A2 using the following procedure:
[0000]
[0197] The C4-hydroxyl of Monomer B-1 was levulinated using levulinic anhydride and diisopropylethylamine (DIPEA) with mixing at room temperature for 16 hours to give the levulinate ester BMod1, which was followed by hydrolysis of the acetonide with 90% trifluoroacetic acid and mixing at room temperature for 4 hours to give the diol BMod2. The C1 hydroxyl of the diol BMod2 was silylated with tert-butyldiphenylsilylchloride by mixing at room temperature for 3 hours to give silyl derivative BMod3. The C2-hydroxyl was then benzoylated with benzoyl chloride in pyridine, and mixed at room temperature for 3 hours to give compound BMod4. The silyl group on BMod4 was then deprotected with tert-butyl ammonium fluoride and mixing at room temperature for 3 hours to give the C1-hydroxyl BMod5. The C1-hydroxyl is then allowed to react with trichloroacetonitrile in the presence of diazobicycloundecane (DBU) and mixing at room temperature for 2 hours to give the trichloroacetamidate (TCA) derivative BMod6, which suitable for coupling, for example with Monomer A-2.
[0198] Monomer A-2 was prepared for coupling by opening the anhydro moiety with BF 3 .Et 2 O followed by acetylation of the resulting hydroxyl groups to give the triacetate derivative AMod1.
[0199] Monomer A2 was prepared for the coupling reaction by opening the anhydro moiety and acetylation of the resulting hydroxyl groups to give the triacetate derivative AMod1. This transformation occurs using boron trifluoride etherate, acetic anhydride and dichloromethane, between −20° C. and room temperature for 3 hours. The C1-Acetate of AMod1 was then hydrolyzed and methylated in two steps to give the diacetate AMod3. That is, first AMod1 was reacted with trimethylsilyl iodide and mixed at room temperature for 2 hours, then reacted with and tetrabutyl ammonium iodide. This mixture was reacted with diisopropylethylamine and methanol and stirred for 16 hours at room temperature, thus forming AMod3. The C4 and C6 acetates of AMod3 are hydrolyzed with sodium methoxide to give the diol Amod4. The AMod3 mixture was also subjected to mixing at room temperature for 3 hours with Dowex 50 Wx4X8-100 resin in the acid form for neutralization. This formed Amod4. The C6-hydroxyl of AMod4 is then benzoylated by treating with benzoyl chloride in pyridine at −40° C. and then allowing it to warm up to −10° C. over 2 hours to give AMod5.
[0200] Coupling of monomer AMod5 with the free C4-hydroxyl group of BMod6 was performed in the presence of BF 3 .Et 2 O and dichloromethane with mixing between −20° C. and room temperature for 3 hours to provide disaccharide BA1. The C4-levulinyl moiety of the disaccharide was then hydrolyzed with hydrazine to give the BA Dimer, which is suitable for subsequent coupling reactions.
Synthesis of EDC Trimer
[0201] The EDC Trimer was prepared in 10 synthetic steps from Monomer E, Monomer D and Monomer C using the following procedure:
[0000]
[0202] Monomer E was prepared for coupling by opening the anhydro moiety with BF 3 .Et 2 O followed by acetylation of the resulting hydroxyl groups to give diacetate EMod1. This occurs by the addition of Monomer E with boron trifluoride etherate, acetic anhydride and dichloromethane at −10° C., and allowing the reaction to warm to room temperature with stirring for 3 hours. The C1-Acetate of EMod1 is then hydrolyzed to give the alcohol, EMod2. This occurs by reacting Emod1 with hydrazine acetate and dimethylformamide and mixing at room temperature for 3 hours. The C1-hydroxyl of Emod2 is then reacted with trichloroacetonitrile to give the trichloro acetamidate (TCA) derivative EMod3 suitable for coupling, which reaction also employs diazabicycloundecane and dichloromethane and mixing at room temperature for 2 hours.
[0203] Monomer D, having a free C4-hydroxyl group, was coupled with monomer EMod3 in the presence of triethylsilyl triflate with mixing at −40° C. for 2 hours to give the disaccharide ED Dimer. The acetal on ring sugar D of the ED Dimer is hydrolyzed to give the C1,C2-diol ED1. This occurs by reacting the ED Dimer with 90% trifluoro acetic acid and mixing at room temperature for 4 hours. The C1-hydroxyl moiety of ED1 was then silylated with tert-butyldiphenylsilyl chloride to give the silyl derivative ED2. The C2-hydroxyl of ED2 was then allowed to react with levulinic anhydride in the presence of dimethylaminopyridine (DMAP) and diethylisopropylamine for approximately 16 hours to give the levulinate ester ED3. The TBDPS moiety is then deprotected by removal with tert-butylammonium fluoride in acetic acid with mixing at room temperature for 3 hours to give ED4 having a C1-hydroxyl. The C1-hydroxyl moiety of ED4 was then allowed to react with trichloroacetonitrile to give the TCA derivative ED5, which is suitable for coupling.
[0204] The C1-hydroxyl moiety of ED4 is then allowed to react with trichloroacetonitrile to give the TCA derivative ED5 suitable for coupling using diazabicycloundecane and dichloromethane, and mixing at room temperature for 2 hours. Monomer C, having a free C4-hydroxyl group, was then coupled with the disaccharide ED5 in the presence of triethylsilyl triflate and mixed at −20° C. for 2 hours to give the trisaccharide EDC Trimer.
Synthesis of the EDCBA Pentamer
[0205] The EDCBA Pentamer was prepared using the following procedure:
[0000]
[0206] The preparation of EDCBA Pentamer is accomplished in two parts as follows. In part 1, the EDC Trimer, a diacetate intermediate, is prepared for the coupling reaction with Dimer BA by initially opening the anhydro moiety and acetylation of the resulting hydroxyl groups to give the tetraacetate derivative EDC1. This occurs by reacting the EDC Trimer with boron trifluoride etherate, acetic anhydride and dichlormethane and stirring between −10° C. and room temperature for 3 hours. The C1-Acetate of EDC1 is then hydrolyzed to give the alcohol, EDC2, by reacting EDC1 with benzylamine [BnNH 2 ] and tetrahydrofuran and mixing at −10° C. for 3 hours. The C1-hydroxyl of EDC2 is then reacted with trichloroacetonitrile and diazabicycloundecane, with mixing at room temperature for 2 hours, to give the trichloro acetamidate (TCA) derivative EDC3 suitable for coupling.
[0000]
[0207] In Part 2 of the EDCBA Pentameter synthesis, the Dimer BA, having a free C4-hydroxyl group, is coupled with trisaccharide EDC3 in the presence of triethylsilyltriflate at −30° C. mixing for 2 hours to give the pentasaccharide EDCBA1. The levulinyl ester on C2 of sugar D in EDCBA1 is hydrolyzed with a mixture of deprotecting agents, hydrazine hydrate and hydrazine acetate and stiffing at room temperature for 3 hours to give the C2-hydroxyl containing intermediate EDCBA2. The C2-hydroxyl moiety on sugar D of EDCBA2 is then alkylated with dihydropyran (DHP) in the presence of camphor sulfonic acid (CSA) and tetrahydrofuran with mixing at room temperature for 3 hours to give the tetrahydropyranyl ether (THP) derivative, EDCBA Pentamer.
Synthesis of Fondaparinux
[0208] Fondaparinux was prepared using the following procedure:
[0000]
[0209] The ester moieties in EDCBA Pentamer were hydrolyzed with sodium and lithium hydroxide in the presence of hydrogen peroxide in dioxane mixing at room temperature for 16 hours to give the pentasaccharide intermediate API1. The five hydroxyl moieties in API1 were sulfated using a pyridine-sulfur trioxide complex in dimethylformamide, mixing at 60° C. for 2 hours and then purified using column chromatography (CG-161), to give the pentasulfated pentasaccharide API2. The intermediate API2 was then hydrogenated to reduce the three azides on sugars E, C and A to amines and the reductive deprotection of the five benzyl ethers to their corresponding hydroxyl groups to form the intermediate API3. This transformation occurs by reacting API2 with 10% palladium/carbon catalyst with hydrogen gas for 72 hours. The three amines on API3 were then sulfated using the pyridine-sulfur trioxide complex in sodium hydroxide and ammonium acetate, allowing the reaction to proceed for 12 hours. The acidic work-up procedure of the reaction removes the THP group to provide crude fondaparinux which is purified and is subsequently converted to its salt form. The crude mixture was purified using an ion-exchange chromatographic column (HiQ resin) followed by desalting using a size exclusion resin or gel filtration (Biorad Sephadex G25) to give the final API, fondaparinux sodium.
Experimental Procedures
Preparation of IntD1
Bromination of Glucose Pentaacetate
[0210] To a 500 ml flask was added 50 g of glucose pentaacetate (C 6 H 22 O 11 ) and 80 ml of methylene chloride. The mixture was stirred at ice-water bath for 20 min HBr in HOAc (33%, 50 ml) was added to the reaction mixture. After stirring for 2.5 hr another 5 ml of HBr was added to the mixture. After another 30 min, the mixture was added 600 ml of methylene chloride. The organic mixture was washed with cold water (200 ml×2), Saturated NaHCO 3 (200 ml×2), water (200 ml) and brine (200 ml×2). The organic layer was dried over Na 2 SO 4 and the mixture was evaporated at RT to give white solid as final product, bromide derivative, IntD1 (˜95% yield). C 14 H 19 BrO 9 , TLC R f =0.49, SiO 2 , 40% ethyl acetate/60% hexanes; Exact Mass 410.02.
Preparation of IntD2 by Reductive Cyclization
[0211] To a stirring mixture of bromide IntD1 (105 g), tetrabutylammonium iodide (60 g, 162 mmol) and activated 3 Å molecular sieves in anhydrous acetonitrile (2 L), solid NaBH 4 (30 g, 793 mmol) was added. The reaction was heated at 40° C. overnight. The mixture was then diluted with dichloromethane (2 L) and filtered through Celite®. After evaporation, the residue was dissolved in 500 ml ethyl acetate. The white solid (Bu 4 NI or Bu 4 NBr) was filtered. The ethyl acetate solution was evaporated and purified by chromatography on silica gel using ethyl acetate and hexane as eluent to give the acetal-triacetate IntD2 (˜60-70% yield). TLC R f =0.36, SiO 2 in 40% ethyl acetate/60% hexanes.
Preparation of IntD3 by De-Acetylation
[0212] To a 1000 ml flask was added triacetate IntD2 (55 g) and 500 ml of methanol. After stirring 30 min, the reagent NaOMe (2.7 g, 0.3 eq) was added and the reaction was stirred overnight. Additional NaOMe (0.9 g) was added to the reaction mixture and heated to 50° C. for 3 hr. The mixture was neutralized with Dowex 50W×8 cation resin, filtered and evaporated. The residue was purified by silica gel column to give 24 g of trihydroxy-acetal IntD3. TLC R f =0.36 in SiO 2 , 10% methanol/90% ethyl acetate.
Preparation of IntD4 by Benzylidene Formation
[0213] To a 1000 ml flask was added trihydroxy compound IntD3 (76 g) and benzaldehyde dimethyl acetate (73 g, 1.3 eq). The mixture was stirred for 10 min, after which D(+)-camphorsulfonic acid (8.5 g, CSA) was added. The mixture was heated at 50° C. for two hours. The reaction mixture was then transferred to separatory funnel containing ethyl acetate (1.8 L) and sodium bicarbonate solution (600 ml). After separation, the organic layer was washed with a second sodium bicarbonate solution (300 ml) and brine (800 ml). The two sodium carbonate solutions were combined and extracted with ethyl acetate (600 ml×2). The organic mixture was evaporated and purified by silica gel column to give the benzylidene product IntD4 (77 g, 71% yield). TLC R f =0.47, SiO 2 in 40% ethyl acetate/60% hexanes.
Preparation of IntD5 by Benzylation
[0214] To a 500 ml flask was added benzylidene acetal compound IntD4 (21 g,) in 70 ml THF. To another flask (1000 ml) was added NaH (2 eq). The solution of IntD4 was then transferred to the NaH solution at 0° C. The reaction mixture was stirred for 30 min, then benzyl bromide (16.1 ml, 1.9 eq) in 30 ml THF was added. After stirring for 30 min, DMF (90 ml) was added to the reaction mixture. Excess NaH was neutralized by careful addition of acetic acid (8 ml). The mixture was evaporated and purified by silica gel column to give the benzyl derivative IntD5. (23 g) TLC R f =0.69, SiO 2 in 40% ethyl acetate/60% hexanes.
Preparation of IntD6 by Deprotection of Benzylidene
[0215] To a 500 ml flask was added the benzylidene-acetal compound IntD5 (20 g) and 250 ml of dichloromethane, the reaction mixture was cooled to 0° C. using an ice-water-salt bath. Aqueous TFA (80%, 34 ml) was added to the mixture and stirred over night. The mixture was evaporated and purified by silica gel column to give the dihydroxy derivative IntD6. (8 g, 52%). TLC R f =0.79, SiO 2 in 10% methanol/90% ethyl acetate.
Preparation of IntD7 by Oxidation of 6-Hydroxyl
[0216] To a 5 L flask was added dihydroxy compound IntD6 (60 g), TEMPO (1.08 g), sodium bromide (4.2 g), tetrabutylammonium chloride (5.35 g), saturated NaHCO 3 (794 ml) and EtOAc (1338 ml). The mixture was stirred over an ice-water bath for 30 min. To another flask was added a solution of NaOCl (677 ml), saturated NaHCO 3 (485 ml) and brine (794 ml). The second mixture was added slowly to the first mixture (over about two hrs). The resulting mixture was then stirred overnight. The mixture was separated, and the inorganic layer was extracted with EtOAc (800 ml×2). The combined organic layers were washed with brine (800 ml). Evaporation of the organic layer gave 64 g crude carboxylic acid product IntD7 which was used in the next step use without purification. TLC R f =0.04, SiO 2 in 10% methanol/90% ethyl acetate.
Preparation of Monomer D by Benzylation of the Carboxylic Acid
[0217] To a solution of carboxylic acid derivative IntD7 (64 g) in 600 ml of dichloromethane, was added benzyl alcohol (30 g) and N-hydroxybenzotriazole (80 g, HOBt). After stirring for 10 min triethylamine (60.2 g) was added slowly. After stirring another 10 min, dicyclohexylcarbodiimide, (60.8 g, DCC) was added slowly and the mixture was stirred overnight. The reaction mixture was filtered and the solvent was removed under reduced pressure followed by chromatography on silica gel to provide 60.8 g (75%, over two steps) of product, Monomer D. TLC R f =0.51, SiO 2 in 40% ethyl acetate/60% hexanes.
Synthesis of the BA Dimer
Step 1. Preparation of BMod1, Levulination of Monomer B1
[0218] A 100 L reactor was charged with 7.207 Kg of Monomer B1 (21.3 moles, 1 equiv), 20 L of dry tetrahydrofuran (THF) and agitated to dissolve. When clear, it was purged with nitrogen and 260 g of dimethylamino pyridine (DMAP, 2.13 moles, 0.1 equiv) and 11.05 L of diisopropylethylamine (DIPEA, 8.275 kg, 63.9 moles, 3 equiv) was charged into the reactor. The reactor was chilled to 10-15° C. and 13.7 kg levulinic anhydride (63.9 mol, 3 equiv) was transferred into the reactor. When the addition was complete, the reaction was warmed to ambient temperature and stirred overnight or 12-16 hours. Completeness of the reaction was monitored by TLC (40:60 ethyl acetate/hexane) and HPLC. When the reaction was complete, 20 L of 10% citric acid, 10 L of water and 25 L of ethyl acetate were transferred into the reactor. The mixture was stirred for 30 min and the layers were separated. The organic layer (EtOAc layer) was extracted with 20 L of water, 20 L 5% sodium bicarbonate and 20 L 25% brine solutions. The ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.) and dried overnight. The yield of the isolated syrup of BMod1 was 100%.
Synthesis of the BA Dimer
Step 2. Preparation of BMod2, TFA Hydrolysis of BMod1
[0219] A 100 L reactor was charged with 9296 Kg of 4-Lev Monomer B1 (BMod1) (21.3 mol, 1 equiv). The reactor chiller was turned to <5° C. and stirring was begun, after which 17.6 L of 90% TFA solution (TFA, 213 mole, 10 equiv) was transferred into the reactor. When the addition was complete, the reaction was monitored by TLC and HPLC. The reaction took approximately 2-3 hours to reach completion. When the reaction was complete, the reactor was chilled and 26.72 L of triethylamine (TEA, 19.4 Kg, 191.7 mole, 0.9 equiv) was transferred into the reactor. An additional 20 L of water and 20 L ethyl acetate were transferred into the reactor. This was stirred for 30 min and the layers were separated. The organic layer was extracted (EtOAc layer) with 20 L 5% sodium bicarbonate and 20 L 25% brine solutions. The ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 50:50, 80:20 (EtOAc/heptane), 100% EtOAc, 5:95, 10:90 (MeOH/EtOAc). The pure fractions were pooled and evaporated to a syrup. The yield of the isolated syrup, BMod2 was 90%.
Synthesis of the BA Dimer
Step 3. Preparation of BMod3, Silylation of BMod2
[0220] A 100 L reactor was charged with 6.755 Kg 4-Lev-1,2-DiOH Monomer B1 (BMod2) (17.04 mol, 1 equiv), 2328 g of imidazole (34.2 mol, 2 equiv) and 30 L of dichloromethane. The reactor was purged with nitrogen and chilled to −20° C., then 5.22 L tert-butyldiphenylchloro-silane (TBDPS-Cl, 5.607 Kg, 20.4 mol, 1.2 equiv) was transferred into the reactor. When addition was complete, the chiller was turned off and the reaction was allowed to warm to ambient temperature. The reaction was monitored by TLC (40% ethyl acetate/hexane) and HPLC. The reaction took approximately 3 hours to reach completion. When the reaction was complete, 20 L of water and 10 L of DCM were transferred into the reactor and stirred for 30 min, after which the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. Dichloromethane solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The yield of BMod3 was about 80%.
Synthesis of the BA Dimer
Step 4. Preparation of BMod4, Benzoylation
[0221] A 100 L reactor was charged with 8.113 Kg of 4-Lev-1-Si-2-OH Monomer B1 (BMod3) (12.78 mol, 1 equiv), 9 L of pyridine and 30 L of dichloromethane. The reactor was purged with nitrogen and chilled to −20° C., after which 1.78 L of benzoyl chloride (2155 g, 15.34 mol, 1.2 equiv) was transferred into the reactor. When addition was complete, the reaction was allowed to warm to ambient temperature. The reaction was monitored by TLC (40% ethyl acetate/heptane) and HPLC. The reaction took approximately 3 hours to reach completion. When the reaction was complete, 20 L of water and 10 L of DCM were transferred into the reactor and stirred for 30 min, after which the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. The DCM solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). Isolated syrup BMod4 was obtained in 91% yield.
Synthesis of the BA Dimer
Step 5. Preparation of BMod5, Desilylation
[0222] A 100 L reactor was charged with 8.601 Kg of 4-Lev-1-Si-2-Bz Monomer B1 (BMod4) (11.64 mol, 1 equiv) in 30 L tetrahydrofuran. The reactor was purged with nitrogen and chilled to 0° C., after which 5.49 Kg of tetrabutylammonium fluoride (TBAF, 17.4 mol, 1.5 equiv) and 996 mL (1045 g, 17.4 mol, 1.5 equiv) of glacial acetic acid were transferred into the reactor. When the addition was complete, the reaction was stirred at ambient temperature. The reaction was monitored by TLC (40:60 ethyl acetate/hexane) and HPLC. The reaction took approximately 6 hours to reach completion. When the reaction was complete, 20 L of water and 10 L of DCM were transferred into the reactor and stirred for 30 min, after which the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. The dichloromethane solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20 (EtOAc/heptane) and 200 L 100% EtOAc. Pure fractions were pooled and evaporated to a syrup. The intermediate BMod5 was isolated as a syrup in 91% yield.
Synthesis of the BA Dimer
Step 6: Preparation of BMod6, TCA Formation
[0223] A 100 L reactor was charged with 5.238 Kg of 4-Lev-1-OH-2-Bz Monomer B1 (BMod5) (10.44 mol, 1 equiv) in 30 L of DCM. The reactor was purged with nitrogen and chilled to 10-15° C., after which 780 mL of diazabicyclo undecene (DBU, 795 g, 5.22 mol, 0.5 equiv) and 10.47 L of trichloroacetonitrile (TCA, 15.08 Kg, 104.4 mol, 10 equiv) were transferred into the reactor. Stirring was continued and the reaction was kept under a nitrogen atmosphere. After reagent addition, the reaction was allowed to warm to ambient temperature. The reaction was monitored by HPLC and TLC (40:60 ethyl acetate/heptane). The reaction took approximately 2 hours to reach completion. When the reaction was complete, 20 L of water and 10 L of dichloromethane were transferred into the reactor. This was stirred for 30 min and the layers were separated. The organic layer (DCM layer) was separated with 20 L water and 20 L 25% brine solutions. The dichloromethane solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90, 20:80, 30:70, 40:60 and 50:50 (EtOAc/Heptane). Pure fractions were pooled and evaporated to a syrup. The isolated yield of BMod6 was 73%.
Synthesis of the BA Dimer
Step 7. Preparation of AMod1, Acetylation of Monomer A2
[0224] A 100 L reactor was charged with 6.772 Kg of Monomer A2 (17.04 mole, 1 eq.), 32.2 L (34.8 Kg, 340.8 moles, 20 eq.) of acetic anhydride and 32 L of dichloromethane. The reactor was purged with nitrogen and chilled to −20° C. When the temperature reached −20° C., 3.24 L (3.63 Kg, 25.68 mol, 1.5 equiv) of boron trifluoride etherate (BF 3 .Et 2 O) was transferred into the reactor. After complete addition of boron trifluoride etherate, the reaction was allowed to warm to room temperature. The completeness of the reaction was monitored by HPLC and TLC (30:70 ethyl acetate/heptane). The reaction took approximately 3-5 hours for completion. When the reaction was complete, extraction was performed with 3×15 L of 10% sodium bicarbonate and 20 L of water. The organic phase (DCM) was evaporated to a syrup (bath temp. 40° C.) and allowed to dry overnight. The syrup was purified in a 200 L silica column using 140 L each of the following gradient profiles: 5:95, 10:90, 20:80, 30:70, 40:60 and 50:50 (EtOAc/heptane). Pure fractions were pooled and evaporated to a syrup. The isolated yield of AMod1 was 83%.
Synthesis of the BA Dimer
Step 8. Preparation of AMod3,1-Methylation of AMod1
[0225] A 100 L reactor was charged with 5891 g of acetyl Monomer A2 (AMod1) (13.98 mole, 1 eq.) in 32 L of dichloromethane. The reactor was purged with nitrogen and was chilled to 0° C., after which 2598 mL of trimethylsilyl iodide (TMSI, 3636 g, 18 mol, 1.3 equiv) was transferred into the reactor. When addition was complete, the reaction was allowed to warm to room temperature. The completeness of the reaction was monitored by HPLC and TLC (30:70 ethyl acetate/heptane). The reaction took approximately 2-4 hours to reach completion. When the reaction was complete, the mixture was diluted with 20 L of toluene. The solution was evaporated to a syrup and was co-evaporated with 3×6 L of toluene. The reactor was charged with 36 L of dichloromethane (DCM), 3.2 Kg of dry 4 Å Molecular Sieves, 15505 g (42 mol, 3 equiv) of tetrabutyl ammonium iodide (TBAI) and 9 L of dry methanol. This was stirred until the TBAI was completely dissolved, after which 3630 mL of diisopropyl-ethylamine (DIPEA, 2712 g, 21 moles, 1.5 equiv) was transferred into the reactor in one portion. The completion of the reaction was monitored by HPLC and TLC (30:70 ethyl acetate/heptane). The reaction took approximately 16 hours for completion. When the reaction was complete, the molecular sieves were removed by filtration. Added were 20 L EtOAc and extracted with 4×20 L of 25% sodium thiosulfate and 20 L 10% NaCl solutions. The organic layer was separated and dried with 8-12 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 5:95, 10:90, 20:80, 30:70 and 40:60 (EtOAc/heptane). The pure fractions were pooled and evaporated to give intermediate AMod3 as a syrup. The isolated yield was 75%.
Synthesis of the BA Dimer
Step 9. Preparation of AMod4, DeAcetylation of AMod3
[0226] A 100 L reactor was charged with 4128 g of 1-Methyl 4,6-Diacetyl Monomer A2 (AMod3) (10.5 mol, 1 equiv) and 18 L of dry methanol and dissolved, after which 113.4 g (2.1 mol, 0.2 equiv) of sodium methoxide was transferred into the reactor. The reaction was stirred at room temperature and monitored by TLC (40% ethyl acetate/hexane) and HPLC. The reaction took approximately 2-4 hours for completion. When the reaction was complete, Dowex 50W×8 cation resin was added in small portions until the pH reached 6-8. The Dowex 50W×8 resin was filtered and the solution was evaporated to a syrup (bath temp. 40° C.). The syrup was diluted with 10 L of ethyl acetate and extracted with 20 L brine and 20 L water. The ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.) and dried overnight at the same temperature. The isolated yield of the syrup AMod4 was about 88%.
Synthesis of the BA Dimer
Step 10. Preparation of AMod5,6-Benzoylation
[0227] A 100 L reactor was charged with 2858 g of Methyl 4,6-diOH Monomer A2 (AMod4) (9.24 mol, 1 equiv) and co-evaporated with 3×10 L of pyridine. When evaporation was complete, 15 L of dichloromethane, 6 L of pyridine were transferred into the reactor and dissolved. The reactor was purged with nitrogen and chilled to −40° C. The reactor was charged with 1044 mL (1299 g, 9.24 mol, 1 equiv) of benzoyl chloride. When the addition was complete, the reaction was allowed to warm to −10° C. over a period of 2 hours. The reaction was monitored by TLC (60% ethyl acetate/hexane). When the reaction was completed, the solution was evaporated to a syrup (bath temp. 40° C.). This was co-evaporated with 3×15 L of toluene. The syrup was diluted with 40 L ethyl acetate. Extraction was carried out with 20 L of water and 20 L of brine solution. The Ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 5:95, 10:90, 20:80, 25:70 and 30:60 (EtOAc/heptane). The pure fractions were pooled and evaporated to a syrup. The isolated yield of the intermediate AMod5 was 84%.
Synthesis of the BA Dimer
Step 11. Preparation of BA1, Coupling of Amod5 with BMod6
[0228] A 100 L reactor was charged with 3054 g of methyl 4-Hydroxy-Monomer A2 (AMod5) from Step 10 (7.38 mol, 1 equiv) and 4764 g of 4-Lev-1-TCA-Monomer B1 (BMod6) from Step 6 (7.38 mol, 1 equiv). The combined monomers were dissolved in 20 L of toluene and co-evaporated at 40° C. Co evaporation was repeated with an additional 2×20 L of toluene, after which 30 L of dichloromethane (DCM) was transferred into the reactor and dissolved. The reactor was purged with nitrogen and was chilled to below −20° C. When the temperature was between −20° C. and −40° C., 1572 g (1404 mL, 11.12 moles, 1.5 equiv) of boron trifluoride etherate (BF 3 .Et 2 O) were transferred into the reactor. After complete addition of boron trifluoride etherate, the reaction was allowed to warm to 0° C. and stirring was continued. The completeness of the reaction was monitored by HPLC and TLC (40:70 ethyl acetate/heptane). The reaction required 3-4 hours to reach completion. When the reaction was complete, 926 mL (672 g, 6.64 mol, 0.9 equiv) of triethylamine (TEA) was transferred into the mixture and stirred for an additional 30 minutes, after which 20 L of water and 10 L of dichloromethane were transferred into the reactor. The solution was stirred for 30 min and the layers were separated. The organic layer (DCM layer) was separated with 2×20 L water and 20 L 25% 4:1 sodium chloride/sodium bicarbonate solution. The dichloromethane solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.) and used in the next step. The isolated yield of the disaccharide BA1 was about 72%.
Synthesis of the BA Dimer
Step 12, Removal of Levulinate
Methyl [(methyl 2-O-benzoyl-3-O-benzyl-α-L-Idopyranosyluronate)-(1→4)-2-azido-6-O-benzoyl-3-O-benzyl]-2-deoxy-α-D-glucopyranoside
[0229] A 100 L reactor was charged with 4.104 Kg of 4-Lev BA Dimer (BA1) (4.56 mol, 1 equiv) in 20 L of THF. The reactor was purged with nitrogen and chilled to −20 to −25° C., after which 896 mL of hydrazine hydrate (923 g, 18.24 mol, 4 equiv) was transferred into the reactor. Stirring was continued and the reaction was monitored by TLC (40% ethyl acetate/heptane) and HPLC. The reaction took approximately 2-3 hour for the completion, after which 20 L of 10% citric acid, 10 L of water and 25 L of ethyl acetate were transferred into the reactor. This was stirred for 30 min and the layers were separated. The organic layer (ETOAc layer) was extracted with 20 L 25% brine solutions. The ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90, 20:80, 30:70, 40:60 and 50:50 (EtOAc/heptane). The pure fractions were pooled and evaporated to dryness. The isolated yield of the BA Dimer was 82%. Formula: C 42 H 43 N 3 O 13 ; Mol. Wt. 797.80.
Synthesis of the EDC Trimer
Step 1. Preparation of EMod1, Acetylation
[0230] A 100 L reactor was charged with 16533 g of Monomer E (45 mole, 1 eq.), 21.25 L acetic anhydride (225 mole, 5 eq.) and 60 L of dichloromethane. The reactor was purged with nitrogen and was chilled to −10° C. When the temperature was at −10° C., 1.14 L (1277 g) of boron trifluoride etherate (BF 3 .Et 2 O, 9.0 moles, 0.2 eq) were transferred into the reactor. After the complete addition of boron trifluoride etherate, the reaction was allowed to warm to room temperature. The completeness of the reaction was monitored by TLC (30:70 ethyl acetate/heptane) and HPLC. The reaction took approximately 3-6 hours to reach completion. When the reaction was completed, the mixture was extracted with 3×50 L of 10% sodium bicarbonate and SOL of water. The organic phase (DCM) was evaporated to a syrup (bath temp. 40° C.) and allowed to dry overnight. The isolated yield of EMod1 was 97%.
Synthesis of the EDC Trimer
Step 2. Preparation of EMod2, De-Acetylation of Azidoglucose
[0231] A 100 L reactor was charged with 21016 g of 1,6-Diacetyl Monomer E (EMod1) (45 mole, 1 eq.), 5434 g of hydrazine acetate (NH 2 NH 2 .HOAc, 24.75 mole, 0.55 eq.) and 50 L of DMF (dimethyl formamide). The solution was stirred at room temperature and the reaction was monitored by TLC (30% ethyl acetate/hexane) and HPLC. The reaction took approximately 2-4 hours for completion. When the reaction was completed, 50 L of dichloromethane and 40 L of water were transferred into the reactor. This was stirred for 30 minutes and the layers were separated. This was extracted with an additional 40 L of water and the organic phase was dried in 6-8 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.) and dried overnight at the same temperature. The syrup was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 20:80, 30:70, 40:60 and 50:50 (EtOAc/heptane). Pure fractions were pooled and evaporated to a syrup. The isolated yield of intermediate EMod2 was 100%.
Synthesis of the EDC Trimer
Step 3. Preparation of EMod3, Formation of 1-TCA
[0232] A 100 L reactor was charged with 12752 g of 1-Hydroxy Monomer E (EMod2) (30 mole, 1 eq.) in 40 L of dichloromethane. The reactor was purged with nitrogen and stirring was started, after which 2.25 L of DBU (15 moles, 0.5 eq.) and 15.13 L of trichloroacetonitrile (150.9 moles, 5.03 eq) were transferred into the reactor. Stirring was continued and the reaction was kept under nitrogen. After the reagent addition, the reaction was allowed to warm to ambient temperature. The reaction was monitored by TLC (30:70 ethyl acetate/Heptane) and HPLC. The reaction took approximately 2-3 hours to reach completion. When the reaction was complete, 40 L of water and 20 L of DCM were charged into the reactor. This was stirred for 30 min and the layers were separated. The organic layer (DCM layer) was extracted with 40 L water and the DCM solution was dried in 6-8 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90 (DCM/EtOAc/heptane), 20:5:75 (DCM/EtOAc/heptane) and 20:10:70 DCM/EtOAc/heptane). Pure fractions were pooled and evaporated to give Intermediate EMod3 as a syrup. Isolated yield was 53%.
Synthesis of the EDC Trimer
Step 4. Preparation of ED Dimer, Coupling of E-TCA with Monomer D
[0233] A 100 L reactor was charged with 10471 g of 6-Acetyl-1-TCA Monomer E (EMod3) (18.3 mole, 1 eq., FW: 571.8) and 6594 g of Monomer D (16.47 mole, 0.9 eq, FW: 400.4). The combined monomers were dissolved in 20 L toluene and co-evaporated at 40° C. This was repeated with co-evaporation with an additional 2×20 L of toluene, after which 60 L of dichloromethane (DCM) were transferred into the reactor and dissolved. The reactor was purged with nitrogen and was chilled to −40° C. When the temperature was between −30° C. and −40° C., 2423 g (2071 mL, 9.17 moles, 0.5 eq) of TES Triflate were transferred into the reactor. After complete addition of TES Triflate the reaction was allowed to warm and stirring was continued. The completeness of the reaction was monitored by HPLC and TLC (35:65 ethyl acetate/Heptane). The reaction required 2-3 hours to reach completion. When the reaction was completed, 2040 mL of triethylamine (TEA, 1481 g, 0.8 eq.) were transferred into the reactor and stirred for an additional 30 minutes. The organic layer (DCM layer) was extracted with 2×20 L 25% 4:1 sodium chloride/sodium bicarbonate solution. The dichloromethane solution was dried in 6-8 Kg of anhydrous sodium sulfate. The syrup was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 15:85, 20:80, 25:75, 30:70 and 35:65 (EtOAc/heptane). Pure fractions were pooled and evaporated to a syrup. The ED Dimer was obtained in 81% isolated yield.
Synthesis of the EDC Trimer
Step 5. Preparation of ED1 TFA, Hydrolysis of ED Dimer
[0234] A 100 L reactor was charged with 7.5 Kg of ED Dimer (9.26 mol, 1 equiv). The reactor was chilled to <5° C. and 30.66 L of 90% TFA solution (TFA, 370.4 mol, 40 equiv) were transferred into the reactor. When the addition was completed the reaction was allowed to warm to room temperature. The reaction was monitored by TLC (40:60 ethyl acetate/hexanes) and HPLC. The reaction took approximately 3-4 hours to reach completion. When the reaction was completed, was chilled and 51.6 L of triethylamine (TEA, 37.5 Kg, 370.4 mole) were transferred into the reactor, after which 20 L of water & 20 L ethyl acetate were transferred into the reactor. This was stirred for 30 min and the layers were separated. The organic layer (EtOAc layer) was extracted with 20 L 5% sodium bicarbonate and 20 L 25% brine solutions. Ethyl acetate solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 20:80, 30:70, 40:60, 50:50, 60:40 (EtOAc/heptane). The pure fractions were pooled and evaporated to a syrup. Isolated yield of ED1 was about 70%.
Synthesis of the EDC Trimer
Step 6. Preparation of ED2, Silylation of ED1
[0235] A 100 L reactor was charged with 11000 g of 1,2-diOH ED Dimer (ED1) (14.03 mol, 1 equiv), 1910.5 g of imidazole (28.06 mol, 2 equiv) and 30 L of dichloromethane. The reactor was purged with nitrogen and chilled to −20° C., after which 3.53 L butyldiphenylchloro-silane (TBDPS-Cl, 4.628 Kg, 16.835 mol, 1.2 equiv) was charged into the reactor. When the addition was complete, the chiller was turned off and the reaction was allowed to warm to ambient temperature. The reaction was monitored by TLC (50% ethyl acetate/hexane) and HPLC. The reaction required 4-6 hours to reach completion. When the reaction was completed, 20 L of water and 10 L of dichloromethane were transferred into the reactor and stirred for 30 min and the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. Dichloromethane solution was dried in 4-6 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). Intermediate ED2 was obtained in 75% isolated yield.
Synthesis of the EDC Trimer
Step 7. Preparation of ED3, D-Levulination
[0236] A 100 L reactor was charged with 19800 g of 1-Silyl ED Dimer (ED2) (19.37 moles, 1 equiv) and 40 L of dry tetrahydrofuran (THF) and agitated to dissolve. The reactor was purged with nitrogen and 237 g of dimethylaminopyridine (DMAP, 1.937 moles, 0.1 equiv) and 10.05 L of diisopropylethylamine (DIPEA, 63.9 moles, 3 equiv) were transferred into the reactor. The reactor was chilled to 10-15° C. and kept under a nitrogen atmosphere, after which 12.46 Kg of levulinic anhydride (58.11 moles, 3 eq) was charged into the reactor. When the addition was complete, the reaction was warmed to ambient temperature and stirred overnight or 12-16 hours. The completeness of the reaction was monitored by TLC (40:60 ethyl acetate/hexane) and by HPLC. 20 L of 10% citric acid, 10 L of water and 25 L of ethyl acetate were transferred into the reactor. This was stirred for 30 min and the layers were separated. The organic layer (EtOAc layer) was extracted with 20 L of water, 20 L 5% sodium bicarbonate and 20 L 25% brine solutions. The ethyl acetate solution was dried in 6-8 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The ED3 yield was 95%.
Synthesis of the EDC Trimer
Step 8. Preparation of ED4, Desilylation of ED3
[0237] A 100 L reactor was charged with 19720 g of 1-Silyl-2-Lev ED Dimer (ED3) (17.6 mol, 1 equiv) in 40 L of THF. The reactor was chilled to 0° C., after which 6903 g of tetrabutylammonium fluoride trihydrate (TBAF, 26.4 mol, 1.5 equiv) and 1511 mL (26.4 mol, 1.5 equiv) of glacial acetic acid were transferred into the reactor. When the addition was complete, the reaction was stirred and allowed to warm to ambient temperature. The reaction was monitored by TLC (40:60 ethyl acetate/hexane) and HPLC. The reaction required 3 hours to reach completion. When the reaction was completed, 20 L of water and 10 L of dichloromethane were transferred into the reactor and stirred for 30 min and the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. The dichloromethane solution was dried in 6-8 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified using a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90, 20:80, 30:70, 40:60, 50:50, 60:40, 70:30, 80:20 (EtOAc/heptane) and 200 L 100% EtOAc. The pure fractions were pooled and evaporated to a syrup and used in the next step. The isolated yield of ED4 was about 92%.
Synthesis of the EDC Trimer
Step 9. Preparation of ED5, TCA Formation
[0238] A 100 L reactor was charged with 14420 g of 1-OH-2-Lev ED Dimer (ED4) (16.35 mol, 1 equiv) in 30 L of dichloromethane. The reactor was purged with nitrogen and stirring was begun, after which 1222 mL of diazabicycloundecene (DBU, 8.175 mol, 0.5 equiv) and 23.61 Kg of trichloroacetonitrile (TCA, 163.5 mol, 10 equiv) were transferred into the reactor. Stirring was continued and the reaction was kept under nitrogen. After reagent addition, the reaction was allowed to warm to ambient temperature. The reaction was monitored by HPLC and TLC (40:60 ethyl acetate/heptane). The reaction took approximately 2 hours for reaction completion. When the reaction was completed, 20 L of water and 10 L of DCM were transferred into the reactor and stirred for 30 min and the layers were separated. The organic layer (DCM layer) was extracted with 20 L water and 20 L 25% brine solutions. The dichloromethane solution was dried in 6-8 Kg of anhydrous sodium sulfate. The solution was evaporated to a syrup (bath temp. 40° C.). The crude product was purified using a 200 L silica column using 140-200 L each of the following gradient profiles: 10:90, 20:80, 30:70, 40:60 and 50:50 (EtOAc/heptane). The pure fractions were pooled and evaporated to a syrup and used in the next step. The isolated yield of intermediate ED5 was about 70%.
Synthesis of the EDC Trimer
Step 10. Preparation of EDC Trimer, Coupling of ED5 with Monomer C
6-O-acetyl-2-azido-3,4-di-O-benzyl-2-deoxy-α-D-glucopyranosyl-(1→4)-benzyl (3-O-benzyl-2-O-levulinoyl)-β-D-glucopyranosyluronate-(1→4)-(3-O-acetyl-1,6-anhydro-2-azido)-2-deoxy-β-D-glucopyranose
[0239] A 100 L reactor was charged with 12780 g of 2-Lev 1-TCA ED Dimer (ED5) (7.38 mole, 1 eq., FW) and 4764 g of Monomer C (7.38 mole, 1 eq). The combined monomers were dissolved in 20 L toluene and co-evaporated at 40° C. Repeated was co-evaporation with an additional 2×20 L of toluene, after which 60 L of dichloromethane (DCM) was transferred into the reactor and dissolved. The reactor was purged with nitrogen and chilled to −20° C. When the temperature was between −20 and −10° C., 2962 g (11.2 moles, 0.9 eq) of TES Triflate were transferred into the reactor. After complete addition of TES Triflate the reaction was allowed to warm to 5° C. and stirring was continued. Completeness of the reaction was monitored by HPLC and TLC (35:65 ethyl acetate/Heptane). The reaction required 2-3 hours to reach completion. When the reaction was completed, 1133 g of triethylamine (TEA, 0.9 eq.) were transferred into the reactor and stirred for an additional 30 minutes. The organic layer (DCM layer) was extracted with 2×20 L 25% 4:1 sodium chloride/sodium bicarbonate solution. Dichloromethane solution was dried in 6-8 Kg of anhydrous sodium sulfate. The syrup was purified in a 200 L silica column using 140-200 L each of the following gradient profiles: 15:85, 20:80, 25:75, 30:70 and 35:65 (EtOAc/heptane). Pure fractions were pooled and evaporated to a syrup. The isolated yield of EDC Trimer was 48%. Formula: C 55 H 60 N 6 O 18 ; Mol. Wt. 1093.09. The 1 H NMR spectrum (d 6 -acetone) of the EDC trimer is shown in FIG. 3 .
Preparation of EDC1
Step 1: Anhydro Ring Opening & Acetylation
6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl-(1→4)-O-[benzyl 3-O-benzyl-2-O-levulinoyl-β-D-glucopyranosyluronate]-(1→4)-O-2-azido-2-deoxy-1,3,6-tri-O-acetyl-β-D-glucopyranose
[0240] 7.0 Kg (6.44 mol) of EDC Trimer was dissolved in 18 L anhydrous Dichloromethane. 6.57 Kg (64.4 mol, 10 eq) of Acetic anhydride was added. The solution was cooled to −45 to −35° C. and 1.82 Kg (12.9 mol, 2 eq) of Boron Trifluoride etherate was added slowly. Upon completion of addition, the mixture was warmed to 0-10° C. and kept at this temperature for 3 hours until reaction was complete by TLC and HPLC. The reaction was cooled to −20° C. and cautiously quenched and extracted with saturated solution of sodium bicarbonate (3×20 L) while maintaining the mixture temperature below 5° C. The organic layer was extracted with brine (1×20 L), dried over anhydrous sodium sulfate, and concentrated under vacuum to a syrup. The resulting syrup of EDC1 (6.74 Kg) was used for step 2 without further purification. The 1 H NMR spectrum (d 6 -acetone) of the EDC-1 trimer is shown in FIG. 4 .
Preparation of EDC2
Step 2: Deacetylation
6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl-(1→4)—O—[benzyl 3-O-benzyl-2-O-levulinoyl-β-D-glucopyranosyluronate]-(1→4)—O-2-azido-2-deoxy-3,6-di-O-acetyl-β-D-glucopyranose
[0241] The crude EDC1 product obtained from step 1 was dissolved in 27 L of Tetrahydrofuran and chilled to 15-20° C., after which 6 Kg (55.8 mol) of benzylamine was added slowly while maintaining the reaction temperature below 25° C. The reaction mixture was stirred for 5-6 hours at 10-15° C. Upon completion, the mixture was diluted with ethyl acetate and extracted and quenched with 10% citric acid solution (2×20 L) while maintaining the temperature below 25° C. The organic layer was extracted with 10% NaCl/1% sodium bicarbonate (1×20 L). The extraction was repeated with water (1×10 L), dried over anhydrous sodium sulfate and evaporated under vacuum to a syrup. Column chromatographic separation using silica gel yielded 4.21 Kg (57% yield over 2 steps) of EDC2 [also referred to as 1-Hydroxy-6-Acetyl EDC Trimer]. The 1 H NMR spectrum (d 6 -acetone) of the EDC-2 trimer is shown in FIG. 5 .
Preparation of EDC3
Step 3: Formation of TCA derivative
6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl-(1→4)—O—[benzyl 3-O-benzyl-2-O-levulinoyl-β-D-glucopyranosyluronate]-(1→4)—O-2-azido-2-deoxy-3,6-di-O-acetyl-1-O-trichloroacetimidoyl-β-D-glucopyranose
[0242] 4.54 Kg (3.94 mol) of EDC2 was dissolved in 20 L of Dichloromethane. 11.4 Kg (78.8 mol, 20 eq) of Trichloroacetonitrile was added. The solution was cooled to −15 to −20° C. and 300 g (1.97 mol, 0.5 eq) of Diazabicycloundecene was added. The reaction was allowed to warm to 0-10° C. and stirred for 2 hours or until reaction was complete. Upon completion, water (20 L) was added and the reaction was extracted with an additional 10 L of DCM. The organic layer was extracted with brine (1×20 L), dried over anhydrous sodium sulfate, and concentrated under vacuum to a syrup. Column chromatographic separation using silica gel and 20-60% ethyl acetate/heptane gradient yielded 3.67 Kg (72% yield) of 1-TCA derivative, EDC3. The 1 H NMR spectrum (d 6 -acetone) of the EDC-3 trimer is shown in FIG. 6 .
Preparation of EDCBA1
Step 4: Coupling of EDC3 with BA Dimer
Methyl O-6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl)-(1→4)-O-[benzyl 3-O-benzyl-2-O-levulinoyl-β-D-glucopyranosyluronate]-(1→4)—O-2-azido-2-deoxy-3,6-di-O-acetyl-α-D-glucopyranosyl-(1→4)—O—[methyl 2-O-benzoyl-3-O-benzyl-α-L-Idopyranosyluronate]-(1→4)-2-azido-6-O-benzoyl-3-O-benzyl-2-deoxy-α-D-glucopyranoside
[0243] 3.67 Kg (2.83 mol) of EDC3 and 3.16 Kg (3.96 mol, 1.4 eq) of BA Dimer was dissolved in 7-10 L of Toluene and evaporated to dryness. The resulting syrup was coevaporated with Toluene (2×15 L) to remove water. The dried syrup was dissolved in 20 L of anhydrous Dichloromethane, transferred to the reaction flask, and cooled to −15 to −20° C. 898 g (3.4 mol, 1.2 eq) of triethylsilyl triflate was added while maintaining the temperature below −5° C. When the addition was complete, the reaction was immediately warmed to −5 to 0° C. and stirred for 3 hours. The reaction was quenched by slowly adding 344 g (3.4 mol, 1.2 eq) of Triethylamine. Water (15 L) was added and the reaction was extracted with an additional 10 L of DCM. The organic layer was extracted with a 25% 4:1 Sodium Chloride/Sodium Bicarbonate solution (2×L), dried over anhydrous sodium sulfate, and evaporated under vacuum to a syrup. The resulting syrup of the pentasaccharide, EDCBA1 was used for step 5 without further purification. The 1 H NMR spectrum (d 6 -acetone) of the EDCBA-1 pentamer is shown in FIG. 7 .
Preparation of EDCBA2
Step 5: Hydrolysis of Levulinyl Moiety
Methyl O-6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl)-(1→4)—O-[benzyl 3-O-benzyl-β-D-glucopyranosyluronate]-(1→4)—O-2-azido-2-deoxy-3,6-di-O-acetyl-α-D-glucopyranosyl)-(1→4)—O-[methyl 2-O-benzoyl-3-O-benzyl-α-L-Idopyranosyluronate]-(1→4)-2-azido-6-O-benzoyl-3-O-benzyl-2-deoxy-α-D-glucopyranoside
[0244] The crude EDCBA1 from step 4 was dissolved in 15 L of Tetrahydrofuran and chilled to −20 to −25° C. A solution containing 679 g (13.6 mol) of Hydrazine monohydrate and 171 g (1.94 mol) of Hydrazine Acetate in 7 L of Methanol was added slowly while maintaining the temperature below −20° C. When the addition was complete, the reaction mixture was allowed to warm to 0-10° C. and stirred for several hours until the reaction is complete, after which 20 L of Ethyl acetate was added and the reaction was extracted with 10% citric acid (2×12 L). The organic layer was washed with water (1×12 L), dried over anhydrous sodium sulfate, and evaporated under vacuum to a syrup. Column chromatographic separation using silica gel and 10-45% ethyl acetate/heptane gradient yielded 2.47 Kg (47.5% yield over 2 steps) of EDCBA2. The 1 H NMR spectrum (d 6 -acetone) of the EDCBA-2 pentamer is shown in FIG. 8 .
Preparation of EDCBA Pentamer
Step 6: THP Formation
Methyl O-6-O-acetyl-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl-(1→4)-O-[benzyl 3-O-benzyl-2-O-tetrahydropyranyl-β-D-glucopyranosyluronate]-(1→4)-O-2-azido-2-deoxy-3,6-di-O-acetyl-α-D-glucopyranosyl-(1→4)-O-[methyl 2-O-benzoyl-3-O-benzyl-α-L-Idopyranosyluronate]-(1→4)-2-azido-6-O-benzoyl-3-O-benzyl-2-deoxy-α-D-glucopyranoside
[0245] 2.47 Kg (1.35 mol) of EDCBA2 was dissolved in 23 L Dichloroethane and chilled to 10-15° C., after which 1.13 Kg (13.5 mol, 10 eq) of Dihydropyran and 31.3 g (0.135 mol, 0.1 eq) of Camphorsulfonic acid were added. The reaction was allowed warm to 20-25° C. and stirred for 4-6 hours until reaction was complete. Water (15 L) was added and the reaction was extracted with an additional 10 L of DCE. The organic layer was extracted with a 25% 4:1 Sodium Chloride/Sodium Bicarbonate solution (2×20 L), dried over anhydrous sodium sulfate, and evaporated under vacuum to a syrup. Column chromatographic separation using silica gel and 10-35% ethyl acetate/heptane gradient yielded 2.28 Kg (88.5% yield) of fully protected EDCBA Pentamer. The 1 H NMR spectrum (d 6 -acetone) of the EDCBA pentamer is shown in FIG. 9 .
Preparation of API1
Step 1: Saponification
Methyl O-2-azido-2-deoxy-3,4-di-O-benzyl-α-D-glucopyranosyl-(1→4)-O-3-O-benzyl-2-O-tetrahydropyranyl-β-D-glucopyranosyluronosyl-(1→4)-O-2-azido-2-deoxy-α-D-glucopyranosyl-(1→4)-O-3-O-benzyl-α-L-Idopyranosyluronosyl-(1→4)-2-azido-3-O-benzyl-2-deoxy-α-D-glucopyranoside disodium salt
[0246] To a solution of 2.28 Kg (1.19 mol) of EDCBA Pentamer in 27 L of Dioxane and 41 L of Tetrahydrofuran was added 45.5 L of 0.7 M (31.88 mol, 27 eq) Lithium hydroxide solution followed by 5.33 L of 30% Hydrogen peroxide. The reaction mixture was stirred for 10-20 hours to remove the acetyl groups. Then, 10 L of 4 N (40 mol, 34 eq) sodium hydroxide solution was added. The reaction was allowed to stir for an additional 24-48 hours to hydrolyze the benzyl and methyl esters completely. The reaction was then extracted with ethyl acetate. The organic layer was extracted with brine solution and dried with anhydrous sodium sulfate. Evaporation of the solvent under vacuum gave a syrup of API1 [also referred to as EDCBA(OH) 5 ] which was used for the next step without further purification.
Preparation of API2
Step 2: O-Sulfonation
Methyl O-2-azido-2-deoxy-3,4-di-O-benzyl-6-O-sulfo-α-D-glucopyranosyl-(1→4)-O-3-O-benzyl-2-O-tetrahydropyranyl-β-D-glucopyranosyluronosyl-(1→4)-O-2-azido-2-deoxy-3,6-di-O-sulfo-α-D-glucopyranosyl-(1→4)-O-3-O-benzyl-2-O-sulfo-α-L-idopyranuronosyl-(1→4)-2-azido-2-deoxy-6-O-sulfo-α-D-glucopyranoside, heptasodium salt
[0247] The crude product of API1 [aka EDCBA(OH) 5 ] obtained in step 1 was dissolved in 10 L Dimethylformamide. To this was added a previously prepared solution containing 10.5 Kg (66 moles) of sulfur trioxide-pyridine complex in 10 L of Pyridine and 25 L of Dimethylformamide. The reaction mixture was heated to 50° C. over a period of 45 min. After stiffing at 1.5 hours at 50° C., the reaction was cooled to 20° C. and was quenched into 60 L of 8% sodium bicarbonate solution that was kept at 10° C. The pH of the quench mixture was maintained at pH 7-9 by addition of sodium bicarbonate solution. When all the reaction mixture has been transferred, the quench mixture was stirred for an additional 2 hours and pH was maintained at pH 7 or greater. When the pH of quench has stabilized, it was diluted with water and the resulting mixture was purified using a preparative HPLC column packed with Amberchrom CG161-M and eluted with 90%-10% Sodium Bicarbonate (5%) solution/Methanol over 180 min. The pure fractions were concentrated under vacuum and was then desalted using a size exclusion resin or gel filtration (Biorad) G25 to give 1581 g (65.5% yield over 2 steps) of API2 [also referred to as EDCBA(OSO 3 ) 5 ]. The 1 H NMR spectrum (d 6 -acetone) of API-2 pentamer is shown in FIG. 10 .
Preparation of API3
Step 3: Hydrogenation
Methyl O-2-amino-2-deoxy-6-O-sulfo-α-D-glucopyranosyl-(1→4)-O-2-O-tetrahydropyranyl-β-D-glucopyranosyluronosyl-(1→4)-O-2-amino-2-deoxy-3,6-di-O-sulfo-α-D-glucopyranosyl-(1→4)-O-2-O-sulfo-α-L-idopyranuronosyl-(1→4)-2-amino-2-deoxy-6-O-sulfo-α-D-glucopyranoside, heptasodium salt
[0248] A solution of 1581 g (0.78 mol) of O-Sulfated pentasaccharide API2 in 38 L of Methanol and 32 L of water was treated with 30 wt % of Palladium in Activated carbon under 100 psi of Hydrogen pressure at 60-65° C. for 60 hours or until completion of reaction. The mixture was then filtered through 1.0μ and 0.2μ filter cartridges and the solvent evaporated under vacuum to give 942 g (80% yield) of API3 [also referred to as EDCBA(OSO 3 ) 5 (NH 2 ) 3 ]. The 1 H NMR spectrum (d 6 -acetone) of API-3 pentamer is shown in FIG. 11 .
Preparation of Fondaparinux Sodium
Step 4: N-Sulfation & Removal of THP
Methyl O-2-deoxy-6-O-sulfo-2-(sulfoamino)-α-D-glucopyranosyl-(1→4)—O-β-D-glucopyranuronosyl-(1→4)-O-2-deoxy-3,6-di-O-sulfo-2-(sulfoamino)-α-D-glucopyranosyl-(1→4)-O-2-O-sulfo-α-L-idopyranuronosyl-(1→4)-2-deoxy-6-O-sulfo-2-(sulfoamino)-α-D-glucopyranoside, decasodium salt
[0249] To a solution of 942 g (0.63 mol) of API3 in 46 L of water was slowly added 3.25 Kg (20.4 mol, 32 eq) of Sulfur trioxide-pyridine complex, maintaining the pH of the reaction mixture at pH 9-9.5 during the addition using 2 N sodium hydroxide solution. The reaction was allowed to stir for 4-6 hours at pH 9.0-9.5. When reaction was complete, the pH was adjusted to pH 7.0 using 50 mM solution of Ammonium acetate at pH 3.5. The resulting N-sulfated EDCBA(OSO 3 ) 5 (NHSO 3 ) 3 mixture was purified using Ion-Exchange Chromatographic Column (Varian Preparative 15 cm HiQ Column) followed by desalting using a size exclusion resin or gel filtration (Biorad G25). The resulting mixture was then treated with activated charcoal and the purification by ion-exchange and desalting were repeated to give 516 g (47.6% yield) of the purified Fondaparinux Sodium form.
[0250] Analysis of the Fondaparinux sodium identified the presence of P1, P2, P3, and P4 in the fondaparinux. P1, P2, P3, and P4 were identified by standard analytical methods.
|
Processes for the synthesis of the Factor Xa anticoagulent Fondaparinux, and related compounds are described. Also described are protected pentasaccharide intermediates as well as efficient and scalable processes for the industrial scale production of Fondaparinux sodium by conversion of the protected pentasaccharide intermediates via a sequence of deprotection and sulfonation reactions.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to carbon artefacts having anti-oxidation coatings over at least part of their surfaces and has one application in carbon brake discs such as are used in aircraft disc-brake assemblies. "Carbon" in this Specification includes graphite.
An aircraft disc-brake assembly may, for example, comprise a plurality of rotor discs keyed at their outer edges to the wheel hub, and a plurality of stator discs keyed at their inner edges to a non-rotating torque tube, the two sets of discs being interleaved. To operate the brake, axial pressure is applied to the stack of interleaved plates, braking being obtained by the rubbing friction between the adjacent flat surfaces of the rotor and stator discs. Such an assembly is described, for example, in "Aircraft Engineering", vol 43, pp 12-14 (June 1971). The discs may be made of steel, but the alternative use of carbon-carbon composite discs has known advantages. For example such discs are lighter than steel discs and are less liable to seize-up from overheating, eg in an emergency stop.
With carbon discs, however, the high temperatures attained during braking tend to cause oxidation of those areas of the disc surface exposed to the atmosphere, in particular the inner and outer peripheral regions; the rubbing surfaces themselves are mutually shielded from the atmosphere when in contact. Such oxidation is, of course, undesirable.
It has already been proposed to apply protective coatings to such areas to prevent or reduce oxidation. For example UK Patent Specification No. 1,311,537 discloses coatings of several alternative substances, including inter alia silicon, nickel and chromium, and German Offenlegungsschrift 2,306,631 (UK Patent Specification No. 1,415,853) describes the use of a mixture of boron-containing and carbonisable organic materials.
The present invention provides a protective coating comprising a combination of superimposed layers of specified substances which has been found particularly effective.
SUMMARY OF THE INVENTION
According to the present invention a carbon artefact, particularly but not exclusively a carbon brake disc, includes an anti-oxidation coating over at least part of its surface, said coating comprising:
A layer of silicon on the surface of the artefact;
A layer of nickel overlying the silicon layer;
And a layer of chromium overlying the nickel layer.
The silicon layer may be deposited by flame-spraying silicon powder on to the surface, the deposit being subsequently arc-melted to produce a glassy layer. The nickel and chromium layers may be deposited by electroplating or electroless plating. In order to provide a suitable keying surface on the silicon, and to increase its electrical conductivity for electroplating the nickel layer, a thin layer of silver may be deposited on the silicon layer by electroless plating; the provision of such a silver layer prior to nickel plating is well known in the electroplating art.
The thickness of the layers is not critical. The silicon layer suitably has a thickness in the range 0.002-0.010 inch, preferably about 0.005 inch. The silver layer may be in the range 10 - 6 - 10 - 4 inch, suitably about 10 - 5 inch. The nickel and chromium layers may each be in the range 0.0005 - 0.005 inch, a preferred thickness being about 0.002 inch.
DESCRIPTION OF THE DRAWINGS
To enable the nature of the present invention to be more readily understood, attention is directed by way of example to the accompanying drawings wherein:
FIG. 1 is a perspective view of part of a carbon-carbon composite brake disc showing the outer periphery.
FIG. 2 shows graphs of percentage weight loss plotted against time of oxidation for uncoated and coated carbon.
FIG. 3 shows graphs of percentage weight loss plotted against number of thermal test cycles for uncoated and coated carbon.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1 the disc 1 is a graphitised carbon-carbon composite rotor disc and is provided with keyways 2 by which it is keyed to the wheel hub in the brake assembly. The edge 3 of the disc is bevelled at 4. The surface areas exposed in use to atmospheric oxidation are the edge surfaces 3 and 4, and the flat surfaces 5 (on both sides of the disc) extending inwards to the line 6, which indicates the limit of the area 7 rubbed by the adjacent stator disc (not shown). The keyways of the stator discs are of similar form but located at their inner peripheries, where corresponding areas are similarly exposed and require protection. The inner periphery of disc 1, and the outer periphery of the stator discs are circular in plan, with bevelled edges similar to 4. These surfaces also require protection.
The above-described surfaces are provided with an anti-oxidation coating produced by the following sequence of operations.
1. Flame-spraying silicon powder on to the surfaces in an argon atmosphere. Six coats are applied, giving a final thickness of about 0.005 inch. After each flame-spraying operation, the applied layer is arc-melted in argon, using an argon-arc welding torch, to produce a a regular, even glassy surface. This treatment also causes the silicon to diffuse into the graphite, thereby improving adhesion. The flame spraying and arc-melting torches may be so located, eg diametrically opposite one another, that both these operations are performed simultaneously as the disc is rotated.
2. Depositing silver on the silicon by electroless plating to a thickness of 10 - 5 inch.
3. Depositing nickel on the silver by electroplating to a thickness of 0.002 inch.
4. Depositing chromium on the nickel by electroplating to a thickness of 0.002 inch.
During electro-deposition, the rubbing surfaces of the disc are protected in a known manner. After electroplating, the discs are heated in vacuum to about 150° C for 48 hours to remove traces of the electrolyte. Conventional plating baths are used.
FIG. 2 shows the results of oxidation-resistance tests performed on 1 cm graphite cubes with different applied coatings. The tests were performed at 1000° C in an air-flow of 5 cm/sec. Percentage weight loss is plotted against time of oxidation.
In FIG. 2:
Curve A is for unprotected graphite.
Curve B is for graphite electroplated with 0.002 inch nickel, preceded by a thin (about 10 - 5 inch) electroless silver layer.
Curve C is for graphite treated as for B, but with 0.001 inch chromium electroplated over the nickel.
Curve D is similar to curve C but with the chromium layer increased to 0.002 inch.
Curve E is for graphite coated with a boron/phenolic-resin material the type disclosed in Offenlegungsschrift 2,306,631.
FIG. 2 shows the superiority of the chromium/nickel combination (Curves C and D) over nickel along (Curve B). Curve E shows good protection, but of limited duration.
In FIG. 2 there is no silicon layer. FIG. 3 shows the improvement effected by its introduction. Unlike the isothermal tests of FIG. 2, the results in FIG. 3 were obtained by subjecting the cubes to continuous repetition of the following 8 min thermal cycle:
1. Heat-up for 3 mins, to appox 1000° C; air static.
2. Hold at temperature for 2 minutes; oxidising air velocity 30 cm/sec.
3. Cool cube outside furnace for 3 minutes; ambient air at about 5 psi through 0.25 diameter tube blown over cube.
4. Return to furnace and repeat (1).
This cycle approximates more closely to operating conditions in a brake assembly. FIG. 3 plots percentage weight loss against number of cycles.
In FIG. 3:
Curve F is for unprotected graphite.
Curve G is for 0.005 inch flame-sprayed, arc-melted, silicon.
Curve H is for 0.002 inch electroplated nickel (preceded by about 10 - 5 inch electroless silver) followed by 0.002 inch electroplated chromium, ie the same combination as curve D in FIG. 2.
Curve J is for the 0.002 inch nickel/0.002 inch chromium combination of curve H, superimposed on the 0.005 inch silicon layer of curve G. Curve J is thus the result with a coating embodying the present invention.
Curve K is for the boron/phenolic-resin material of curve E in FIG. 2.
It will be observed that the coating of curve J increased the number of thermal cycles required to give a weight loss of 15% by a factor of approximately 2.5 as compared with a nickel/chromium coating alone (curve H), and by a factor of approximately 3.0 as compared with silicon alone (Curve G). Or, to express the improvement in another way, the number of cycles (100) required to give a weight loss of 15% with the present coating exceeded the sum of the number required with the coatings giving curves G and H (33+40 = 73) by about 30%, ie the whole is greater than the sum of the parts.
|
An anti-oxidation coating, particularly for the exposed peripheral regions of graphite brake discs for aircraft, comprises a layer of silicon on the surface of the graphite, a layer of nickel overlying the silicon layer and a layer of chromium overlying the nickel layer. The silicon layer is suitably formed by flame-spraying followed by arc-melting, and the nickel and chromium layers by electroplating.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Application No. 61/979,070 filed Apr. 14, 2014, and entitled “TOWEL BAR.”
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a decorative bar or rail formed of a natural stone rod combined with a metal armature or bracketed structure which is configured to be mounted on a wall surface of a room or a floor surface of a building to provide an attractive and useful holder or railing.
[0003] For example, the stone and metal bar may be installed on the wall of a bathroom for use as a towel holder or a hand support; it may be installed on a door as a door pull; it may be installed in a closet for use as a rod on which to hang clothes; or it may be mounted on vertical supports on the side of a staircase to serve as a hand or guard rail or as the cap on a railing at a balcony edge. In general, the present invention is intended to add an attractive architectural accent in any situation where a bar or railing is provided in a building.
[0004] The use of stone for architectural purposes is known throughout history. Large vertical columns have graced the facades of buildings since early Greco-Roman times. Natural stone is a durable and attractive building material but its use has been limited by its lack of tensile strength. When used in compression, as in vertical stone columns for example, the stone is capable of bearing enormous loads. However, when a lateral force is applied that causes internal tension, for example when weight is applied to the center of a horizontal stone beam, the stone has a tendency to crack. For this reason metals and plastics have long since replaced stone as the materials of choice for architectural purposes where a tensile force is present or expected.
[0005] It is known from the Chinese Patent No. 2857765Y to reinforce a bar made of stone by means of an internal metal rod. The disclosed bar is intended for use in a bathroom, for example as a towel bar or shower curtain rod. A cylindrical metal rod is somehow embedded in the center of a stone bar, which may be round or square in cross-section, presumably by drilling a round hole along the longitudinal central axis of the stone. Once reinforced in this way, the bar can be placed in use horizontally presumably by supporting it at both ends in a manner that is not defined or explained.
[0006] The Chinese Patent No. 201284914Y discloses an improvement in this prior art stone bar which avoids drilling a long hole through the center of the bar. This reference teaches the reinforcement of stone curtain rods, towel racks and the like by inserting a metal rod in a longitudinal notch or groove on one or more sides of the bar and affixing the rod(s) to the stone by means of an adhesive. The metal rod can be round, square or even triangular in cross-section. It can fill a groove in the stone bar or be covered by a separate, filler material that fills the remainder of the groove. Once inserted, however, the metal rod fulfills no other purpose than to reinforce the stone bar. As in the case with the Chinese Patent No. 2857765Y, this metal rod is substantially hidden from view.
[0007] These two prior art references, taken together, teach how natural stone bars may be reinforced. However, the reinforced stone bars, so constructed, must be held by some type of supporting fixture when installed in a bathroom or the like. This supporting fixture must presumably grip or clamp the outer surface of the stone which, being brittle, is subject to damage, either upon installation or during use. Because this configuration as not robust, such stone bars may be considered impractical for architectural use. Furthermore, these references teach making substantial cuts or openings in the stone bars for insertion of the reinforcing metal rods.
[0008] The Chinese Patent No. 2857765Y shows that the diameter of the metal rod is approximately one-third the diameter or width of the stone bar. It would be exceedingly difficult to drill a longitudinal hole through a stone rod from one end to the other. The Chinese Patent No. 201284914Y discloses various types of stone bars with various configurations of longitudinal grooves for insertion of the metal rods. In each embodiment shown, the groove is approximately one quarter of the width of the stone bar. In all cases where a round or square metal rod is embedded in a stone bar for reinforcement, this rod must have sufficient thickness to withstand any bending stresses that are anticipated. The substantial cuts in the stone, for the purposed of reinforcement, result in a weakened stone structure which is naturally fragile and brittle and therefore subject to breakage.
SUMMARY OF THE INVENTION
[0009] It is a principal objective of the present invention, therefore, to provide means for both reinforcing and holding a natural stone rod in a robust manner for architectural use which enhances the overall attractiveness, usefulness and practicality of an installation and allows for a broader range of applications.
[0010] This objective, as well as other objectives which will become apparent from the discussion that follows, is achieved, according to the present invention, by providing a decorative bar configured to be mounted on a surface (wall or floor) of a room or building, which comprises (a) an elongate rod formed of natural stone and having a substantially constant cross-sectional shape from a first end to an opposite, second end and a longitudinal groove extending along one side, and (b) an elongate metal armature or bracketed support member, collectively to be referred to as a brace, having a portion thereof inserted in and substantially filling the longitudinal groove in the stone rod. The metal brace has a flange or bracket at each end, and at a midpoint or other intervals necessary for support in the case of a long stone rod, configured to be attached to a surface of a building to affix and retain the stone bar in a mounted relationship to this surface with its longitudinal groove on a side which is not readily visible to a casual observer.
[0011] To provide tensile strength to the stone rod without removing a substantial amount of the stone, the portion of the metal brace that is inserted in and substantially fills the longitudinal groove in the stone is preferably a relatively flat piece of material, with a height dimension substantially greater than the thickness dimension. Because of the structural dynamics involved, the metal can be quite thin. In a preferred embodiment of the present invention, this portion of the metal brace has a thickness of approximately ⅛ of an inch. The metal thickness could range from 1/16 to ⅜ of an inch, depending upon the proportions of the stone rod and the span of the bar.
[0012] In another preferred embodiment of the present invention the portion of the metal brace that is inserted in the stone has an “L” shaped cross-section in the region thereof which includes the portion inserted in the groove, with this inserted section being formed by an upper, or vertical portion of the “L”. The horizontal flange of the “L” shaped angle serves to stabilize the bar against lateral force. In other preferred embodiments the inserted portion of the metal brace has a “T” shaped cross-section or a Christian cross-shaped cross-section.
[0013] Preferably also, the groove in the stone rod has a depth substantially equal to or slightly less than one half of the height or diameter of the stone rod, and a width dimension slightly greater than the width dimension of the portion of the metal brace that is inserted into the groove. In one preferred embodiment of the invention the depth of the groove as in the range of ⅝ to ¾ of an inch for a stone rod that is approximately 1½ inches thick.
[0014] The stone rod can have any cross-sectional contour, but for aesthetic purposes the cross section is preferably egg-shaped, oval, circular, rectangular (including square) or trapezoidal.
[0015] Advantageously a layer of adhesive is provided in the groove between the stone bar and the aforesaid portion of the metal brace, bonding the stone to the metal and thereby creating one structurally unified piece.
[0016] In one embodiment of the invention the longitudinal groove in the stone rod extends all the way from one end to the other. This longitudinal groove has a constant depth over the full length of the stone rod. In another embodiment of the invention the longitudinal groove extends along the length of the stone rod from a point adjacent to the first end, without reaching the first end, and/or to a point adjacent to the second end without reaching the second end, thus stopping short of one or both ends. In this case the groove preferably tapers from the substantially constant depth to a zero depth near the respective end. The taper can be linear or, advantageously, a segment of a circle formed by the rotating cutting instrument that creates the groove. Alternatively, the groove can have a non-tapered jump, or step, from its maximum depth to zero depth.
[0017] The attachment flanges or brackets at each end of the metal brace may assume any number of configurations, depending upon the architectural requirements. Advantageously, the flanges or brackets may be configured such that the decorative bar can be mounted horizontally to a vertical surface, such as a bathroom wall. For example, both flanges may be configured to mount the bar such that it is horizontal and parallel to the wall surface, as in the case of a typical towel bar installation. Alternatively, the flanges at opposite ends of the bar can be configured such that they mount on intersecting perpendicular wall surfaces, such as a 90 degree corner in a room, creating a corner-mounted bar. Advantageously, a corner-mounted bar is an efficient use of space. Additionally, supporting a bar from two perpendicular walls is inherently more stable than cantilevering the bar from one wall. In another embodiment the flanges can be configured to mount to parallel walls that are perpendicular to the bar such that the bar spans from wall to wall, as with a bar for hanging clothes in a closet or alcove.
[0018] In another embodiment of the invention the flanges or brackets can be configured to facilitate mounting the bar on one or more floor surfaces, such as the surfaces of a staircase, thus forming a handrail for the stairs. Alternatively the bar can be mounted to posts that are secured to a floor, such as posts at a balcony edge, creating a railing cap at the balcony edge.
[0019] For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a front-view perspective showing one preferred embodiment of a towel bar according to the invention.
[0021] FIG. 2 is a cross section through the towel bar shown in FIG. 1 , taken on the line 2 - 2 in FIG. 1 .
[0022] FIG. 3 is a rear-view perspective of the towel bar of FIG. 1 .
[0023] FIG. 4 is a variation of the embodiment of FIG. 1 , showing a corner-mounted metal armature, or brace.
[0024] FIG. 5 is a front elevation of the corner-mounted towel bar of FIG. 4 .
[0025] FIG. 6 is a front-view perspective showing a second preferred embodiment of a towel bar according to the invention.
[0026] FIG. 7 is a cross section through the towel bar shown in FIG. 6 , taken on the line 7 - 7 in FIG. 6 .
[0027] FIG. 8 is a rear-view perspective of the towel bar embodiment of FIGS. 6 and 7 .
[0028] FIG. 9 is a front-view perspective showing a variation on this second embodiment, showing a longer towel bar with a center support bracket.
[0029] FIG. 10A is a front elevation of the towel bar shown in FIG. 9 .
[0030] FIG. 10B is a partial elevation of the end of the stone rod showing a curved end to the slot in the stone rod.
[0031] FIG. 10C is a partial elevation of the end of the stone rod showing a tapered end to the slot in the stone rod.
[0032] FIG. 10D is a partial elevation of the end of the stone rod showing a stepped end to the slot in the stone rod.
[0033] FIG. 11 is a partial section showing another preferred embodiment of the invention, in this case for a stone railing with a flat metal reinforcing bar.
[0034] FIG. 12 is a partial section showing a variation on the preferred embodiment of FIG. 11 , with a cross-shaped metal reinforcing bar.
[0035] FIG. 13 shows one end of a stone rod that is egg-shaped in cross section with a groove in the bottom face that extends upward approximately to the mid-point of the height of the rod and laterally through the end of the rod.
[0036] FIG. 14 shows a stone rod that is circular in cross section.
[0037] FIG. 15 shows a stone rod that is oval in cross section.
[0038] FIG. 16 shows a stone rod that is rectangular in cross section.
[0039] FIG. 17 shows a stone rod that is trapezoidal in cross section.
[0040] FIG. 18 shows a stone rod that is egg-shaped in cross section where the groove does not pass through the end of the rod.
[0041] FIG. 19 shows a metal bar that is flat.
[0042] FIG. 20 shows an “L” shaped metal angle.
[0043] FIG. 21 shows a “T” shaped metal extrusion.
[0044] FIG. 22 shows a “+” shaped metal extrusion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] The preferred embodiments of the present invention will now be described with reference to FIGS. 1-22 of the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0046] Briefly in overview, the present invention relates to a decorative rod formed of natural stone which is adhered to a metal armature or bracketed brace. The metal brace both reinforces the stone rod and provides a means for mounting the stone rod to a surface. The brace is configured to be mounted on a wall surface of a room or on a floor surface or post of a building, to provide an attractive and useful holder, such as a towel bar, hand rail or door pull.
[0047] One preferred embodiment of this invention is the towel bar illustrated in FIGS. 1 through 5 . FIG. 1 shows an elongate stone rod 1 that is egg-shaped in cross-section, supported on a metal armature. The metal armature is comprised of a front rail 3 with flanges 4 at both ends that turn 90 degrees towards the wall and wall plates 5 that turn 90 degrees and attach to a wall with fasteners 6 . There is a slot, or groove 2 , cut into the underside of this stone rod that allows the front metal rail 3 to insert into the stone rod. In this embodiment, as shown in this figure, the stone component is a long rod 1 ranging from 24 inches long, for one towel, to 48 inches long, for two towels. The armature is approximately 1½ inches longer than the stone rod such that the stone rod does not meet the end flanges and therefor appears to be suspended on the front metal rail.
[0048] FIG. 2 is a sectional drawing, taken at line 2 - 2 on FIG. 1 . FIG. 2 shows a stone rod 1 that is approximately 1⅛ inches wide by 1½ inches tall and egg-shaped in cross section with a groove 2 in the underside that is approximately 3/16 of an inch wide and ¾ of an inch deep, or roughly to the mid point of the rod. The front metal rail 3 is shown imbedded in the groove 2 in the stone rod. A layer of adhesive 7 fills the space between the metal rail and the stone and binds the stone to the metal. The imbedded metal reinforces and stabilizes the stone rod to prevent it from cracking if hit or bumped. The front metal rail 3 is approximately 1½ inches tall and ⅛ of an inch thick. A horizontal flange 8 projects approximately ½ of an inch from the backside of the rail. This flange stiffens the rail and provides resistance to lateral force. The metal side flange 4 projects approximately 2¾ inches out from the wall. The metal wall plate 5 can be seen. Fasteners 6 attach through the wall plate to secure the towel bar to the wall.
[0049] The cross sectional shape of the stone rod could alternatively be round, oval, rectangular or trapezoidal, as shown in FIGS. 13 through 18 .
[0050] FIG. 3 shows the towel bar from the back side, with the stone rod 1 separated from the metal armature. The groove 2 in the stone is continuous from end to end, allowing the metal front rail to imbed into the stone rod when the stone is lowered into place. The horizontal stiffening flange 8 stops short of the side brackets 4 so that this flange is not visible to the casual observer when the stone is in place. The back side of the wall plates 5 and fasteners 6 can be seen. The wall plates turn downward, allowing for additional fasteners and providing additional stability.
[0051] A variation of this preferred embodiment is illustrated in FIG. 4 and FIG. 5 . The illustrated towel bar is designed to mount into a 90 degree corner. FIG. 4 shows the stone rod 1 separated from the metal armature and viewed from the back. The continuous groove 2 in the stone rod can be seen. The metal end flange 4 and wall plate 5 seen in FIG. 1 through FIG. 3 can be seen on one end of the armature in this figure. This plate 5 parallel to the stone rod. On the other end is a wall plate 9 that is perpendicular to the stone rod, and is bolted 6 to the perpendicular wall, thus forming a corner-mounted installation. FIG. 5 is a front elevation of this embodiment with the stone rod 1 separated from the metal support structure below. In this figure the typical wall plate 5 is shown on the right hand side of the drawing and the corner-mount plate 9 is shown on the left. This is a towel bar intended for two towels and the armature approximately 50 inches long. There is an additional metal bracket 28 at the center of the armature that stabilizes this long towel bar. A corner-mounted installation is an economical use of space. Mounting onto two perpendicular walls is inherently more stable than mounting onto a single wall.
[0052] A second preferred embodiment of this invention is the towel bar illustrated in FIGS. 6 through 10 . In this embodiment, as shown in FIG. 6 , the stone component is a long rod 10 ranging from 26 inches long, for one towel, to 50 inches long, for two towels. There is a slot, or groove 11 , cut into the underside of the stone rod. This groove does not pass through the ends of the stone rod; it stops approximately one inch from each end of the stone rod. The slot is approximately ¾ of an inch deep by 3/16 of an inch wide, and approximately 2 inches shorter than the stone rod. The stone rod projects beyond and appears to rest on the two metal brackets 13 near each end of the rod. Spanning between the metal brackets is a metal angle 12 , most of which is imbedded into the groove in the stone rod and therefore mostly not visible.
[0053] FIG. 7 is a sectional drawing, taken at line 7 - 7 on FIG. 6 . FIG. 7 shows a stone rod 10 that is approximately 1⅛ inches wide by 1½ inches tall and egg-shaped in cross section with a groove 11 in the underside that as approximately 3/16 of an inch wide and ¾ of an inch deep, or roughly to the mid point of the rod. An “L” shaped metal angle 12 and 14 is shown with the upward pointing member substantially embedded in the groove in the stone rod. A layer of adhesive 7 fills the space between the metal and the stone and binds the stone and metal together. The imbedded metal angle reinforces and stabilizes the stone rod to prevent it from cracking if hit or bumped. The vertical component 12 of the angle is approximately ¾ of an inch tall and ⅛ of an inch thick. A ½ inch wide horizontal flange 14 projecting towards the wall provides resistance to lateral force. The metal angle spans between and is supported by a metal bracket 13 near each end of the towel bar. Each bracket is approximately ¾ of an inch wide by 1½ inches tall and projects 3 inches from the wall. On the back surface of each bracket is a cylindrical void 15 approximately ½ of an inch in diameter and ⅞ of an inch deep. This void allows the bracket to slide onto a cylindrical aluminum bushing that would be bolted to the wall 16 . The bracket is locked into place by an Allan screw 31 .
[0054] FIG. 8 shows this embodiment of the towel bar from the back side, with the stone rod 10 separated from the metal support structure. The groove 11 in the stone stops before reaching the ends of the rod. The metal angle 12 and 14 that spans between the support brackets 13 can vary in length and is dependent on the length of the stone rod. For a single-towel bar this angle would be approximately 24 inches long which is 2 inches shorter than the stone rod. The cylindrical recesses 15 for the attachment bushings can be seen on the back face of the brackets. The Allan screw holes 31 are visible on the underside of the brackets.
[0055] FIG. 9 shows a variation of this embodiment of the towel bar, viewed from the back side, with the stone rod 10 separated from the metal support structure. This figure illustrates a long bar intended for two towels and it therefore has a center bracket 17 for additional support. The stone rod would be approximately 50 inches long. The metal support angle would be about 48 inches long. FIG. 10A is a front elevation of this embodiment of the towel bar with the stone rod 10 seemingly resting on the two end brackets 13 and the center bracket 17 .
[0056] FIG. 10B is an enlarged partial view of left end of the towel bar shown in this preferred embodiment. The groove 11 in the stone rod 10 shown by the dotted line tapers from roughly ¾ of an inch to zero as a segment of a circle which would be created by the circular blade that is used to make the groove. FIG. 10C is a variation of this end condition which shows the groove ending with a gradual angle 29 . FIG. 10D shows a stepped end to the groove. These latter two conditions might result if the groove is created with a drilling or grinding tool.
[0057] Another preferred embodiment of the invention is illustrated in FIGS. 11 and 12 which show a railing cap or hand rail. In FIG. 11 a cylindrical stone rod 18 with a groove 19 on the underside which is cut to approximately the mid point of the cylinder is shown imbedded onto a metal bar 25 . Adhesive 3 bonds the stone to the metal. The stone rod and metal bar span between posts 20 that are attached to a floor. The diameter of the stone rod and the dimensions of the metal bar are dependent on the particular requirements of the installation, for example the distance between support posts. FIG. 12 shows an alternate metal supporting member 28 , in the form of a Christian cross. A metal extrusion with this shape might be advantageous in some situations. It might allow for easier attachment of the metal structure to the vertical post, for example, and the horizontal flanges add stability against lateral force.
[0058] FIGS. 13 through 17 show possible cross sectional contours of the stone rod, all with a groove cut into the underside that extends to a depth of approximately the midpoint of the stone rod and through the end of the rod. The shapes shown in FIG. 13 and FIG. 14 have been seen in the embodiments described above. FIG. 15 is a rod with an oval 21 contour. FIG. 16 is a rod with a rectangle 22 contour and with rounded corners. FIG. 16 is a trapezoid 23 contour with rounded corners.
[0059] FIG. 18 shows an egg-shaped rod 1 in section with a groove 24 that does not pass though the end of the rod. This groove condition could occur with any of the various cross sectional shapes.
[0060] FIGS. 19 through 22 show possible cross sectional shapes of the metal member that is used to reinforce the stone rod. FIG. 19 is a flat bar 25 . FIG. 20 is an “L” shaped metal angle. FIG. 21 is a “T” shaped extrusion. FIG. 22 is a Christian-cross shaped extrusion.
[0061] In each case where the claimed invention is to be installed, the specific stone rod size and shape and the specific metal brace size, shape and configuration would be determined by the particular conditions or requirements of the installation.
[0062] There has thus been shown and described a novel decorative stone and metal bar for architectural use which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which to be limited only by the claims which follow.
|
A decorative bar, configured to be mounted on a surface (wall or floor) of a room or building, comprises (a) an elongate rod formed of natural stone and having a substantially constant cross-sectional shape from a first end to an opposite, second end and a longitudinal groove extending along one side, and (b) an elongate metal armature or brace having a portion thereof inserted in and substantially filling the longitudinal groove in the stone rod. The metal brace has a flange or bracket at each end configured to be attached to the surface (wall or floor) of a building to affix and retain the stone rod in a mounted relationship to this surface with its longitudinal groove on a side which is not readily visible to a casual observer.
| 4
|
BACKGROUND OF THE INVENTION
The invention is in the field of external rearview mirrors which are controlled by the driver from inside the vehicle.
Especially in the last ten years, numerous types of interiorly controlled external mirrors have been developed, the most popular type being operated by a single swivel-mounted toggle on the driver's door panel, this toggle being connected in one way or another through cables to the reflective mirror element. This type of device, as well as the others that are in use, suffers from the failing that when the mirror is displaced from its proper position for one driver, or when another driver operates the vehicle, it must be painstakingly reset by trial and error. This resetting is problematic in any event, but is especially undesirable if the driver does not notice that adjustment is necessary until he enters a freeway. The danger of deflecting the eyes from the forward roadway for the period of time necessary to adjust the outside mirror by remote control is in current metropolitan traffic conditions is obvious.
SUMMARY OF THE INVENTION
The present invention avoids the above-mentioned danger and problem by providing a rearview mirror which is adjustable about two orthogonal axes by means of a pair of digital knobs which have a number of "clicks" or incremental settings such that the driver may judge the number of clicks from the base setting by feel without requiring visual reference to anything. The knobs may be indexed by numbers, or the like, so that a particular combination of numbers will always yield the proper mirror setting for one particular driver and the driver can initially determine the number of clicks required for his setting.
Thus not only is the mirror very simply readjusted for a husband and wife who use the same car, but a whole family or any number of people can share the same vehicle without the usual nuisance of mirror readjustment. Although the invention is designed for external rearview mirrors, it could be used in modified form for internal mirrors as well. However, internal rearview mirrors are more simply adjusted because they can be moved directly by the hand and because the rear window of the vehicle serves as an alignment references which is not present when trying to adjust the outside mirror.
Although numerous interior control mechanisms could be selected, the one illustrated comprises a pair of parallel dials, each having a coaxial pinion gear which operates a rack gear which in turn moves the cable wire, the other ends of the two wires being connected to levers which are part of a novel mirror element support system disclosed below.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a sectional elevational view of the rear of the mirror element taken along lines 1--1 of FIG. 2;
FIG. 2 is a horizontal sectional view of the mirror portion showing the lever, pivot, and spring mechanisms, and also showing connecting cables and mirror element housing;
FIG. 3 is a front elevational view of the control dials as they appear from inside the vehicle;
FIG. 4 is a sectional view taken between the dials along the line 4--4 of FIG. 2 showing the rack and pinion structure;
FIG. 5 is an elevational view of the inside of a dial showing the scalloped edge and the stops;
FIG. 6 is an exploded perspective view of the control portion of the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The external portion of a rearview mirror is shown in FIG. 2 at 10 supported by an arm 12 from the side 14 of a vehicle. A housing 16 is connected to this arm, which serves to shield the mirror element 18 from wind and weather.
The mirror element 18 engages a ball 20 which is mounted to the interior of the housing 16 by means of a snap-on socket 22 molded of rubber or other slightly expansible composition. A pair of mounting forks 24 are also mounted to the interior of the housing 16 and act as fulcrums for levers 25 and 26 which contact the rear surface of the mirror by means of enlarged bosses 28 on the ends thereof at points 30 and 32, respectively, defining a substantiant vertical axis 34 and a substantially horizontal axis 36. It can be seen from an examination of FIG. 1 that by operating the levers individually, the mirror will be made to rotate about the axis defined by the other lever. In other words, pressure applied by lever 26 against the rear surface of the mirror will adjust the mirror element about vertical axis 34, whereas adjustment about the horizontal axis is effected by movement of the lever 25.
A coil tension spring 38 is utilized to insure the mirror is always biased against its three support points, and an accordian skirt may be added to insure that the operative mechanism of the mirror is not exposed to dirt and the elements. The inner ends of the levers 25 and 26 are connected to the core elements 42 of Bowden wires, the sheaths 44 of which are engaged in seating member 46.
It should be noted at this point that it is impossible to apply compressive, buckling forces to the cable cores by manipulating the mirror element 18 directly because of the reversing action of the levers 25 and 26. Because it is only possible to exert tensile forces on these core elements, a principal cause of jamming and subsequent inoperability of Bowden cables has been removed.
It should be clear from the above discription how the mirror element is operated by the cables. FIGS. 3 through 6 illustrate a control assembly mounted to the door panel on the driver's side or an equivalent location to enable the driver to easily manipulate the assembly. The Bowden wire cables enter and are secured by a bracket 48, the cores 42 extending from the sheaths and being gripped by set screws 50 in racks 52.
These racks as seen in FIGS. 3 and 6 are free to slide behind a front plate 54 which would ordinarily be flush with the interior door panel. A casing 56 is mounted behind the front plate and a slot 58 is provided in the forward portion of the casing to seat a divider 60. On each side of the divider is disposed an operative element 62 which includes a disc or dial 64 having scalloped, preferably numbered edges 66, a coaxial fixed pinion gear 68 which engages one of the racks 52, and a pair of stop members 70 which define limits of rotation in both directions because of the presence of the stud 71 molded in the casing 52, as can be easily visualized.
These operative elements are journalled on a pin 74 skewered through the casing and a portion of each dial protrudes forwardly through a rectangular opening 76 and is accessible from the vehicle compartment as can be seen in FIG. 5. The front plate 54 defines a pair of adjacent wells 78, each of which houses a leafspring 80, which urges the respective racks against the pinions to insure that the engagement is positive.
Mounted to the interior of the casing is a detent 82 supported on the end of a leafspring. This detent will engage in scallops 66 to define a plurality of discrete positions for the dials.
In operation, each of the dials 64 is rotated to control a respective one of the directional adjustment capabilities of the mirror element. An indicator 84 is provided on the front plate of the assembly or elsewhere to select one of the numerals from each of the dials so that a combination of two digits will provide information sufficient to set the mirror. Thus, once the mirror has been originally set so that the particular user has the rear visibility that he desires, by remembering the two digits which show up on the dials aligned with the indicator, regardless of what disturbance the mirror element has been through since the last time he drove, the driver will always be able to immediately reset the mirror to his liking.
Because rotation of the dials results in distinctive clicks of the incremental stages of adjustment are reached, the driver need not visually refer to the numbers on the dial but can back them each up to zero with his thumb and click them into the numbered position by feel without ever looking away from the road.
The main features of the invention are, of course, the separation of the adjustment of the mirror element into motion about two independent axes and the control of these two motions separately by a digital, indexed pair of operative elements of one form or another to permit the duplication of the setting by merely selecting two previously-learned numerals or numbers of clicks. Although the dial controls are favored, other mechanisms permitting independent, digital control of cable displacement could be used.
The invention as thus described is universally usable by any number of people with equal convenience, is economical to manufacture and represents no major departure installation-wise from those adjustable external rearview mirrors currently in use so that adaptation would be simplified. The unique mirror element suspension and adjustment system permits the independent adjustment of the mirror about two orthogonal axes and at the same time prevents buckling of the core elements of the Bowden wire cables, which could be caused by compressive forces.
|
An external vehicular rearview mirror assembly comprises a reflective mirror element which is adjustable about two perpendicular axes by means of a pair of Bowden wire cables operated from within the vehicle by two dials or knobs which are digital insofar as each knob is selectively positionable at one of several discrete positions which are indexed so that the exact positioning of the mirror can be unerringly duplicated.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional Patent Application Ser. No. 61/501,535, filed on Jun. 27, 2011 and entitled “Cooling Module with Parallel Blowers”, the content of which being incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to cooling systems generally, and more particularly to cooling fan arrays specifically arranged for enhanced performance in motivating cooling fluid through an electronics chassis.
BACKGROUND OF THE INVENTION
Designers of electronic equipment have become increasingly challenged to provide high-power devices in relatively small packages. These devices require compact and highly efficient cooling systems. A typical cooling system involves moving air across one or more printed circuit boards. The flow path layout, type of air moving device, and how well it is integrated into the system are all key elements in achieving the desired performance in a small package size with limited noise.
One such electronic device is a telecommunications router which typically includes a series of electronics communications “cards” arrayed with cooling fans in a chassis. The desire to make routers more powerful, yet compact in size, leaves little space for cooling system components necessary to address ever-increasing heat loads. Conventional system designs often employ fans that are not well matched to the system pressures, or do not move air efficiently within the space constraints, and result in unacceptable noise and relatively large power consumption.
Design efforts to date typically use multiple axial fans arranged in a “tray”, as illustrated in FIG. 1 . The fans either push cooling air through a chassis or pull warm air out from the chassis. Higher fan speeds have been used to address increased flow requirements, but as system pressures increase, designers have responded by adding additional trays of axial fans arranged in series. An example of such series of axial fan trays is illustrated in FIG. 2 . In theory, each axial fan tray handles half of the system pressure. The conventional arrangement illustrated in FIG. 2 sets forth an orientation with both fan trays downstream from the electronics being cooled in the electronics chassis, thereby pulling cooling air through the system. In other conventional arrangements, fan trays may be disposed upstream of the electronics being cooled, or fan trays being disposed both upstream and downstream of the electronics in a push-and-pull-through system. Relatively high aerodynamic efficiencies may be achieved with this type of air mover, but unfortunately require high rotational speeds that typically result in unacceptable acoustic levels.
Centrifugal blowers are better suited for the higher pressures encountered in high cooling load applications. However, centrifugal blowers have not typically been considered for electronics chassis cooling, particularly in compact arrangements, due to their relatively larger physical size. As a result, centrifugal blowers have not commonly been considered for fit within cooling system packaging space. For example, a single inlet centrifugal blower sized to match the performance of two axial fans in series can require twice the volumetric space, be less efficient, and result in a less uniform flow field.
It is therefore an object of the present invention to provide a cooling system that simultaneously increases performance and reduces noise of conventional air movers.
It is a further object of the present invention to provide a cooling arrangement that is particularly well suited for cooling densely populated electronic components, such as telecommunication edge routers.
SUMMARY OF THE INVENTION
By means of the present invention, enhanced cooling to electronics chassis may be achieved with greater efficiency and reduced acoustic levels. The present cooling system provides cooling fluid, such as cooling air, in a generally uniform flow field across electronic components for cooling thereof. The electronic components may be disposed in a chassis, such as a telecommunication edge router, server, or a power supply unit.
In one embodiment, a cooling fan array of the present invention is arranged for motivating cooling fluid through an interior chamber of an electronics chassis generally along a flow direction. The cooling fan array includes a frame having a cooling fluid entrance and a cooling fluid exit in fluid communication with the interior chamber, with at least one of the frame entrance and exit directing air flow therethrough along a direction parallel with the flow direction. The frame further includes a plurality of modules individually removable from and replaceable in the frame without operational interruption to others of the modules. Each of the modules includes a centrifugal blower with an impeller driven by a motor and defining an axis of rotation, wherein the blower includes an inlet arranged to intake the cooling fluid along a respective intake direction transverse to the flow direction. The blowers are arranged in the frame in one or more sets, with each set including at least two blowers oriented with respective inlets in facing relationship with one another and with respective axes of rotation being axially aligned with one another, the facing inlets being axially spaced apart by a spacing dimension that is less than 75% of a diameter dimension of the impeller within the set, such that the blowers operate in parallel to motivate the cooling fluid through the cooling fluid inlet.
In another embodiment, an electronics chassis of the present invention includes an interior chamber through which cooling fluid is motivated generally along a flow direction to cool electronic components. The chassis further includes a frame having an entrance through which the cooling fluid is drawn from the interior chamber, and an exit. A plurality of modules may be disposed in the frame, and are individually removable from and replaceable in the frame without operational interruption to others of the modules. Each of the modules includes a centrifugal blower with an impeller driven by a motor and defining an axis of rotation. The centrifugal blower includes dual opposed inlets arranged to intake the cooling fluid along respective intake directions transverse to the flow direction. The blowers are arranged in the frame in one or more sets, with each set including at least two blowers oriented with respective inlets in facing relationship with one another and with respective axes of rotation being axially aligned with one another, the facing inlets being axially spaced apart by a spacing dimension that is less than 75% of a diameter dimension of the impeller within the set, such that the blowers operate in parallel to motivate the cooling fluid through the frame inlet.
In a further embodiment, an electronics chassis includes an interior chamber through which cooling fluid is motivated generally along a flow direction to cool electronic components disposed in the interior chamber. The chassis further includes a frame having an entrance through which the cooling fluid is drawn from the interior chamber, and an exit. A plurality of modules in the frame are individually removable from and replaceable in the frame without operational interruption to others of the modules. Each of the modules includes one or more sets of two centrifugal blowers having forward-curved impellers driven in opposite circumaxial directions with respect to one another about respective impeller axes of rotation. The centrifugal blowers each have an inlet and an outlet, wherein the respective centrifugal blower inlets of the set are arranged to intake the cooling fluid along respective substantially opposite intake directions that are both transverse to the flow direction. The blowers of the set are arranged in the frame to operate in parallel to motivate the cooling fluid through the frame entrance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an axial fan tray arrangement of the prior art;
FIG. 2 is a schematic diagram of an axial-type fan tray arrangement in series of the prior art;
FIG. 3 is an illustration of a cooling fan array of the present invention;
FIG. 4 a is a schematic illustration of an electronics chassis of the present invention incorporating the cooling fan array of FIG. 3 ;
FIG. 4 b is a schematic illustration of an electronics chassis of the present invention incorporating a cooling fan array of the present invention;
FIG. 5 a is a schematic illustration of an electronics chassis of the present invention incorporating a cooling fan array of the present invention;
FIG. 5 b is a schematic illustration of a cooling fan array of the present invention;
FIG. 5 c is a schematic illustration of a cooling fan array of the present invention; and
FIG. 6 is a chart depicting performance characteristics of a cooling fan array of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The objects and advantages enumerated above together with other objects, features, and advances represented by the present invention will now be presented in terms of detailed embodiments described with reference to the attached drawing figures which are intended to be representative of various embodiments of the invention. Other embodiments and aspects of the invention are recognized as being within the grasp of those having ordinary skill in the art.
With reference now to the drawings, and first to FIGS. 3 and 4 a , a cooling fan array 10 includes a frame 12 having a cooling fluid entrance 14 and a cooling fluid exit 16 . Frame 12 includes a plurality of modules 18 a - 18 c that are individually removable from and replaceable in frame 12 without operational interruption to others of modules 18 a - 18 c . Such a characteristic is known in the art as being “hot swappable”, in that each of modules 18 a - 18 c may be removed from frame 12 for repair or replacement without interrupting or substantially affecting the operation of the remaining modules 18 a - 18 c of housing 12 . In this manner, maintenance may be performed upon a respective module 18 a - 18 c without requiring shut down of the entire cooling fan array 10 , which would require shut down of the electronics chassis being cooled by cooling fan array 10 . In some cases, removal of one or more of modules 18 a - 18 c from housing 12 requires increased blower speed in the remaining modules to accommodate and maintain a desired cooling fluid flow rate through the electronics chassis. Control systems for electronically controlling the blowers of hot-swappable modules for air-cooling systems are well understood in the art.
Each of the modules 18 a - 18 c in frame 12 may include one or more double-width double-inlet forward curved (DWDI-FC) centrifugal blowers 20 . In the example arrangement of FIG. 3 , frame 12 includes three modules 18 a - 18 c , each of which includes three DWDI-FC centrifugal blowers 20 . It is to be understood, however, that frame 12 of the present invention may include any number of a plurality of modules 18 a - 18 c , with each module having, for example, one or more DWDI-FC centrifugal blowers 20 . Moreover, modules 18 a - 18 c of frame 12 may include different numbers of DWDI-FC blowers 20 . In typical embodiments, each DWDI-FC centrifugal blower 20 a - 20 c is driven by a motor, such as a DC brushless motor that is independently controllable by a control system to adjust and maintain desired cooling air flow characteristics through frame 12 and the associate electronics chassis.
FIG. 4 a illustrates frame 12 secured to an electronics chassis 30 in an embodiment wherein cooling fan array 10 is arranged to pull air flow through a series of electronics communication cards arrayed in an interior chamber 32 of electronics chassis 30 generally along a flow direction 34 to cool the electronic components disposed at interior chamber 32 of electronics chassis 30 . Cooling fluid flow (represented by arrows) is drawn through electronics chassis 30 from an inlet 36 , into cooling fluid entrance 14 of frame 12 , and finally out from cooling fan array 10 at cooling fluid exit 16 . Centrifugal blowers 20 in parallel motivate the cooling fluid flow along flow direction 34 , and motivate the cooling fluid flow “in parallel” by each blower individually acting upon cooling fluid flow through interior chamber 32 of electronics chassis 30 . In addition, blowers 20 a - 20 c of each of modules 18 a - 18 c motivate the cooling fluid flow “in parallel” by receiving cooling fluids to their respective inlets that is sourced directly from cooling fluid passing through interior chamber 32 , and not as exhaust from an “upstream” blower within its associated frame 12 . It is contemplated that a plurality of frames 12 may be employed in a cooling fan array 10 , wherein the respective frames 12 may operate in series to motivate cooling fluid through electronics chassis 30 . In such case, blowers 20 of a “downstream” housing 12 would in fact receive the exhaust from an “upstream” blower. However, the blowers 20 within a respective frame 12 operate in parallel to receive substantially only “fresh” air entering frame 12 through cooling fluid entrance 14 .
Blowers 20 , such as blowers 20 aa - 20 ac each include dual opposed inlets 22 , 24 arranged to intake the cooling fluid along respective intake directions 26 , 28 which are transverse to flow direction 34 . Such an arrangement is best viewed in FIG. 4 b , which is identical to the system illustrated in FIG. 4 a with the exception of the cooling fluid outlet directionality. Cooling fluid exit 16 of the embodiment illustrated in FIG. 4 a is transverse to flow direction 34 , while cooling fluid exit 16 of the embodiment illustrated in FIG. 4 b permits outflow parallel to flow direction 34 . It is contemplated that frame 12 may be provided, in some embodiments, with any suitable cooling fluid outlet arrangement and orientation, including for either or both of cooling fluid outlet directions transverse or parallel to flow direction 34 .
In some embodiments, each of blowers 20 include a single-scroll blower housing 42 which defines the dual-opposed inlets 22 , 24 and a blower outlet 44 . Centrifugal blowers 20 may further include a forward-curved impeller having a diameter dimension “y”, and defining an axis of rotation 52 which extends through inlets 22 , 24 substantially transverse to flow direction 34 . Blowers 20 each include a motor 54 for rotation of the respective impellers about their rotation axis 52 . In the illustrated embodiments, respective blowers 20 in modules 18 define sets 41 of axially adjacent blowers. For example, blowers 20 aa - 20 ac , as shown in FIG. 4 b , represent a set 41 a of blowers having respective impellers that axially aligned about axis of rotation 52 . In this example, blower 20 aa is a part of module 18 a , blower 20 ab is a part of module 18 b , and blower 20 ac is a part of module 18 c . Thus, set 41 a of blowers 20 aa - 20 ac may include one or more blowers from a plurality of distinct modules 18 a - 18 c . In other embodiments, however, blower sets 41 a - 41 c may be confined to a plurality of blowers within a single respective module 18 a - 18 c . Blower sets 41 a - 41 c preferably include a plurality of centrifugal blowers 20 that are arranged in frame 12 with their respective impeller axes of rotation axially aligned with one another, with axially adjacent inlets of axially adjacent blowers 20 being in mutually facing relationship. In the illustrated embodiment, blowers 20 a - 20 c of blower set 41 a are DWDI-FC centrifugal blowers having respective impeller axes of rotation aligned along axis 52 . Axially adjacent blower inlets 24 a , 22 b and 24 b , 22 c are in facing relationship with one another drawing inlet air in opposite directions and transverse to flow direction 34 , as depicted by the air flow arrows in FIG. 4 b . This arrangement has been discovered by the applicant to improve air flow efficiencies in motivating air flow through electronics chassis 30 .
In some embodiments, adjacent blower inlets 24 a , 22 b and 24 b , 22 c are not only axially aligned, but also spaced apart by a specific spacing dimension “x”. In some embodiments, such spacing dimension “x” may be less than about 0.75 (75%) of diameter dimension “y” of the impeller of blowers 20 , and more preferably between 0.5 and 0.75 (50%-75%) of diameter dimension “y” of the impeller of blowers 20 . In the event that the diameter dimension “y” of the axially adjacent pair of blowers is not equal, the spacing dimension “x” may be determined as 0.5-0.75 (50-75%) of the diameter dimension “y” of the larger impeller. Similarly, a spacing dimension “z” between a blower inlet and an axially adjacent wall, such as between blower inlet 22 a and a side wall 9 of frame 12 , may be between about 0.2-0.5 (20-50%) of diameter dimension “y” of the respective blower impeller, and more preferably between 0.23-0.36 (23-36%) of the respective impeller diameter dimension “y”.
The arrangements illustrated in FIGS. 4 a and 4 b have been found to provide surprisingly enhanced aerodynamic efficiency for each blower 20 , such that total power input to motivate a desired cooling fluid flow may be reduced. In addition, the surprising efficiency of the proposed arrangement reduces sound emissions, which is also a beneficial operating characteristic of the cooling fan arrays of the present invention. Such enhancements in efficiency and sound reductions may be accomplished in a housing volume that is not substantially larger than the volume assumed by conventional fan trays. Therefore, it is believed that the arrangements of the present invention substantially improve cooling fan arrays.
Applicants are particularly surprised to discover that the small axial spacing between adjacent blower inlets, and between a blower inlet and an axially adjacent wall, does not diminish aerodynamic performance in the operation of the centrifugal blowers. FIG. 6 is a graphical depiction of aerodynamic performance curves at various relative dimensions for spacing “A”, wherein spacing “A” may be between a blower inlet and an axially adjacent wall, equivalent to spacing dimension “z” in FIG. 4 b , or one-half of the spacing dimension between axially adjacent inlets, equivalent to spacing dimension “x”/2. As depicted in FIG. 6 , the present arrangement of axially aligned centrifugal blowers with a spacing “A” of 36% of the impeller diameter exhibits aerodynamic performance that is equivalent to centrifugal blowers with “unrestricted” inlets, which are defined as having a spacing “A” that is sufficiently large to avoid disturbance to inlet air flow. In effect, therefore, the “unrestricted inlet” data in FIG. 6 assumes an infinite spacing “A”.
The data graphically depicted in FIG. 6 reveals a surprising result of the present invention, in that a centrifugal blower arrangement with a spacing “A” of 36% of an impeller diameter dimension “y” of the blower applied to motivating air through an interior chamber 32 of electronics chassis 30 , as depicted by the “system curve” of FIG. 6 , exhibits substantially equivalent aerodynamic performance to centrifugal blowers with unrestricted inlets. Such a discovery is counter to conventional understanding of centrifugal blower aerodynamic performance, wherein restricted inlet spacing “A” consistently reduces aerodynamic performance of the blower. Applicants have surprisingly discovered that, even with centrifugal blower inlets “restricted” with a spacing “A” of 36% of the impeller diameter, can achieve aerodynamic performance equivalent to centrifugal blowers with unrestricted inlets, as measured in a cooling system application. FIG. 6 further reveals that the present arrangement of axially aligned centrifugal blowers with a spacing “A” of 23% of the impeller diameter, as applied in motivating air through chassis 30 , is substantially equivalent to conventional centrifugal blower arrangements with a spacing “A” of 50% of the impeller diameter.
Applicants theorize that the discovery of unexpected aerodynamic performance at small spacing dimensions between adjacent centrifugal blowers may be at least in part the result of coinciding vortices just upstream from the respective blower inlets, wherein the coincidence of the vortices is created as a consequence of the small axial spacing dimensions. The coincident vortices may be synergistic in generating a highly efficient aerodynamic flow into the respective blower inlets. Such a finding is contrary to conventional understanding, which predicts aerodynamic performance degradation with the presence of another operating blower within the flow field of the first blower. The results depicted in FIG. 6 clearly indicate otherwise.
The arrangement illustrated in FIG. 4 b includes a frame 12 incorporating a separation plate 62 defining an outlet plenum 64 of frame 12 which primarily separates inlets 22 , 24 of blowers 20 from respective outlets 44 . Outlet plenum 64 is therefore fluidly connected to cooling fluid entrance 14 only through blowers 20 , such that cooling fluid is motivated through interior chamber 32 of electronics chassis 30 into cooling fluid entrance 14 and into respective inlets 22 , 24 of blowers 20 for exhaust out through blower outlets 44 , and ultimately out through cooling fluid exit 16 . Thus, outlet plenum 64 is fluidly connected to cooling fluid exit 16 .
Separation plate 62 creates separation between a negative pressure side 13 from a positive pressure side 11 of frame 12 . Separation plate 62 therefore eliminates the need for separate ducts from each blower 20 in a module 18 , and reduces recirculation to negative pressure side 13 in the event of blower failure. The need for back draft dampers is therefore substantially reduced or eliminated. As illustrated in FIG. 3 , each module 18 a - 18 c may include a separation plate 62 a - 62 c for separating positive and negative pressure sides 11 , 13 of a respective module 18 . Outlet plenum 64 may further be divided by divider plates 63 a , 63 b to define individual module outlet plenums 64 a - 64 c . Divider plates 63 a , 63 b segment outlet plenum 64 as individual outlet zones from the blowers of each module 18 a - 18 c.
Outlets 44 of blowers 20 may be canted at an angle, such as at 45°, to promote cooling fluid exhaust more directly out through cooling fluid exit 16 along an outlet axis 58 that is substantially transverse to flow direction 34 . In other embodiments, such as that illustrated in FIG. 4 b , blower outlets 44 may be directed axially in parallel with flow direction 34 to direct exhaust cooling fluid axially out from cooling fluid exit 16 .
The systems illustrated in FIGS. 4 a and 4 b depict a “pull” system employing a plurality of DWDI-FC centrifugal blowers arranged to motivate the cooling fluid flow in parallel, and with parallel cooling fluid discharges. Moreover, the respective inlets 22 , 24 of blowers 20 are arranged transverse to flow direction 34 . Such arrangement represents a substantial noise reduction in comparison to similar packaging space allocated for conventional axial fan trays.
A further embodiment is illustrated in FIG. 5 a , wherein cooling fan array 110 includes a frame 112 having a cooling fluid entrance 114 and a cooling fluid exit 116 . Frame 112 includes a plurality of modules 118 a - 118 c that are individually removable from and replaceable in frame 112 without operational interruption to others of modules 118 a - 118 c . In this embodiment, each of the modules 118 in cooling fan array 110 includes one or more sets of “forward-curved” centrifugal blowers 180 . In the example arrangement of FIG. 5 a , each set of forward curved centrifugal blowers 180 includes two centrifugal blowers 182 a , 182 b placed back to back, such that inlet 184 a of blower 182 a is oppositely disposed from inlet 184 b of blower 182 b . Due to such opposite orientations, the respective impellers of blowers 182 a , 182 b may be configured to rotate in opposite circumaxial directions with respect to one another about an axis of rotation 152 . The opposite circumaxial rotational directions have been found to generate desired cooling fluid flow characteristics through frame 112 and interior chamber 132 . Blower sets 180 may include two or more blowers 182 a , 182 b which may be arranged to coordinate with other blowers of the module 118 and/or array 110 to motivate cooling fluid flow through interior chamber 132 of electronics chassis 130 . Blower sets 180 may operate to motivate the cooling fluid flow along flow direction 134 , and to motivate the cooling fluid flow “in parallel”.
In the illustrated embodiment, each module 118 a - 118 c includes two sets 180 of forward-curved centrifugal blowers 182 a , 182 b . Frame 112 of the present invention, however, may include any number of a plurality of modules 118 a - 118 c , with each module having one or more sets 180 of blowers 182 . In some embodiments, respective sets 180 of blowers 182 a , 182 b among a plurality of modules 118 may be arranged so that their respective axes of rotation through inlets 184 a , 184 b are all substantially mutually aligned along a respective axis 152 , 154 . In typical embodiments, each blower 182 may be driven by a motor, such as a DC brushless motor that is independently controllable by a control system to adjust and maintain desired cooling fluid flow characteristics through frame 112 and the associated electronics chassis 132 .
Blowers 182 each include a respective inlet 184 that is arranged to intake the cooling fluid along a respective intake direction 126 , 128 which is transverse to flow direction 134 . In the embodiment illustrated in FIG. 5 a , cooling fluid exit 116 permits outlet flow from blowers 182 along an outlet direction 135 that is substantially transverse to flow direction 134 . It is contemplated, however, that frame 112 may be provided with any suitable cooling fluid exit arrangement and orientation, including for either or both of cooling fluid outlet directions transverse or parallel to flow direction 134 .
It is contemplated that the blower sets 180 may be configured to provide desired cooling fluid flow in a manner similar to blowers 20 described hereinabove. Blower sets 180 , however, utilize, for example, single-inlet forward-curved centrifugal blowers placed in back to back relationship to together motivate cooling fluid flow through electronics chassis 130 . In some embodiments, respective blowers 182 a , 182 b may be in abutting relationship with one another, or may be spaced apart by a desired spacing dimension. Moreover, mutually facing inlets of axially adjacent blowers may preferably have a spacing dimension “x 1 ” of less than about 0.75 (75%) of a diameter dimension “y 1 ” of the impellers of respective blowers 182 a , 182 b , and more preferably between 0.5-0.75 (50-75%) of diameter dimension “y 1 ”. The respective inlets 184 a , 184 b of blowers 182 a 182 b lead to impellers which may preferably be axially aligned along a respective axis of rotation.
Another embodiment is illustrated in FIG. 5 b wherein cooling fan array 210 includes a frame 212 having a cooling fluid entrance 214 and a cooling fluid exit 216 . Frame 212 includes a plurality of modules 218 a - 218 c that are individually removable from and replaceable in frame 212 without operational interruption to others of modules 218 a - 218 c . In this embodiment, each of the modules 218 in cooling fan array 210 includes one or more sets of centrifugal blowers 280 , which may include forward-curved impellers. In the illustrated embodiment, each set of centrifugal blowers 280 includes two centrifugal blowers 282 a , 282 b placed in facing relationship to one another, such that inlet 284 a of blower 282 a is in generally facing relationship with inlet 284 b of blower 282 b . The respective impellers of blowers 282 a , 282 b may be configured to rotate in opposite circumaxial directions with respect to one another about an axis of rotation 252 . Blower sets 280 may be arranged to coordinate with other blowers of the respective module 218 and/or array 210 to motivate cooling fluid flow through the associated electronics chassis 230 . Blower sets 280 may operate to motivate the cooling fluid flow along flow direction 234 , and to motivate the cooling fluid flow “in parallel”.
In the illustrated embodiment, each module 218 includes one set 280 of centrifugal blowers 282 a , 282 b . Frame 212 of the present invention, however, may include any number of a plurality of modules 218 , with each module 218 having one or more sets 280 of blowers 282 . In typical embodiments, each blower 282 may be driven by a motor, such as a DC brushless motor that is independently controllable by a control system to adjust and maintain desired cooling fluid flow characteristics through frame 212 and the associated electronics chassis 232 .
Blowers 282 each include a respective inlet 284 that is arranged to intake the cooling fluid along a respective intake direction 226 , 228 that is transverse to flow direction 234 . In the embodiment illustrated in FIG. 5 b , cooling fluid exit 216 permits outlet flow from blowers 282 along an outlet direction 235 that is in alignment/parallel to flow direction 234 . It is contemplated, however, that frame 212 may be provided with any suitable cooling fluid outlet arrangement and orientation, including for either or both of cooling fluid outlet directions transverse or parallel to flow direction 234 .
It is contemplated that the blower sets 280 may be configured to provide desired cooling fluid flow in a manner similar to blowers 20 , 182 described above. Blower sets 280 , however, utilize, for example, single-inlet forward-curved centrifugal blowers placed in substantially face to face relationship to together motivate cooling fluid flow through electronics chassis 230 . Respective blowers 282 a , 282 b may be spaced apart by a desired spacing dimension “x 2 ” that is less than about 0.75 (75%) of the diameter dimension “y 2 ” of the impellers of blowers 282 a , 282 b , and more preferably between 0.5-0.75 (50-75%) of diameter dimension “y 2 ”. The respective inlets 284 a , 284 b of blowers 282 a , 282 b lead to impellers which are preferably axially aligned along a respective axis of rotation 252 , 254 .
A still further embodiment is illustrated in FIG. 5 c wherein cooling fan array 310 includes a frame 312 having a cooling fluid entrance 314 and a cooling fluid exit 316 . Frame 312 includes a plurality of modules 318 a - 318 c that are individually removable from and replaceable in frame 312 without operational interruption to others of modules 318 a - 318 c . In this embodiment, each of the modules 318 in cooling fan array 310 includes one or more sets of centrifugal blowers 380 . In the example arrangement of FIG. 5 c , each set of centrifugal blowers 380 includes two centrifugal blowers 382 a , 382 b placed front to front in generally facing relationship with one another, such that inlet 384 a of blower 382 a is in facing relationship with inlet 384 b of blower 382 b . The respective impellers of blowers 382 a , 382 b may be configured to rotate in opposite circumaxial directions with respect to one another about an axis of rotation 352 . Blower sets 380 may include two or more blowers 382 a , 382 b which may be arranged to coordinate with other blowers of the module 318 and/or array 310 to motivate cooling fluid flow through the interior chamber of electronics chassis 330 . Blower sets 380 may operate to motivate the cooling fluid flow along flow direction 334 , and to motivate the cooling fluid flow “in parallel.”
In the illustrated embodiment, each module 318 includes one set 380 of forward-curved centrifugal blowers 382 a , 382 b . Frame 312 of the present invention, however, may include any number of a plurality of modules 318 , with each module having one or more sets 380 of blowers 382 . In some embodiments, respective sets 380 of blowers 382 a , 382 b among a plurality of modules 318 may be arranged so that their respective inlets 384 a , 384 b are all substantially mutually aligned along a respective axis of rotation 352 . In typical embodiments, each blower 382 may be driven by a motor, such as a DC brushless motor that is independently controllable by a control system to adjust and maintain desired cooling flow characteristics through frame 312 and the associated electronics chassis 332 .
Blowers 382 each include a respective inlet 384 that is arranged to intake the cooling fluid along a respective intake direction 326 , 328 which is transverse to flow direction 334 . In the embodiment illustrated in FIG. 5 c , cooling fluid outlet 316 permits outlet flow from blowers 382 along an outlet direction 335 that is substantially transverse to flow direction 334 .
It is contemplated that the blower sets 380 may be configured to provide desired cooling fluid flow in a manner similar to blowers 20 , 182 , 282 described hereinabove. Blower sets 380 , however, utilize, for example, single inlet forward curved centrifugal blowers placed in substantially face to face relationship to together motivate cooling fluid flow through electronics chassis 330 . In some embodiments, respective blowers 382 a , 382 b may preferably be spaced apart by a desired spacing dimension “x 3 ” that is less than about 0.75 (75%) of a diameter dimension “y 3 ” of the impellers of blowers 282 a , 282 b , and more preferably between 0.5-0.75 (50-75%) of diameter dimension “y 3 ”. The respective inlets 384 a , 384 b of blowers 382 a , 382 b lead to impellers which are preferably axially aligned along a respective axis of rotation 352 .
Table 1 represents actual performance measured on an example embodiment cooling fan array in accordance with the present invention, compared to axial fans in series, as described in “prior art” FIGS. 1 and 2 .
TABLE 1
Delta from
Example
Axial Fans in series
Example
Embodiment
(FIG. 1&2)
Embodiment
Air Flow
295 cfm
295 cfm
—
Static Pressure
2.9 in. of H 2 O
2.9 in. of H 2 O
—
Tip Speed
5700 ft/min
13,000 ft/min
+128%
Sound Power
Est. 75 dBA
Est. 90 dBA
+15 dBA
Physical Volume
27 × 10 5 mm 3
21 × 10 5 mm 3
−22%
Table 2 represents actual performance of an example embodiment cooling fan array in accordance with the present invention, compared to conventional single width, single inlet centrifugal blowers.
TABLE 2
Single width, single
Delta from
Example
inlet
Example
Embodiment
FC Centrifugal
Embodiment
Air Flow
295 cfm
295 cfm
—
Static Pressure
2.9 in. of H 2 O
2.9 in. of H 2 O
—
Tip Speed
5700 ft/min
5,000 ft/min
−12%
Sound Power
Est. 75 dBA
Est. 73 dBA
−2 dBA
Physical Volume
27 × 10 5 mm 3
42 × 10 5 mm 3
+155%
It is clear from the above data that the arrangements of the present invention are capable of producing similar air performance to conventional arrangements, while substantially reducing tip speed, which is a major indicator of acoustic levels. The present arrangements also have substantially reduced volume in comparison to conventional centrifugal blower arrangements, due primarily to the discovery of desired aerodynamic performance with significantly reduced spacing dimensions “x” between respective facing inlets of axially adjacent centrifugal blowers. The surprising aerodynamic performance permits the construction of a highly compact array of centrifugal blowers to achieve either greater performance than conventional arrangements of similar size, or reduced noise output in comparison of conventional blower arrangements of similar size.
The cooling fan arrays of the present invention, therefore, provide substantially enhanced efficiency and reduced acoustic signatures, without requiring substantially increased volume to the housing.
The invention has been described herein in considerable detail in order to comply with the patent statutes, and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the invention as required. However, it is to be understood that the invention can be carried out by specifically different methods/devices and that various modifications can be accomplished without departing from the scope of the invention itself.
|
A cooling system for an electronics chassis includes a plurality of centrifugal blowers arranged to motivate cooling air through the electronics chassis. The centrifugal blowers are arranged in one or more sets, each having blowers oriented with respective inlets in mutual facing relationship. The orientation, positioning, and alignment of the centrifugal blowers facilitates a compact arrangement of the plurality of blowers that achieves increased aerodynamic efficiencies to reduce noise output and energy consumption.
| 5
|
RELATED APPLICATIONS
The present application is a divisional application of U.S. patent application Ser. No. 13/503,244 filed on Jul. 9, 2012, which is a national phase entry of International Application No. PCT/JP2010/068304 filed on Oct. 19, 2010, which claims priority from Japanese Application No. 2009-243519 filed on Oct. 22, 2009, the disclosure of which are incorporated herein by reference.
FIELD OF INVENTION
The present invention relates to a device for treating fluorine-containing water, and more particularly relates to a device for treating fluorine-containing water for removing fluorine highly from fluorine-containing water such as waste water containing a fluorine-based etching agent, and efficiently recovering the removed fluorine as calcium fluoride having high purity.
BACKGROUND OF INVENTION
A large amount of an etching agent which contains hydrogen fluoride or hydrogen fluoride and ammonium fluoride as main ingredients has been used in a semiconductor manufacturing process, a related process thereof, or a surface treatment process of various materials including metal materials, single crystal materials, optical materials, and the like. An etching agent which contains hydrogen fluoride as a main ingredient or an etching agent which contains hydrogen fluoride and ammonium fluoride (buffered hydrofluoric acid) as main ingredients contains high levels of fluorine as HF. Therefore, when these etching agents flow into a waste water system, waste water thereof become to contain fluorine at a high concentration. As materials treated with etching agents are washed with a large amount of cleaning water during etching process and after the process, a large amount of waste water containing low levels of fluorine is discharged from the washing process.
According to a conventional method, waste water containing high levels of fluorine and waste water containing low levels of fluorine are mixed and treated. Patent Document 1 discloses a method for treating fluorine-containing waste water wherein the waste water is fed to and passed through a reaction tower packed with granular calcium carbonate.
The method described in Patent Document 1, treatment is performed by a merry-go-round method, in which a plurality of towers packed with calcium carbonate are arranged in series. First, raw water is sequentially passed from a first tower (tower in a first stage) to the following tower(s) to remove and recover fluorine. When the fluorine concentration of the raw water flowing into the first tower and the fluorine concentration of the treated water flowed out from the first tower become almost the same, feeding raw water to the first tower is stopped, the calcium fluoride is recovered from the first tower, and the first tower is packed with fresh calcium carbonate. Then, raw water is fed to and passed through the second tower, and flows sequentially to the following tower(s) for the first tower.
Patent Document 1 describes that granular calcium carbonate packed in each calcium carbonate packed tower has a diameter of about 0.1 to 0.5 mm, and specifically granular calcium carbonate having a diameter of 0.25 mm is used in Examples thereof.
Patent Document 2 discloses a method for removing fluorine from fluorine-containing raw water including a process of feeding the raw water to a reaction tower packed with granular calcium carbonate to remove the fluorine, wherein acid or alkali is added to the raw water based on an α-value calculated from measured values of fluorine concentration and acid concentration in the raw water.
LIST OF DOCUMENTS
Patent Document 1: Japanese Patent 3466637
Patent Document 2: Japanese Patent 2565110
The method described in Patent Document 1 has a problem that, in order to recover high purity calcium fluoride from the calcium carbonate packed towers, raw water is passed until the fluorine concentration of the raw water flowing into the tower in the first stage and the fluorine concentration of the treated water therefrom become almost the same, i.e., the fluorine removal ratio of the calcium carbonate packed tower in the first stage becomes almost zero. As a result thereof, fluorine leaks into the treated water of the calcium carbonate packed tower (reaction tower) in the second stage as illustrated in FIG. 4 , so that the fluorine removal ratio becomes low. For example, in Example 1 of Patent Document 1, when the fluorine removal ratio of the first tower packed with the calcium carbonate is 0%, the fluorine removal ratio of the second tower is 72.7 to 77.6%, i.e., the fluorine removal ratio of the entire device is 72.7 to 77.6%, so that treated water of high water quality cannot be obtained.
In order to solve the above problem, it has also been designed to increase the number of the towers packed with calcium carbonate and to arrange the calcium carbonate packed towers in series in three or more stages. However, in this case, the treating device is enlarged in its scale, which is not preferable in every respect of the device cost, installation area, maintenance, and the like.
OBJECT AND SUMMARY OF INVENTION
It is an object of the present invention to solve the above-described problems, and provide a method and a device for treating fluorine-containing water capable of removing fluorine in fluorine-containing water efficiently and recovering high purity calcium fluoride when treating the fluorine-containing water by passing the same through plurality of, preferably two, calcium carbonate packed towers arranged in series.
The present inventors have conducted extensive research for solving the above-described problems, and have found that an increase in the purity of the recovered calcium fluoride and an increase in the fluorine removal ratio can be realized with a relatively small device by the use of calcium carbonate granules having a specific volume mean granule diameter.
The present invention has been accomplished based on such findings, and the gist thereof is described below.
A first aspect provides a method for treating fluorine-containing water including passing fluorine-containing water through calcium carbonate packed towers arranged in series in a plurality of stages to remove fluorine in the fluorine-containing water and recover calcium fluoride, in which the calcium carbonate granules packed in each tower have a volume mean diameter of 30 to 150 μm.
A second aspect provides a method for treating fluorine-containing water in which the calcium carbonate packed towers are arranged in series in two stages in the first aspect.
A third aspect provides a method for treating fluorine-containing water in which the calcium carbonate granules contain granules having a diameter of lower than 20 μm at a ratio of 15% or lower in the first or second aspect.
A fourth aspect provides a method for treating fluorine-containing water in which the fluorine-containing water is passed through the calcium carbonate packed towers at a space velocity (SV) of 0.1 to 5 hr −1 in any one of the first to third aspects.
A fifth aspect provides a device for treating fluorine-containing water, having a unit for treating fluorine-containing water in which calcium carbonate packed towers are provided in series in a plurality of stages, a unit for passing fluorine-containing water through the unit for treating fluorine-containing water, a unit for extracting treated water from the unit for treating fluorine-containing water, and a unit for recovering calcium fluoride from the calcium carbonate packed towers, in which the volume mean diameter of the calcium carbonate packed in the calcium carbonate packed towers is 30 to 150 μm.
A sixth aspect provides a device for treating fluorine-containing water in which the calcium carbonate packed towers of the unit for treating fluorine-containing water are arranged in series in two stages in the fifth aspect.
A seventh aspect provides a device for treating fluorine-containing water in which the calcium carbonate granules contain granules having a diameter of lower than 20 μm at a ratio of 15% or lower in the fifth or sixth aspect.
An eighth aspect provides a device for treating fluorine-containing water in which the fluorine-containing water is passed through the calcium carbonate packed towers at an SV of 0.1 to 5 hr −1 in any one of the fifth to seventh aspects.
Advantageous Effects of Invention
According to the present invention, an increase in the fluorine removal ratio and an increase in the purity of calcium fluoride can be realized with a relatively small device by the use of calcium carbonate granules having a specific volume mean diameter when passing fluorine-containing water through a plurality of calcium carbonate packed towers in series to remove the fluorine in the fluorine-containing water and recover the removed fluorine as calcium fluoride.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a system diagram illustrating an embodiment of a device for treating fluorine-containing water of the invention.
FIG. 2 is a system diagram illustrating a first water passage direction in the device for treating fluorine-containing water of FIG. 1 .
FIG. 3 is a system diagram illustrating a second water passage direction in the device for treating fluorine-containing water of FIG. 1 .
FIG. 4 is a graph illustrating the breakthrough curve of fluorine in a conventional method (Diameter of calcium carbonate granules: 250 μm).
FIG. 5 is a graph illustrating the breakthrough curve of fluorine in a method of the invention (Diameter of calcium carbonate granules: 90 μm).
DESCRIPTION OF EMBODIMENTS
Hereinafter, embodiments of a method and a device for treating fluorine-containing water of the invention are described in detail with reference to the drawings.
FIG. 1 is a system diagram illustrating an embodiment of a device for treating fluorine-containing water of the invention. FIGS. 2 and 3 are system diagrams illustrating water passage directions in the device for treating fluorine-containing water. The devices of FIGS. 1 to 3 include calcium carbonate packed towers 1 and 2 , a raw water tank 3 , a raw water pump 4 , a reaction liquid tank 5 , a reaction liquid transfer pump 6 , a treated water tank 7 , and opening-and-closing valves V 1 to V 8 . In FIGS. 2 and 3 , piping through which water passes is represented by a thick line and opened valves are represented by black and closed valves are represented by white.
The device for treating fluorine-containing water illustrated in FIG. 1 is provided with water passage piping and valves in such a manner as to realize water passage of a merry-go-round system capable of switching a first water passage direction in which raw water (fluorine-containing water) is sequentially passed through the tower 1 and the tower 2 ( FIG. 2 ) and a second water passage direction in which raw water is sequentially passed through the tower 2 and the tower 1 ( FIG. 3 ).
The device for treating fluorine-containing water illustrated in FIG. 1 is one example of the device for treating fluorine-containing water of the invention, and the invention is not limited to the device for treating fluorine-containing water illustrated in FIG. 1 . For example, the device can be configured so that the calcium carbonate packed towers are arranged in series in three or more stages. However, in terms of the object of the invention of realizing an increase in the fluorine removal ratio and an increase in the purity of the recovered calcium fluoride without increasing the size of the device, it is preferable to provide the calcium carbonate packed towers in series in two stages.
In FIG. 1 , although water is passed through the towers 1 and 2 in an upward flow, the flow can be changed to a downward flow. However, in the treatment of fluorine-containing water, carbonic acid gas is emitted as described later due to a reaction of calcium carbonate and hydrogen fluoride. Therefore, in the case of a downward flow, a water break phenomenon arises in the towers due to the gas flow, and the reaction is hindered by deflection of the water current. Therefore, an upward flow is preferable.
The device for treating fluorine-containing water of FIG. 1 includes:
a first pipe connected to the calcium carbonate packed towers configured to pass the fluorine-containing water through the calcium carbonate packed towers, and having one portion connected to one of the calcium carbonate packed towers and having a first valve V 1 , and another portion connected to another of the calcium carbonate packed towers through a second valve V 2 ;
a second pipe connected to the one or another of the calcium carbonate packed towers configured to extract treated water from the calcium carbonate packed towers;
a third pipe having one portion connected to the one of the calcium carbonate packed towers and having a third valve V 3 , and another portion connected to the another of the calcium carbonate packed towers through a fourth valve V 4 ;
a fourth pipe connected to the reaction water tank 5 and including a portion connected to an inlet of the another of the calcium carbonate packed towers and having a fifth valve V 5 , and another portion connected to an inlet of the one of the calcium carbonate packed towers and having a sixth valve V 6 ; and
a fifth pipe connected to the treated water tank 7 through the second pipe, and including a portion connected to an exit of the one of the calcium carbonate packed towers and having a seventh valve V 7 , and another portion connected to an exit of the another of the calcium carbonate packed towers and having an eighth valve V 8 .
The raw water tank 3 is connected to the first pipe to supply the fluorine-containing water in the raw water tank to one or another of the calcium carbonate packed towers; the reaction liquid tank 5 is arranged between the calcium carbonate packed towers; and the treated water tank 7 is connected to the one or another of the calcium carbonate packed towers through the second pipe.
In the device for treating fluorine-containing water of FIG. 1 , first, the valves V 1 , V 3 , V 5 , and V 8 are opened and the valves V 2 , V 4 , V 6 , and V 7 are closed as illustrated in FIG. 2 . Then, raw water in the raw water tank 3 is passed through the tower 1 to supply outflow water of the tower 1 to the reaction liquid tank 5 with the raw water pump 4 , the liquid in the reaction liquid tank 5 is passed through the calcium carbonate packed tower 2 with the pump 6 , and then the outflow water is extracted as treated water through the treated water tank 7 .
Thus, the raw water is passed through the tower 1 and the tower 2 in this order to be treated. When the fluorine removal ratio of the tower 1 becomes almost 0% i.e., when the fluorine concentration of the inflow raw water of the tower 1 and the fluorine concentration of the outflow water thereof becomes almost the same, the passage of the raw water into the tower 1 is stopped. Then, packed granules containing calcium fluoride generated by the reaction of the calcium carbonate and the fluorine in the raw water in the tower 1 are recovered and also fresh calcium carbonate granules are packed in the tower 1 . Thereafter, the water passage direction of the raw water is switched to set the direction to the water passage direction illustrated in FIG. 3 .
Namely, the valves V 2 , V 4 , V 6 , and V 7 are opened and the valves V 1 , V 3 , V 5 , and V 8 are closed firstly. By this, the raw water in the raw water tank 3 is passed through the tower 2 to supply the outflow water of the tower 2 to the tank 5 with the pump 4 . Then, the liquid in the tank 5 is passed through the tower 1 with the pump 6 , and then the outflow water is extracted as treated water through the treated water tank 7 .
Thus, the raw water is passed through the tower 2 and the tower 1 in this order to be treated. When the fluorine removal ratio of the tower 2 becomes almost 0% i.e., when the fluorine concentration of the inflow raw water of the tower 2 and the fluorine concentration of the outflow water thereof becomes almost the same, the passage of the raw water into the tower 2 is stopped. Then, packed granules containing calcium fluoride generated by the reaction of the calcium carbonate and the fluorine in the raw water in the tower 2 are recovered and also fresh calcium carbonate granules are packed in the tower 2 . Thereafter, the water passage direction of the raw water is switched to set the direction to the water passage direction illustrated in FIG. 2 .
Treatment thereafter is performed by switching the water passage direction of FIG. 2 and the water passage direction of FIG. 3 as described above.
In the invention, calcium carbonate granules having a volume mean diameter of 30 to 150 μm are used as the calcium carbonate to be packed in the calcium carbonate packed towers for treating fluorine-containing water.
When the volume mean diameter of the calcium carbonate granules is smaller than 30 μm, fine calcium carbonate granules leak from the calcium carbonate packed tower due to carbonic acid gas generated by the reaction of the calcium carbonate and the hydrogen fluoride in the raw water, resulting that the treatment becomes unstable and that the fluorine removal ratio decreases.
In contrast, when the volume mean diameter of the calcium carbonate granules is larger than 150 μm, the reaction rate of the calcium carbonate and the hydrogen fluoride is low, so that a sufficient fluorine removal ratio cannot be achieved by the two calcium carbonate packed towers as described later. Moreover, the progress of the reaction to the inside of the calcium carbonate granules takes long time, so that the purity of the recovered calcium fluoride becomes low.
By the use of calcium carbonate granules having a volume mean diameter of 30 to 150 μm, preferably 30 to 100 μm, and more preferably 40 to 90 μm, high purity calcium fluoride with a purity of 90% or more and preferably 98% or more can be recovered and also a fluorine removal ratio of 90% or more, preferably 97% or more, and more preferably 99% or more can be achieved by the two calcium carbonate packed towers.
The calcium carbonate granules having the volume mean diameter of the calcium carbonate granules in the above-described specific range have preferably a ratio of fine calcium carbonate granules having a diameter of lower than 20 μm is 15% or lower, preferably 5% or lower, and more preferably 1% or lower.
Even if the calcium carbonate granules have the volume mean diameter in the above-described specific range, when the granules contain a large amount of fine granules with a diameter of lower than 20 μm have a tendency such that fine calcium carbonate granules leak from the calcium carbonate packed towers due to the carbonic acid gas generated by the reaction of the calcium carbonate and the hydrogen fluorine in the raw water, so that the treatment becomes unstable and the fluorine removal ratio also decreases.
In the invention, the mechanism of the action of improving the effects of the increase in the purity of the recovered calcium fluoride and the increase in the fluorine removal ratio by the use of the calcium carbonate granules with an appropriate volume mean diameter is considered as follows.
In the treatment of fluorine-containing water by calcium carbonate, the calcium carbonate is changed to the calcium fluoride by the reaction of hydrogen fluoride to the calcium carbonate represented by the following reaction formula (1).
CaCO 3 +2HF→CaF 2 +H 2 O+CO 2 (1)
This reaction gradually progresses from the surface of calcium carbonate granules. The reaction rate at this time can be represented by a model equation represented by the following equation (2), and the reaction rate becomes high in inverse proportion to the square of the granule radius.
- r A = 3 ϕ D Av R 2 C Al ( 1 - x B ) 1 / 3 1 - ( 1 - x B ) 1 / 3 ( 2 )
r A : Reaction rate, R: Particle radius
In terms of the reaction rate, the calcium carbonate granules are preferable to have a small diameter. By reducing the diameter of the calcium carbonate granules, the rising of the breakthrough curve of fluorine becomes sharp as illustrated in FIG. 5 , so that a high fluorine removal ratio can be achieved even in the case where the calcium carbonate packed towers (reaction towers) are arranged in two stages. When the diameter of the calcium carbonate granules is excessively large, the substitution to calcium fluoride is not sufficiently performed to the inside of the calcium carbonate granules in some cases. Therefore, the diameter of the calcium carbonate granules is preferably relatively small also in terms of the purity of the recovered calcium fluoride. However, when the diameter of the calcium carbonate granules is excessively small, fine granules of the calcium carbonate leak from the calcium carbonate packed towers due to carbonic acid gas generated by the reaction of the calcium carbonate and the hydrogen fluoride, so that the treatment becomes unstable, and the fluorine removal ratio decreases.
In view of the above, calcium carbonate granules with a volume mean diameter of 30 to 150 μm, preferably 30 to 100 μm, and more preferably 40 to 90 μm are used in the invention.
In the invention, when the flow rate of the raw water into the calcium carbonate packed towers is too high, the reaction of the calcium carbonate and the fluorine in the raw water does not sufficiently progress and a problem of leakage of fine granules arises. In contrast, when the flow rate is excessively low, the treatment efficiency decreases. Therefore, the SV of the raw water flowing through the calcium carbonate packed towers is preferably about 0.1 to 5 hr −1 and more preferably about 0.3 to 2 hr −1 .
The raw water flowing through the calcium carbonate packed towers preferably has a pH of about 4 to 6. Therefore, it is preferable that the pH of the raw water is controlled as required, and thereafter the raw water is passed through the calcium carbonate packed towers. Moreover, as described in Patent Document 2, it is more preferable that an α value is calculated from the fluorine concentration and the acid concentration of the raw water, and then acid or alkali is added based on the a value as an index to adjust the raw water.
Since the calcium fluoride recovered from the calcium carbonate packed towers by the invention has high purity, the calcium fluoride can be reused as a raw material for manufacturing hydrofluoric acid. The hydrofluoric acid is manufactured by reacting concentrated sulfuric acid with calcium fluoride according to the reaction of the following reaction formula (3). However, in this case, since the diameter of the calcium carbonate granules for use in the invention is relatively small, the particle diameter of calcium fluoride obtained by the treatment of the raw water is also relatively small, so that the reaction rate with concentrated sulfuric acid also becomes high. Therefore, the calcium fluoride thus obtained is suitable as a raw material for manufacturing hydrofluoric acid.
CaF 2 +H 2 SO 4 →2HF+CaSO 4 (3)
The invention can be effectively applied to treatment of high concentration fluorine-containing water with a fluorine concentration of about 2000 to 100000 mg/L which is discharged from a fluorine etching process or the like, a low concentration fluorine-containing water with a fluorine concentration of about 20 to 1000 mg/L, or a mixed water thereof.
EXAMPLES
Hereinafter, the invention is more specifically described with reference to Examples and Comparative Examples.
The following Examples employed raw water prepared by diluting reagent hydrofluoric acid with pure water to adjust the concentration to 10,000 mg−F/L (pH 3.5).
Example 1
150 ml of calcium carbonate granules with a volume mean diameter of 30 μm were packed in each of two towers (columns) having an inner diameter of 20 mm. Calcium carbonate packed towers thus formed were arranged in series in two stages as illustrated in FIG. 1 . Then, raw water was passed through the calcium carbonate packed tower 1 and the calcium carbonate packed tower 2 in this order to be treated. The supply rate of the raw water pump 4 was 300 mL/hr and the SV of the water flowing into the packed towers 1 and 2 was 2 hr −1 . When the fluorine concentrations of the water flowing into the tower 1 and the water flowing out therefrom became the same, feeding the raw water to the tower 1 was stopped, the granules in the tower 1 were extracted, and then 150 ml of fresh calcium carbonate granules with a volume mean diameter of 40 μm were packed in the tower 1 . After re-packing the calcium carbonate, the raw water was made flow through the tower 2 and the tower 1 in this order to be treated.
The results of measuring the fluorine ion concentration of the treated water and the total fluorine concentration and analyzing components contained in the extracted granules are shown in Table 1.
As shown in Table 1, in this Example, the treatment was stably performed with a fluorine removal ratio of 90% or more. Moreover, the calcium fluoride purity of the recovered substance was 98% or more, so that a high purity calcium fluoride crystal was obtained.
Example 2
Example 2 was conducted in the same manner as in Example 1, except using calcium carbonate granules with a volume mean diameter of 90 μm. The results are shown in Table 1.
As shown in Table 1, in this Example 2, the treatment was stably performed with a fluorine removal ratio of 90% or more. Moreover, the calcium fluoride purity of the recovered substance was 98% or more, so that a high purity calcium fluoride crystal was obtained.
Example 3
Example 3 was conducted in the same manner as in Example 1, except using calcium carbonate granules with a volume mean diameter of 150 μm as the calcium carbonate granules. The results are shown in Table 1.
As shown in Table 1, in this Example 3, the treatment was stably performed with a fluorine removal ratio of 90% or more. Moreover, the calcium fluoride purity of the recovered substance was 98% or more, so that a high purity calcium fluoride crystal was obtained.
Comparative Example 1
Comparative Example 1 was conducted in the same manner as in Example 1, except using calcium carbonate granules with a volume mean diameter of 20 μm as the calcium carbonate granules. The results are shown in Table 1.
In this Comparative Example 1, fine calcium carbonate granules leaked from the calcium carbonate packed towers due to carbonic acid gas generated by the reaction of the calcium carbonate and the hydrogen fluoride. Therefore, the fluorine removal ratio was lower than 90%, and the treatment became unstable. When the fine granules which leaked were analyzed, it was found that fine granules with a diameter of lower than 20 μm leaked.
Comparative Example 2
Comparative Example 2 was conducted in the same manner as in Example 1, except using calcium carbonate granules with a volume mean diameter of 250 μm as the calcium carbonate granules. The results are shown in Table 1.
In this Comparative Example 2, since the diameter of the calcium carbonate granules was large, the reaction rate of the calcium carbonate and the hydrogen fluoride was low. Therefore, the treatment was not sufficiently performed by the two calcium carbonate packed towers, so that the fluorine removal ratio was lower than 90%. Moreover, since the progress of the reaction to the inside of the calcium carbonate granules took long time, the calcium fluoride purity of the obtained recovered substance was low as compared with that of the Examples.
TABLE 1
Volume mean
CaF 2
diameter
Raw water
Treated water
purity of
of calcium
T-F
T-F
F −
F removal
recovered
carbonate
concentration
concentration
concentration
ratio
substance
(μm)
mg/L
mg/L
mg/L
%
%
Example 1
30
10000
200~400
5~20
96~98
>98
Example 2
90
10000
10~30
10~30
>99
>98
Example 3
150
10000
100~300
100~300
97~99
>98
Comparative
20
10000
2300~4200
10~20
58~77
>98
Example 1
Comparative
250
10000
1000~1500
1000~1500
85~90
95~98
Example 2
Examples 4 to 7
Examples 4-7 were conducted in the same manner as in Example 2, except using calcium carbonate granules with a volume mean diameter of 90 μm and having various granulesize distributions as the calcium carbonate granules. The results are shown in Table 2.
Table 2 shows the following facts.
When fine granules are hardly contained (Example 4), the treatment was stably performed with a fluorine removal ratio of 90% or more. Moreover, the calcium fluoride purity of the recovered substance was 98% or more, so that a high purity calcium fluoride crystal was obtained.
However, when fine granules were contained, fine granules with a diameter of lower than 20 μm leaked from the calcium carbonate packed towers due to carbonic acid gas generated by the reaction of the calcium carbonate and the hydrogen fluoride. Therefore, when the amount of fine granules with a diameter of lower than 20 μm is small (Example 5), no problems arise. However, when such fine granules were contained at a ratio of 15% or more (Examples 6 and 7), the fluorine removal ratio was lower than 90% in some cases, the treatment became unstable.
TABLE 2
Content of granules
with a volume mean
diameter of lower
CaF 2
than 20 μm of
Raw water
Treated water
purity of
calcium carbonate
T-F
T-F
F −
F removal
recovered
granules
concentration
concentration
concentration
ratio
substance
%
mg/L
mg/L
mg/L
%
%
Example 4
<1
10000
10~30
10~30
>99
>98
Example 5
5
10000
30~300
10~30
97~99
>98
Example 6
16
10000
200~1100
10~30
89~98
>98
Example 7
25
10000
600~1500
10~30
85~94
>98
The invention is described in detail with reference to specific aspects. However, it is clear for a person skilled in the art to alter the aspects in various manners without deviating from the scope of the intention.
|
A device for treating fluorine-containing water includes a fluorine treating unit treating the fluorine-containing water in which calcium carbonate packed towers are arranged in series in a plurality of stages; a fluorine passing unit passing the fluorine-containing water through the fluorine treating unit; an extracting unit extracting treated water from the fluorine treating unit; and a recovery unit recovering calcium fluoride from the calcium carbonate packed towers.
| 2
|
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a device and the corresponding process for quantitative assessment of the orientation of two machines or machine parts relative to one another which are connected by a cardan shaft with two universal joints.
A device of this type is known and is shown in FIG. 1 . Such a device requires a precise and relatively costly rotary joint 22 in order to keep a means 24 for sending and receiving a measurement light beam 28 from a source at distance from the machine shaft 10 which is to be measured. For this purpose, for example, an extender rail 20 and clamp devices 16 are used in addition.
SUMMARY OF THE INVENTION
A primary object of this invention is to devise a device that is comparable comparable to the known device but which is clearly more economical and does not adversely affect the ease of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a known device.
FIG. 2 is a perspective view showing alignment being performed with a device in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention is based on the finding that it is often necessary, in practice, to determine the parallel axial offset of machines which are structurally connected by a cardan shaft with two universal joints. Generally, a cardan shaft is used when there is, in principle, a parallel axial offset and knowing the absolute magnitude of the offset is not critical. However, for reasons of rotational kinematics, it is especially important that the axes of the shafts of the machines which have been coupled to one another in this way are, for the most part, parallel in order to avoid even the smallest variations of angular accelerations on the rotating machine elements. Accordingly, in accordance with the invention, it is not necessary to provide a measurement system which, at the same time, can detect the parallel and angular offset of shafts. Rather, it is sufficient to provide a measurement system which can detect simply the angular offset of these shafts in a precise manner. With consideration of certain geometrical boundary conditions and relationships, it is thus possible to devise a measurement device and a process in which a conventional measurement rotary joint can be completely eliminated. Conclusions regarding the angular misalignment of these shafts and the corresponding machines can be drawn from the detectable amounts of offset which are detected in different rotary positions of the shafts which are to be measured by means of conventional sensors using simple formulas.
Details of the invention are shown in FIG. 2 . There, a cardan shaft 62 and universal joints 60 , 64 are assumed to have been already removed for the measurement and therefore are schematically shown only by a broken line. As is apparent from the figure, the machines 30 , 31 may stand on bases 32 , 33 of different heights and thus have a parallel offset of their shafts. The extender 40 can be attached conventionally or by means of screws to the coupling support 36 and can carry an extra extender 42 ; but this is optional. In any case, either a light transmitter and/or receiver is mounted either directly on the extender directly or indirectly by means of the extra extender 42 . In this example, a receiving module 44 as is known in the prior art.
In the illustrated measurement position, which is also called the “3 o'clock position,” the receiving module can determine the incidence site of the incident light beam 53 which is emitted by a light transmitter 52 . The light transmitter 52 is mounted on a second extender or a holding device 50 which is likewise mounted on the corresponding coupling support of the machine 31 . The measurement is taken such that the receiving module is operated in the conventional manner in one mode and that it allows determination of the incidence direction of an incident light beam by means of two photosensitive plates.
In accordance with the invention, it is simplest to turn the extender by 180° to determine the measurement quantities of interest (therefore, to set, for example. the “9 o'clock position”), to move the corresponding module 44 such that it can also be hit by the light beam 53 in this position, and to take an additional measurement using the light transmitter and the receiving module in this position. (If the functions of the light transmitter and of the receiving module are combined in a single housing, it is also possible, in accordance with the invention, to provide this combination in interplay with a plane mirror, especially a large-area planar mirror). In this position, the two photosensitive plates of the receiving module thus see one direction of incidence of the light beam which, when the machines 30 , 31 are not aligned parallel, is distinguished from the direction of incidence in the “3 o'clock” position according to two detectable angle coordinates. Therefore, only the respective directions of incidence are measured and the position of the incident light beam is of subordinate importance in accordance with the invention. For this reason, it is therefore also possible and uncritical to move the light receiving or transmitting module ( 44 , optionally 52 , or both at the same time) relative to one another on the extender or extenders, and then, to fix it briefly thereon for an individual measurement.
In principle, the invention makes do without the extra extender 42 if measurement positions can be set which lie rotated roughly 180° apart. If this is not the case, the extra extender 42 should be used, and instead of simply structured determination equations for determining the relative position of the machines, then ones should be used which take into account the corresponding projections (therefore the sine and cosine portions) of the angle of rotation of the extenders which differs from 180°.
It is advantageous to take three or more measurements in additional measurement positions, i.e., rotational positions of the extenders and to combine them using statistical considerations or compensation computations into a more accurate measurement result than is possible with only two measurements.
In another advantageous embodiment of the invention, it is provided that the extenders 40 and/or 50 be equipped with compensation weights (not shown) such that the torques applied to the shafts or mountings can be kept as small as possible. In this way, detection of the measurement values is facilitated, especially for smoothly running shafts.
|
A device for quantitative assessment of the orientation of two machines relative to one another has auxiliary devices in the form of extenders or holding devices ( 40, 50 ) on which displacement and/or mounting of light transmitting or receiving devices ( 44, 52 ) are mountable in a manner that makes the use of a precision pivot bearing unnecessary.
| 6
|
This is a continuation of application Ser. No. 596,249, filed July 16, 1975, abandoned.
BACKGROUND
In the processing industries it is often necessary to mix or blend two or more fluid materials to prepare a final product. One means of providing adequate mixing of such fluids is to channel the fluids through a tubular member having a baffle assembly mounted therein, such as that disclosed in U.S. Pat. No. 3,652,061. Such an assembly may include a plurality of hemi-elliptical blades which blades are mounted in orthogonal pairs, to form baffles which deflect and mix two or more fluid streams passing through the conduit. A number of these pairs of blades are mounted at longitudinally spaced positions within the conduit with each pair of blades being rotated 90° with respect to the adjacent pairs.
As disclosed in the above U.S. Patent, individual blades of the baffle assembly may be soldered, welded or otherwise fixedly attached to the interior surface of the surrounding tube. Such a mounting arrangement has the disadvantage that the baffle blades are difficult to clean since the surrounding tubular member prevents access to them. Thorough cleaning of these blades is necessary, however, to prevent contamination of later substances which may be mixed in the mixer.
To facilitate cleaning the individual baffle blades may be mounted on a common elongated support member so that they extend radially outwardly from the member to points closely adjacent to the surrounding inner surface of the conduit. The support member and the attached baffles may then be removed from the surrounding conduit for cleaning.
Since the baffle blades are not connected to the inner surface of the tubular member the support member and blades will be free to slide longitudinally within the conduit and will also be free to rotate within the conduit due to the force of the fluid flowing past the blade surfaces. Motion of the assembly within the conduit is undesirable since it causes wear on the blades and distorts the desired mixing action. In order to prevent motion of the assembly within the conduit while providing a baffle assembly which is removable, the present invention discloses an improved mounting means which serves to hold the baffle assembly in a stable orientation within the surrounding conduit.
SUMMARY OF THE INVENTION
A motionless mixer includes a conduit defining a channel, an elongated member disposed longitudinally within the channel having a transverse end surface with a slot-like aperture formed therein and a plurality of baffle means attached to the elongated member at spaced longitudinal points. A cross member of a first cross sectional area has ends which are attached respectively to opposed sides of the channel. The cross member includes a longitudinal portion of decreased cross sectional area which is adopted to mate with the slot-like aperture in the end surface of the elongated member.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut away top view of a motionless mixer showing the improved mounting means of the present invention.
FIG. 2 is a sectional view taken along plane 2--2 of FIG. 1.
FIG. 3 is a partially cut away top view of a motionless mixer showing a second embodiment of the improved mounting means.
FIG. 4 is a sectional view taken along plane 4--4 of FIG. 3.
DESCRIPTION OF THE INVENTION
A motionless mixer 2 as shown in FIG. 1 includes a hollow conduit 4 defining a channel 5 and a baffle assembly 6 which is mounted longitudinally within the channel 5. The baffle assembly 6 includes an elongated support member 8, which may be a cylindrical rod, arranged substantially along the longitudinal axis of the conduit 4. A slot 7 is formed in a first lateral end surface 9 of the member 8.
A plurality of baffles 10, 12, 14 and 16 are attached at equally spaced longitudinal points along the member 8. Each of these baffles includes a first and a second mutually orthogonal hemi-elliptical blades. Baffle 10, for example, includes hemi-elliptical blades 20 and 22, while baffle 12 includes the hemi-elliptical blades 30 and 32. The two blades of each baffle are attached to opposed sides of member 8 and are arranged so that they are mutually orthagonal as seen for instance in blades 20 and 22 of baffle 10. Elliptical apertures such as 34 in blade 30 and 36 in blade 32 may be provided in inner side of each of the baffle blades. The blades can then be attached to member 8 along the surfaces defined by these apertures. Each baffle, such as 12, is rotated 90° with respect to adjacent baffles such as 10 and 14. In order to provide adequate mixing or blending of fluids introduced into the tubular member 4 each of the hemielliptical blades, such as 20, 22, 30 and 32 of the baffles 10 and 12 of baffle assembly 6 extend outwardly from the member 8 so that their outer edges are located immediately adjacent to the inner surface of the conduit 4.
In order to hold the baffle assembly 6 in a stable orientation within the conduit 4 a cross member 36 is attached across the channel 5. This cross member 36, as best seen in FIG. 2, is fixedly attached at its ends 35 and 37 to opposed sides of the inner surface of the conduit 4. The cross member may be attached by welding, soldering or other suitable process. The cross member 36 includes a portion 38 of decreased cross sectional area which is arranged about the center of member 36 and is best seen in FIG. 2.
When the baffle assembly 6 is inserted into the conduit 4, slot 7 in the end 9 of member 8 mates with the portion 38 of cross member 36. Pressure from the fluid which flows in channel 5 in the direction indicated by arrows 11 of FIG. 1 pushes the baffle assembly 6 downstream holding the slot 7 of member 8 in firm contact with portion 38 of cross member 36 thereby maintaining the baffle assembly 6 in a substantially uniform longitudinal position within the channel 5. By the mating slot 7 with the portion 38 of cross member 36, the baffle assembly 6 is also prevented from rotation about its longitudinal axis within the channel 5. The presence of cross member 36 thereby provides both rotational and longitudinal stability for the baffle assembly 6 within the channel 5.
By utilizing a cross member 36 having a portion 38 of decreased cross sectional area, a cross member 36 may be provided having maximum width and therefore strength at its end points 35 and 37 which are connected to the inner wall of conduit 4 while having a narrower central portion to mate with the slot 7 in member 8. Since a member 8 having too great a cross sectional area would hinder fluid flow, a member of limited cross sectional area is desirable. The cross sectional area of member 8 limits the practical size of slot 7 which must be narrower than the total distance across the member. Providing a cross member 36 having an area of decreased cross sectional area 38 permits the utilization of a narrower slot 7 and thereby provides more strength for the end 9 of member 8.
Alternatively the downstream end 9 of the supporting member 8 may include an enlarged flared portion 40 as shown in FIGS. 3 and 4. Since the portion 40 is enlarged a slot 42 can be formed in the end 9 which is slightly wider then the full distance across cross member 36. In this embodiment the whole cross sectional area of cross member 36 is available to support the baffle assembly 6. Because of the enlarged portion 40 the end 9 of member 8 is not unduly weaken by the presence of the relatively wide slot 42. Since the enlarged portion 40 is only provided adjacent to the end 9 it provides minimum resistance to fluid flowing the conduit 4. As in the embodiment described above with reference to FIGS. 1 and 2 the slot 42 provides rotational and longitudinal stability for baffle assembly 6.
|
A motionless mixer including a number of baffles attached to a central rod is slidably mountable within a hollow cylindrical conduit. A cross member is attached across the interior of the conduit and is configured to mate with a slot formed in the downstream end of the central rod, to prevent longitudinal motion or rotation of the mixer within the conduit.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an anchor for tying a masonry veneer wall to the framing of an architectural structure.
2. Description of the Prior Art
With modern construction techniques, it is a common practice to enclose the framing of a building with a masonry veneer wall.
Many architects and engineers firmly believe that masonry veneer wall cracking would be reduced to a minimum if walls were permitted more freedom of movement. Accordingly, systems have been heretofore designed to provide lateral restraint of a masonry veneer wall while permitting horizontal and vertical movement.
In one form of such system, heretofore manufactured and sold by the applicant's assignee, AA Wire Products Company of Chicago, Ill., a flexible tie for tying masonry veneer walls to concrete or to steel is provided which is sold under the trademark "DOVETAIL FLEX-O-LOK" (to concrete) and "FLEX-O-LOK" (to steel). Examples of such ties include a masonry veneer wall laterally tied to concrete or steel columns, or masonry veneer walls laterally tied to concrete or steel beams, or precast concrete panels or stone laterally tied to poured concrete or steel back-up. In such an arrangement, a wire form or flat steel form of anchor is fastened either to an intervening flat plate or directly to an architectural structure as a matter of customer choice, whereupon a tying member adjustably moves relative to the anchor and is inserted between courses of the adjoining masonry veneer wall, thereby to permit the desired flexibility.
Another such system manufactured and sold by AA Wire Products Company is disclosed in applicant's U.S. Pat. No. 4,373,314, issued Feb. 15, 1983. This patent discloses an anchor formed of an integral metal form which is preformed as an L-shaped bar such as an angle iron. An outstanding leg of the anchor is vertically disposed and has one or more slotted holes formed therein in a selected spaced relation depending on the end use. The leg overlying the building frame member is provided with holes through which fasteners, such as screws or nails, are inserted for securing the anchor to either metal or wood studs.
The depth of the outstanding leg and the spacing of the slotted openings is selectively varied to allow a desired thickness of insulating material to be placed in the gap between the building frame member and the masonry veneer wall. The relative thinness of the outstanding anchor leg allows adjacent pieces of insulating material to be placed within close proximity of one another, thus minimizing energy-losing holes in the insulation.
A wire tie is inserted through one of the slotted holes in the anchor and is vertically adjustable within the vertically disposed slots. A portion of the tie is embedded in a horizontal masonry joint of the masonry veneer wall. The wire may bear against the perimeter of the slotted hole.
The prior art is also exemplified by U.S. Pat. No. 4,021,990 issued May 10, 1977 wherein a masonry veneer wall anchor comprises a plate member having a vertically projecting bar portion secured thereto and disposed in substantially parallel relationship with the plate member. The anchor is employed to secure a wallboard to a vertical channel or standard framing member. Thereafter, a mason inserts a wall tie between the plate member and projecting bar portion and the wall tie is built into the outer wythe of the wall system. Since the wall tie is capable of vertical movement, vertical adjustability is effected.
To ensure structural stability and to resist lateral pressure, such as that resulting from wind forces, it is necessary to tie the masonry veneer wall to the framing. Furthermore, it is often desirable to maintain a gap between the framing and masonry veneer wall for ventilation and drainage purposes or to accommodate a layer of insulating material.
SUMMARY OF THE INVENTION
According to the present invention, an anchor is formed of an integral metal form which is preformed as an L-shaped bar such as an angle iron so that an outstanding leg of the anchor may be disposed in the horizontal position. A slotted hole formed in the outstanding leg is also disposed to extend horizontally. The other leg of the anchor overlying the building frame member is provided with holes through which fasteners, such as screws or nails, are inserted for securing the anchor to either metal or wood studs.
The depth of the outstanding leg and the spacing of the slotted opening is selectively varied to allow a desired thickness of drywall or insulating material to be placed in the gap between the building frame member and the veneer wall. The relative thinness of the outstanding anchor leg allows adjacent pieces of plasterboard (drywall) or insulating material to be placed within close proximity of one another, thus minimizing energy-losing holes in the insulation.
Further, the leg of the anchor overlying the building frame member is made with a large surface area to prevent damage to the drywall or insulating material when it is mounted such that the drywall or insulating material is interposed between the anchor and building frame member. Therefore, the anchor can be anchored to the building frame member through the drywall or insulating material without damaging it. That is to say, the anchor is fastened to the building frame member but a sheet of drywall or insulating material is placed between the anchor and the building frame member.
In accordance with this invention, a closed rectangular loop having a length dimension just slightly less than that of the slot is bent medially at right angles to form an L-shaped wire tie. Such tie is inserted into the slotted hole in the anchor and is adjustable to be embedded in a horizontal masonry joint, but substantially only in the vertical direction. The opposite parallel legs of the tie bear against the respective ends of the slotted hole. By virtue of such provision the present invention provides improved resistance to compressive as well as axial forces, thereby maximizing its functional effectiveness.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a masonry veneer wall construction incorporating a wall with insulation and embodying the principles of the invnetion;
FIG. 2 is a top plan view of the masonry veneer wall construction of FIG. 1;
FIG. 3 is a vertical sectional view taken along the line III--III of FIG. 2;
FIG. 4 is a fragmentary perspective view of a masonry veneer wall construction incorporating a wall with drywall backing and embodying the principles of the invention; and
FIG. 5 is a vertical sectional view taken along the line V--V of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1-3, there is shown an insulated wall construction W which comprises a masonry veneer wall M, building frame member F, and an insulation layer or plasterboard sheet I. Plasterboard is also commonly referred to as drywall and the terms are used interchangeably herein. A wall anchoring means A embodying principles of the present invention is included for tying or fixing the masonry veneer wall M to the building frame member F.
According to the invention, the anchoring means A comprises a metallic member shaped as a prefabricated L-shaped metal form with an anchoring leg 10 and an outstanding leg 12 which are perpendicularly offset with respect to one another. Thus, the anchoring means A is comparable to an angle iron.
The anchoring leg 10 includes a horizontally disposed top edge 14 and angled edges 16 and 18. The anchoring leg 10 is intended to be fastened to a corresponding building frame member, whether that building frame member be made of wood, such as the building frame member F, or of steel or concrete. In order to affix the anchoring leg 10 to an adjoining surface of the corresponding building frame member there is provided a pair of vertically aligned, spaced apart through holes 20 centrally located on the anchoring leg 10. A pair of horizontally aligned, spaced apart through holes 22 are provided for affixing the anchoring means A to the corresponding building frame member in a rotated position to provided anchoring means similar to that disclosed in applicant's prior U.S. Pat. No. 4,373,314.
The outstanding leg 12 includes a longitudinal edge 24 and opposite end edges 26 and 28. An elongated slot or opening 30 is provided in the outstanding leg 12 to accommodate a tie, such as the triangular tie of my prior patent, in accordance with this invention. The slot or opening 30 is located inwardly of the longitudinal edge 24 and is bounded longitudinally by ends 34 and 36 and laterally by sides 38 and 40. The ends 34 and 36 are located inwardly of the edges 26 and 28.
According to the present invention, the width of the outstanding leg 12 may be varied so that the anchoring means A can be provided in different sizes for different applications. Thus, the length of the outstanding leg 12 between corner joint 42 and the side 38 of the elongated slot or opening 30 may be varied to accommodate varying thicknesses of the insulation layer or plasterboard sheet I. As an example of how the width of the outstanding leg 12 may be selected to accommodate various thicknesses of the insulation layer or plasterboard I, it is noted that to accommodate a one inch (25.4 mm) thick insulation layer or plasterboard sheet, the dimension between the corner joint 42 and the side 38 of the elongated slot or opening 30 may be set at 11/8 inch (28.6 mm). To accommodate a two inch (50.8 mm) thick insulation layer or plasterboard sheet, the dimension may be set at 21/8 inch (54.0 mm).
Regarding the insulation layers or plasterboard sheets I interposed between the masonry veneer wall M and the building frame member F, the insulation layers or plasterboard sheets may be brought together, one on top of another, so that they are separated only by the thickness of the outstanding leg 12 of the anchor A. If the edges of the insulation layer or plasterboard sheets are notched to fit around the outstanding leg 12, the insulation layers or plasterboard sheets I may be abutted. Moreover, slots may be cut into the insulation layers or plasterboard sheets I through which the outstanding leg is inserted. With any of these approaches, minimal energy losing air gaps in the insulation may be achieved.
In order to effect flexible anchoring and wall clamping of the masonry veneer wall M to the building frame member F, the tie 32 of the present invention is provided. The tie 32 comprises a square or rectangular-shaped closed loop of galvanized wire having longitudinal legs 45 and 46 and transverse legs 47 and 48. The transverse legs are medially bent at right angles so that the tie assumes an L-shaped profile shown in FIGS. 4 and 5. The tie may be made of wire of various sizes, for example 3/16 inch mill galvanized wire gauge or 6 to 9 gauge wire.
The tie 32 has horizontally disposed legs 45 and 46 which are of a length slightly less than the length of the slot 30. Thus, the transverse legs 47 and 48 will engage and abut the corresponding ends 36 and 34 of the slot 30. The upstanding section of the transverse legs 47 and 48 are inserted through the slot or opening 30 to fasten the masonry veneer wall M to the anchoring means A, thus fastening the masonry veneer wall M to the building frame member F. Additionally, the upstanding section of the legs 47 and 48 serve to confine the insulation layer or plasterboard sheet I and maintain an air gap G between the masonry veneer wall M and the insulation layer or plasterboard sheet I more or less equal to the dimension between the side 40 of the outstanding leg 12 and the longitudinal edge 24.
Shown in FIGS. 4 and 5 is another wall construction W' in which a plasterboard I' is interposed between the anchoring means A and a building frame member F'. In this construction, the anchoring means A is fastened to the building frame member F' through the plasterboard I'.
It is most clearly shown in FIG. 5 that, because the anchor means A is located on the masonry veneer wall side of the plasterboard I', the dimension between the corner joint 42 and the side 38 of the slot or opening 30 is made very short as no insulation layer or plasterboard need be accommodated. Similarly, should no plasterboard I' be used at all, the shortened anchoring means A may be used to fasten the masonry veneer M directly to the building frame F'.
It is noted that the surface area of the anchoring leg 10 of the anchoring means A is large enough to prevent damage to the plasterboard I' when the wall construction W' shown in FIGS. 4 and 5 is employed. Thus, the plasterboard I' may be interposed between the building frame member F' and the anchoring means A without concern as to whether the anchoring means A will dig into the plasterboard I' and thus, mar its surface.
Although modifications might be suggested by those skilled in the art, it will be understood that I wish to embody within the scope of the patent described herein all such modifications as reasonably and properly come within the scope of my contribution to the art.
|
A masonry veneer wall anchor formed on an integral metal form preformed an an L-shaped bar has one leg overlying a building frame member for attachment thereto and has a horizontally disposed outstanding leg with an elongated slotted hole through which a tying member formed as a closed rectangular-sized loop with longitudinal and transverse legs offset at a 90° angle so that one section of the transverse legs may be inserted for vertical adjustment, the tying member engaging the edges of the slot at the transverse legs to provide improved resistance to compressive as well as pulling forces, thereby maximizing functional effectiveness.
| 4
|
BACKGROUND OF THE INVENTION
The present invention relates to a method for the fabrication of a slide fastener chain with reinforcement tapes at the ends thereof and an apparatus therefor. In particular, the present invention relates to a method and an apparatus, in the manufacturing process of a slide fastener with a separable end stop, for cutting a slide fastener chain of continuous length with reinforcement tapes at individual space sections into individual slide fastener chains of definite product length having reinforcement tapes at the ends thereof bonded thereto together with removal of extraneous portions of the reinforcement tape.
Many slide fasteners with a separable end stop are provided with reinforcement tapes at both ends thereof. Such reinforcement tapes are made of a thermoplastic film or sheet and adhesively bonded to the space sections of a continuous length slide fastener chain where the carrier tapes have no interlocking elements fastened thereto and the slide fastener of continuous length is subsequently cut at the space sections together with the reinforcement tape into the product length whereby slide fasteners with reinforcement tapes at both ends thereof are obtained. In addition to cutting off of the carrier tapes per se, the extraneous portions of the reinforcement tape out of the edges of the carrier tapes must be removed by cutting.
In the prior art, no convenient and exact method or apparatus is known for the fabrication of the above described slide fasteners with reinforcement tapes at the ends thereof. For example, an apparatus is described in Japanese Patent Publication No. 39-17044 according to which the adhesive bonding of the reinforcement tapes to the fastener chain is simultaneously performed with cutting off of the extraneous portions of the reinforcement tapes but the cutting of the fastener chain into individual product length must be carried out separately following the above mentioned bonding of the reinforcement tapes and cutting off of the extraneous portions of the reinforcement tapes resulting in two-step cutting with decreased productivity and also with inexactness of cutting since the fastener chain is not under tension at the moment of cutting.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to provide a convenient method for the fabrication of a slide fastener chain with reinforcement tapes at the ends thereof and an apparatus therefor.
The method of the present invention comprises:
(a) a step of placing a fastener chain with a reinforcement tape adhesively bonded to the space section thereof on a die,
(b) a step of process-holding the fastener chain at a side of the cutting line thereof on to the die,
(c) a step of positioning the press-held fastener chain by sliding while thus being pressed down,
(d) a step of press-holding the fastener chain at the other side of the cutting line thereof on to the die, and
(e) a step of cutting the fastener chain on the die along the cutting line together with extraneous portions of the reinforcement tape bonded thereto.
The apparatus of the present invention designed for practicing the above method for the fabrication of a slide fastener chain with reinforcement tapes at the ends thereof is essentially composed of:
(1) a die,
(2) two guide plates for the fastener chain each with a protruded guide rail on the upper surface thereof positioned in the front and at the rear of the die running in the direction of the center line of the die,
(3) a vertically movable cutter blade positioned above the die,
(4) a first presser positioned at the rear of the cutter blade and engaged by an engagement means with downward enforcement with a first spring, and
(5) a second presser with free vertical movement positioned in the front of the cutter blade with downward enforcement with a second spring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a slide fastener with a separable end stop and a slider finished in accordance with the method of the invention to provide the reinforcement tapes at both ends thereof.
FIG. 2 is a plan view of a continuous length fastener chain with reinforcement tapes attached to the space sections before fabrication according to the invention;
FIG. 3 is a perspective view for illustrating a typical process of preparing the continuous length fastener chain of FIG. 2.
FIG. 4 is an elevational side view of apparatus embodying the invention.
FIG. 5 is an elevational front view of the apparatus of FIG. 4 as partially cut in the main part thereof;
FIG. 6 is a cross sectional view of the apparatus of FIG. 5 along the line VI--VI.
FIG. 7 is a cross sectional view of the apparatus of FIG. 5 along the line VII--VII;
FIG. 8 is a perspective view of the cutter blade of the apparatus of FIG. 5.
FIG. 9 to FIG. 15 are for illustrating the steps of fabrication in accordance with the inventive method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method and apparatus of the present invention are now illustrated in detail by way of example with reference to the drawings annexed.
The objective product of the present invention is a slide fastener 1 as illustrated in FIG. 1 in which reinforcement tapes 3,3' are adhesively bonded to the ends of both carrier tapes of a product length as interengaged with each other at the rows of the interlocking elements 2 with a slider mounted thereon and provided with a separable end stop T enabling the slide fastener to be severed into two separate stringers at the end.
The reinforcement tapes 3 made of a thermoplastic resin film or sheet are provided at the lower ear ends of the carrier tapes following the rows of the elements 2 by adhesively bonding in order to impart rigidity to the slide fastener. Such a slide fastener with reinforcement tapes is manufactured by first adhesively bonding pieces of a plastic film 3 on to the individual space sections of a pair of continuous length fastener stringers F to form a continuous length fastener chain A as shown in FIG. 2 with reinforcement tapes 3 at intervals and then cutting it along the main cutting line L 1 into individual product length with simultaneous cutting off of the extraneous portions of the reinforcement tapes 3a, 3b along the auxiliary cutting lines L 2 to L 5 followed by assembling of the thus obtained fastener chains of product length by mounting a slider, an upper end stop and a separable end stop at the lower end. Thus cutting work should be performed not only along the main cutting line L 1 but also along the auxiliary cutting lines L 2 to L 5 as is shown in FIG. 2 to cut off the extraneous portions of the reinforcement tape 3 at both sides 3a, 3a and at the center 3b simultaneously.
An exemplary process for preparing the continuous length fastener chain A with reinforcement tapes 3 shown in FIG. 2 is illustrated in FIG. 3, in which a pair of continuous length fastener chains F, F provided with space sections 4 in advance are transferred on the die 6 in the direction shown by the arrow 7 and become settled at an exact position to place a space section 4 on the die 6. In parallel with the above movement of the fastener chains F, a continuous length plastic tape S, in which notched sections 9 are formed at one side thereof by cutting with a punch 8, is fed on to the fastener chains F intersecting at a right angle so as that the notched section 9 is just on the spaced section 4 of the fastener chains F on the die, where a hot punch 10 is lowered to adhesively bond with heat the tape S to the space section 4 of the fastener chains F to be a reinforcement tape 3 followed by cutting of the tape S along the cutting line 12 with a cutter blade 11 to give a continuous length fastener chain A with reinforcement tapes 3 at intervals on the spaced sections 4 by repeating the above procedure.
In FIGS. 4 and 5 illustrating the apparatus embodying the present invention, 13 is a die unit and 14 is a punching unit and the die unit 13 is provided with a base 15, a die plate 16 on the base 15 and a die 17 protruding above the die plate 16 as partly embedded in the die plate 16. To the die plate 16 are integrally fixed two chain-guide plates 18, 19 at the forward position, i.e. to the right in FIG. 5, and at the rearward position, i.e. to the left in FIG. 5, respectively, having the top surfaces at the same coplanar level with the upper surface of the die 17 forming a plane. These chain-guide plates 18, 19 respectively have a linear protrusion or guide 20, 21, both of which lie on the extension of the center line of the die 17 to form a straight line altogether. The die 17 is provided on the upper surface with a groove-like receptacle 22 which fits an undermentioned cutter blade 29 in shape.
The above-mentioned punch unit 14 is provided with a cylinder 24 fixed to the above-mentioned base 15 through a frame 23 and a punch plate 25 securedly fixed to the piston rod 24a of the cylinder 24. On the lower surface of the punch plate 25 are provided a pair of guide bushes 26, 26 which perform sliding movement relative to respective guide pins 27, 27 erected on the base 15 and inserted into the respective guide bushes 26, 26. On the lower surface of the punch plate 25 is fixedly provided a punch holder 28 which in turn serves to clamp the cutter blade 29, having a cross section, as shown in FIGS. 7 and 8, to match the cutting lines L 1 to L 5 in FIG. 2, being provided correspondingly with cutter sections 29a, 29b, 29c for cutting the reinforcement tape and cutter sections 29d, 29e for cutting the carrier tapes in an E-shaped integral arrangement.
At the rearward position and at the front position to the above-mentioned cutter blade 29 are provided a pair of rear pressers 30, 30 and a pair of front pressers 31, 31, respectively, in a symmetrical disposition relative to the center line of the die 17 positioned at the right and left sides of the linear protrusions 21 and 20, respectively. The front pressers 31, 31 are each composed of a pad holder 34 inserted with free vertical movement into a guide hole 32 in the punch holder 28 and having a hook protrusion 33 coming into engagement with the punch holder 28 at the top thereof, a rectangular pad 35 connected to the lowermost end of the pad holder 34 and a compressive spring 36 to exert a downward pressure on the pad holder 34. Each of the pads 35 has a goove-like cutting 37 on the lower surface thereof along the center line of the die 17, as is shown in FIGS. 4 and 7, where the row of the elements comes to fit the pad 35 when the pad 35 is lowered to press-hold the fastener chain at the position.
The lower surface of the pad 35 is at the height level slightly lower than the edge 29' of the cutter blade 29 by a height difference H shown in FIG. 5 when the pad is in the pulled-up position not in contact with the fastener chain to be press-held therewith.
Similarly the rear pressers 30, 30 are each composed of a pad holder 38 inserted with free vertical movement into a guide hole 38' in the punch holder 28, a pad 39 connected to the lowermost end of the pad holder 38 and a compressive spring 40 to exert a downward pressure on the pad holder 38. Each of the pads 39 is provided with a notch 41 at the front portion thereof through which the one of the cutter sections 29a, 29b can move up and down and also provided with an element-guide groove 43 with a stopper face 42 on the lower surface along the center line of the die 17.
The rear pressers 30 each have a step 44 on the rear surface of the pad holder 38 where the presser 30 is engaged with a stopper 45 to be held above the fastener chain while the stopper 45 is inserted into a holder 46 with free horizontal sliding. The stopper 45 is operated by a solenoid 47 through a linking mechanism which is composed of a plunger 47a of the solenoid, a link 48 connected to the plunger 47a, a first lever 50, pivoted on a pin 49 as a fulcrum, connected to the link 48 at one end, a stopper screw 51 at the other end of the first lever 50, a second lever 52 in contact with the stopper screw 51 at the rear end thereof and fixed to a rotatable shaft 54 at the other end thereof supported by a bearing 53 fixed to the upper surface of the punch plate 25, a third lever 55 fixed to the shaft 54 at the upper end thereof and extending downwardly through a hole 56 in the punch plate 25 and a pin 57 at the lowermost end of the third lever 55 and engaged with an engagement groove 45' at the rear end of the above-mentioned stopper 45 while the second lever 54 is upwardly biased to rotate counterclockwise in FIG. 5 on the shaft 54 by a compressive spring 58 acting between the second lever 52, at around the middle part thereof, and the punch plate 25. The first lever 50 is connected to a tension spring 64 which exerts a pulling force on the first lever 50 to rotate it clockwise in FIG. 4 to return to its original position in readiness for the next actuation of the solenoid 47 when the solenoid 47 is deactivated.
The above-mentioned solenoid 47 is operated by a switching unit in front of the base 15 composed of a switch 59, a switching pin 60 to operate the switch 59 and a switching lever 61 to press down the switching pin 60. A switch 62 provided on the back surface of the base 15 serves to switch an electromagnetic valve (not shown in the figures) of the cylinder 24 and the switch 62 is turned on when cutting with the cutter blade 29 has been completed by being pressed by an operating member 63 descending with the cutter blade 29 and fixed to the lateral side of the punch plate 25 as shown in FIG. 4.
In the following, the process steps in the method by use of the above apparatus are described in sequence with reference to FIGS. 4, 5 and 9 to 15.
A continuous length fastener chain A (as shown in FIG. 2) with reinforcement tapes 3 adhesively bonded to the individual space sections 4 is placed on the chain-guide plates 18, 19 and the die 17 along the center line of the die 17 in such a manner that the reinforcement tape 3 on a space section 4 is approximately above the die 17 and both of the fastener chains F, F are positioned with the gap 5 therebetween to fit the linear protrusions 20, 21 on the chain-guide plates 18, 19 as shown in FIG. 9. The next step is to push the switching lever 61 manually to turn on the switch 59 whereby the solenoid 47 is actuated so that the plunger 47a is pulled up, the first lever 50 rotates counterclockwise in FIG. 4 around the pin 49, the second lever 52 is pushed by the stopper screw 51 to rotate clockwise in FIG. 5 on the shaft 54, whereby the third lever 55 also rotates clockwise in FIG. 5, pulling the stopper 45 rearwardly by means of the engagement pin 57, resulting in disengagement of the stopper 45 from the step 44 of the pad holder 38, permitting the sudden downward movement of the rear pressers 30, which are under downward pressure by the compressive springs 40, so that the fastener chains F, F are press-held by the pads 39, 39 with a relatively small pressure. In this case, the rows of elements 2, 2 are received within the element-guide grooves 43, 43 provided on the lower surfaces of the pads 39, 39 as shown in FIG. 10.
When the stopper 45 has disengaged from the engagement step 44, the solenoid 47 is deactivated so that the stopper 45 is urged against the lateral surface of the pad holder 38 by the compressive force of the spring 58.
The next step is to pull the thus press-held fastener chain manually forwardly, i.e. in the rightward direction in FIG. 5 or in the direction of the arrow a in FIG. 10, by hand slightly until the terminals 2', 2' of the element rows 2, 2 come into contact with the stopper faces 42 of the elementguide grooves 43 where the fastener chains F, F are stopped at their exact positions as shown in FIGS. 11 and 12. During the movement of the fastener chains by manual pulling, the fastener chains are gently press-held by the pads 39 so that the fastener chains are under suitable tension to avoid distortion or creasing ensuring exact positioning.
Then the cylinder 24 is operated by supplying air, for example, by operating a foot switch (not shown in the figures) below the base 15 so that the cutter blade 29, the punch plate 25 and the front pressers 31 are all lowered whereby the pads 35 first come to contact with the fastener chain to press-hold the fastener chain at the front side of the cutting line as shown in FIGS. 13 and 14 and then the cutter blade 29 is lowered to cut the fastener chain and the reinforcement tape along the cutting lines L 1 to L 5 simultaneously giving separated fastener chains F and F' bearing the reinforcement tapes at their respective ends, the extraneous portions 3a, 3b of the reinforcement tape 3 having been cut off. It is mentioned that of course the cutting along the main cutting line L 1 is performed by the cutter sections 29d, 29e and the cutting along the auxiliary cutting lines L 2 to L 5 is performed by the cutter sections 29a, 29b, 29c. Thus a single cutting movement of the cutter blade 29 gives a fastener chain F, F with the reinforcement tape 3 on the lower ear ends and another fastener chain F', F' with the reinforcement tape 3' on the upper ends as shown in FIG. 15.
When the cutting movement of the cutter blade 29 has been completed, the switch 62 is operated by the member 63 so that the cylinder 24 is switched to elevation and the cutter blade 29 begins to ascend with the press-holding of the fastener chain by the pads 35 of the front presser 31 being continued until the cutter blade 29 reaches a height where the height difference between the edge 29' of the cutter blade 29 and the lower surface of the pads 35 becomes equal to or larger than H shown in FIG. 5 in prevention of lifting of the fastener chain by the upward movement of the cutter blade 29 apart from the die 17. Further elevation of the cutter blade 29 brings the engagement step 44 to the height of the stopper 45 where the stopper 45 and the engagement step 44 come into engagement with each other by virtue of the compressive spring 58. The above description is for one cycle of the operational movement of the apparatus with which the fabrication of fastener chains with reinforcement tapes can be performed efficiently by repeating the above cycle.
As described above in detail, the illustrated method and apparatus ensure a high working efficiency in the fabrication of fastener chains with reinforcement tapes since cutting of the fastener chains per se and cutting off of the extraneous portions of the reinforcement tapes can be performed simultaneously and, moreover, give an advantage of well-finished products by exact cutting along the correct cutting lines since the fastener chain is positioned to the correct cutting position as being gently press-held with the pressers at one side of the main cutting line followed by cutting while being press-held also at the other side of the main cutting line with another pair of pressers so that the fastener chain is under tension in the section between two pairs of pressers avoiding slackening or creasing of the fastener chain which otherwise might lead to inexactness of cutting.
|
A method is provided for fabricating a slide fastener chain having a certain length and reinforcement tapes at its ends from a manufactured, continuous length fastener chain which is provided with space sections each of which entirely consists of a reinforced tape. According to the method, the original length fastener chain is held first by a pair of pressers on a die at one side of the main crosswise cutting line, then by another pair of pressers at the other side to form a right position so that the reinforced space section is cut along the crosswise line and at the same time, the lengthwise lines by a cutter blade. This method is performed using an apparatus with a linkage motion of its individual parts whereby working efficiency is improved and a good cutting finish is obtained.
| 8
|
FIELD OF THE INVENTION
The present invention relates generally to cabling systems and connections, and more particularly, to a system and method for insulating and sealing terminations of wire.
BACKGROUND OF THE INVENTION
When alternating current at elevated frequencies passes through a wire, a phenomenon occurs that forces the outer surface or skin of a wire to carry most of the electrical current. This phenomenon, called the skin effect, increases in intensity as the frequency of operation increases. One type of wire that compensates for the skin effect is Litz wire. Litz wire, from the German “Litzendraht”—Litz for “strands” of wire and Draht for “wire”, is a type of electrical conductor that comprises multiple strands of individually insulated wires that allow the flow of high frequency alternating electrical current without appreciable loss because of electrical resistance or impedance in the conductors. The diameter of individual Litz wire strands is very small, and its radius is about the same or less than the depth of skin effect conduction. By bundling many individually insulated small wires together, the skin effect may be negated.
In addition to Litz wire, bundles of ordinary stranded wire employed at low frequency are not appreciably affected by the Skin Effect. As a result, stranded wire may be employed in electric motors, transformers, etc. Stranded wire overcomes many problems encountered with a single solid wire having about the same total diameter. If the stator of an electric motor stator is wound with a large diameter wire or a heavy cable is placed into the lamination of a transformer, it would be difficult to bend the wires into place. However, many individually insulated smaller diameter wires may be substituted for one large insulated solid wire. A bundle of smaller diameter wires having an overall diameter of a single wire may be bent and angled much more easily than the single large diameter wire.
Since Litz wire is made of many individually insulated wires, it is difficult to terminate unless all of the insulation in the termination area is first removed. Unfortunately, removing this insulation may damage the wire's physical structure. Until recently, low temperature film insulation was used, which was removed by dipping the insulated wire bundle into molten solder to burn off the insulation. However, the trend has been to use high temperature film insulation, which molten solder cannot remove. Crimp terminals cannot make a satisfactory connection, because the terminal's insulation piercing teeth cannot reach every strand in the Litz wire bundle. Another method is to use fused salts to chemically dissolve the organic film insulation. This does not work well in production because the chemical residue from the salts cannot be completely removed from inside the Litz wire bundle after the insulation is dissolved. Removing the insulation strand by strand is a labor intensive and time consuming process.
To date, the only proven successful production method to terminate large bundles of insulated wire is tube fusing, using the SN-Fusing process. The general term “fusing” is a method of joining low resistance metals with a type of machine similar to a resistance welding machine, but without appreciable distortion or damage to the parts being joined. Normally, when copper is resistance welded (i.e., spot welded, butt welded, etc.), it is drastically distorted to a point where some of the metal looses its physical integrity. This does not occur with fusing.
There are different methods of wire fusing, including “commutator fusing,” also known as “tang fusing,” and “hot staking” or “SN-fusing.” In commutator/tang fusing, the parts are heated, cleaned, softened, and pushed together until all the air between them is eliminated, and the high points of one metal part are pushed into the low points of the other. A surface adhesion contact holds the parts together.
With SN-fusing, or tin-fusing, a diffusion metallurgical bond is developed. If tin is heated until it is liquid, and a bar of copper is inserted into the molten liquid tin, the copper bar eventually dissolves. This solvent action, called wetting, is what permits tin to coat copper by dissolving its surface molecules. Tin adheres the surface of copper with a strength comparable to that which a piece of solid metal holds itself together, that is, by the attraction between adjacent atoms. Tin, being attached by such attractive forces, cannot be mechanically pried from the surface of the copper. Further, tin cannot be completely drained or wiped away when molten or liquid, since the surface of the copper remains permanently wetted by a film of the tin. A copper/tin inter-metallic compound is formed whenever tin wets copper. This compound itself is not strong. Therefore, by using a minimum amount of tin brought in contact with a base copper alloy for as short a time as possible, the copper may be “tinned” (i.e., wetted or coated), while keeping the basic strengths and properties of copper. For tinning to occur, the copper must be relatively clean of any foreign matter.
SN-fusing comprises six basic steps as illustrated in FIG. 1 . In Step S 1 , fusing pressure is applied to the parts that are being joined, until a preset level of pressure is reached. In step S 2 , heat is applied to a fusing electrode(s), and then dissipated into the parts being fused. In Step S 3 , as heat in the parts being fused increases, the wire's film insulation, if any, is vaporized. In Step S 4 , the tin, which is at its molten point, acts as a solvent to clean the surface of the copper conductors. In step S 5 , as the dissipated heat increases, the tin and any inter-metallic compounds are vaporized and/or driven from the joint's interface. In step S 6 , the resultant ultra-pure copper at the interface of the parts is then fused, resulting in a diffusion bond. However, the fusing pressure must be continually applied until the joint cools to a reasonable temperature, otherwise the plastic metals may separate because of the contractual forces that are being applied to them during cooling.
When many individual wire leads need to be joined together or to other stranded or solid wire, a tinned tube may be used. The tube acts as a gathering device as well as a mechanical terminal. The wires are placed into a tinned copper tube. Fusing electrodes then engulf the tube and it is fused. The advantage of the tube is that the tin inside the tube cannot easily be removed from the joint area during heating, since the tube holds it in place. Therefore, the tin wets most (or all) of the wires inside the tube before it is driven out of the joint. This means that most, if not all, of the conductors inside the tube, will be cleaned by the tin.
Unfortunately, wetting all of the copper wires with tin does not always result because the amount of tin that coats the terminal's tube is extremely small. To overcome this problem, additional heat and compression may be applied. The tin and the compression sealing of the joint help protect the termination from outside environmental pollution. This pollution is normally atmospheric gases as well as moisture. However, when the termination, after fusing, is immersed in a liquid that has a very thin consistency, the liquid may be drawn into the termination through capillary action, where the non-tin coated material is not diffusion bonded to the wires in the center of the bundle, or at the ends of the tube where the wires enter the tube. Most liquids will not damage a diffusion bonded joint if the wires keep their tin coating just outside of the joint area. Certain fluids, such as human body fluids, tend to corrode the wires at the point where they enter the termination's tube structure. This corrosion weakens the physical integrity of the wire bundle as it enters either side of the tube. Eventually, the wire bundle may be weakened to a point where the wires actually break or they have lost enough strands so that the current passing through them overheats because of resulting high resistance area(s) in the wire. As this over-heated area continues to heat the wire, the electrical connection may be destroyed.
Further, while fusing without tin is normally employed to join bare stranded wire to other bare stranded wire or solid bare wire, in certain circumstances, tin coated tubes may also be used. The phenomenon of moisture entering the terminating tube may also occur when tin is used to coat the interior of the tube.
If this type of corrosion and erosion continues for some time, the electrical characteristics of the termination may be in jeopardy because of the resulting increase in the electrical resistance, which may affect the wire's ability to conduct electrical power. This has happened to pacemaker or defibrillator leads that are inserted into a human body for prolonged periods of time. At the point of lead failure, the only solution is to replace the leads. Of course, this means that a surgical procedure needs to be performed.
One method of solving the corrosion problem is to apply a hot melt plastic material to both ends of the tube. However, this may not be easily done automatically. Also, for an intimate seal to result between the metal terminal and the plastic material, both materials would have to reach the temperature of, or above, the melted plastic. If the entire terminal's ends do not reach this temperature, the plastic will not make intimate contact with the metal.
Accordingly, what would be desirable, but has not yet been provided, is a system and method for insulating fused Litz or bare stranded wire terminations that overcomes the deficiencies in the prior art described hereinabove.
SUMMARY OF THE INVENTION
The above-described problems are addressed and a technical solution is achieved in the art by providing a method for insulating a plurality of wires, comprising the steps of: placing a portion of the plurality of wires and an insulating material in a tube having an open end; applying pressure to the tube; and during the applying of pressure step, heating the tube, the plurality of wires, and the insulating material to a temperature above a melting point of the insulating material, wherein the insulating material is melted and driven toward the open end of the tube.
Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube. The applied pressure and heat are sufficient to deform the tube and compress the wires, the insulating material, and the tube together such that the wires are pressed against other wires and the insulating material. The heat is sufficient to fuse the wires to each other but insufficient to melt the tube or wires.
According to an embodiment of the present invention, the insulating material may be a thermoplastic or wax. The insulating material may have the shape of a solid tube, or may be sprayed on either the wires or on an inner surface of the tube, or the wires may have been previously coated with insulating material. Alternatively, the insulating material may have the shape of a washer which is initially oriented along a plane perpendicular to the wires and the tube proximal to the open end of the tube.
According to an embodiment of the present invention, the insulating material maintains the same composition upon heating and re-solidifying.
According to an embodiment of the present invention, the tube may be open at both ends, whereby the insulating material is driven toward the ends and forms an insulating barrier about the wires proximal to the ends.
According to an embodiment of the present invention, the tube is initially closed at one end, whereby the insulating material is driven toward the open end and forms an insulating barrier about the wires proximal to the open end.
According to an embodiment of the present invention, the tube is initially closed at one end and an opening in the closed end is formed to relieve pressure buildup of volatized materials.
According to an embodiment of the present invention, the insulating barrier is substantially impermeable to fluids, including bodily fluids.
The above-described problems are addressed and a technical solution is achieved in the art by providing an insulated wire joint, comprising: a tube having an open end; and a portion of a plurality of wires placed in the tube; and an insulating material formed proximal to the open end of the tube by the application pressure and heat to the tube, the portion of the plurality of wires, and the insulating material. During the application of pressure and heat, the temperature of the insulating material is raised above its melting point, thereby driving the insulating material away from the generated heat toward the open end. Upon removal of heat, the insulating material solidifies.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more readily understood from the detailed description of exemplary embodiments presented below considered in conjunction with the attached drawings in which like reference numerals refer to similar elements and in which:
FIG. 1 is a process flow exhibiting exemplary steps of conventional SN-fusing (i.e., tin-fusing);
FIG. 2 is a side view of one example of a tube termination, wires, and insulating material to be assembled into a terminated wire assembly, according to an embodiment of the present invention;
FIG. 3 is a front view of the tube, stranded wire, and insulating material of FIG. 2 ;
FIGS. 4A-4C and FIGS. 5A-5C show the tube of FIG. 3 and a pair of fusing electrodes, according to certain embodiments of the present invention;
FIGS. 6A-6C are side views of FIGS. 5A-5C , respectively;
FIGS. 7A-7C and 8 A- 8 C are side and rear views, respectively, of the tube held by the electrodes with the insulating material and wires inserted into the tube termination, according to certain embodiments of the present invention;
FIGS. 9A-9C are diagrammatic views showing the electrodes and tube/wire assemblies of FIGS. 8A-8C , respectively, during the application of electrode pressure but before the application of electrical power;
FIGS. 10A and 10B are partial exploded views of a part of the tube and wires of FIGS. 9A-9C ;
FIG. 11 is similar to FIGS. 10A and 10B but after the application of heat and electrical power;
FIG. 12 is an enlarged view of FIG. 11 ;
FIG. 13 is a perspective of a terminated tube and wire assembly made pursuant to the above described method;
FIG. 14 is similar to FIG. 13 and shows an alternate form of tube termination;
FIG. 15 is similar to FIG. 14 and shows the tube termination substantially closed/sealed at one end; and
FIG. 16 shows the sealed tube termination of FIG. 15 with an opening for venting volatile materials during fusing, according to an embodiment of the present invention.
It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 2 and 3 , the present invention includes the use of a terminal tube 10 made of suitable metal such as copper, brass, bronze, steel, or other alloys, depending upon the application. The present invention further includes bare or insulated, solid or stranded wire 16 and an insulating material 18 . In a preferred embodiment, the terminal tube 10 comprises a tin-plated cylindrical tube which is easily manufactured and simply cut and tinned in tubular form. Alternatively, the terminal tube 10 can be made from rolled sheet metal with a soldered, welded seam, or otherwise joined seam (not shown). A preferred feature is that the terminal tube 10 should be electrically continuous such that current and heat will flow evenly through both half-cylinders of the terminal tube 10 in a manner described below. It is also preferred that the cross-sectional shape of the terminal tube 10 be substantially circular so that an operator or a mechanical placement apparatus need not be concerned with the angular orientation of the terminal tube 10 with respect to fusing electrodes 12 and 14 (to be described hereinbelow). In certain embodiments, a tube may have a slit along its length. If a tube having an angular (e.g., square) shape in cross-section with a slit is placed in an assembly with the slit face down, and pressure is applied to the non-slit side, the terminal tube 10 may spread apart at the slit, resulting in a failed termination.
In a preferred embodiment, the insulating material 18 is a thermoplastic. In an alternative embodiment, the insulating material 18 is made of wax or other plastic(s). In a preferred embodiment, the insulating material 18 may be formed into a hollow tube having an inner diameter, d′, that is larger than an outer diameter, d, of the wire(s) 16 and an outer diameter that is smaller than an inner diameter, d″, of the terminal tube 10 . The insulating material tube 18 may be inserted about the wire(s) 16 and the terminal tube 10 inserted about the insulating material tube 18 prior to a heating and deformation step to be described hereinbelow with reference to FIGS. 7A-7C and 8 A- 8 C.
In yet another alternative embodiment, the insulating material 18 may be sprayed on the wire(s) 16 or on an inner surface of the terminal tube 10 . In yet another alternative embodiment, the insulating material 18 , may have the shape of a washer, wherein, prior to heating and deformation steps, the washer-shaped insulating material 18 is placed about the wire(s) 16 , and the terminal tube 10 is placed about the washer-shaped insulating material 18 proximal to one or both ends of the terminal tube 10 oriented along a plane perpendicular to the longitudinal orientation of the wire(s) 16 and the terminal tube 10 .
In a preferred embodiment, the insulating material 18 has thermal and chemical properties such that it melts without decomposing during the application of heat and electricity to be described hereinbelow, but re-solidifies without decomposing when heat and electricity are removed. The insulating material seals the termination in two ways: (1) the molten insulating material 14 glues itself to the wire(s) 16 and the terminal tube 10 , and (2) the molten insulating material glues itself together and seals the wires 16 after they are individually coated.
With reference to FIGS. 4A-6C , the method according to the present invention includes the use of a pair of fusing electrodes 12 and 14 . Unlike low resistance welding electrodes, at least one of the fusing electrodes 12 and 14 comprise high resistance electrodes, typically made of tungsten or other suitable material, and serve to apply to the work high pressure, high heat, and some current as further described below. The fusing electrodes 12 and 14 are mounted for movement toward and away from each other. In the illustrated embodiments, the fusing electrode 12 is stationary and the fusing electrode 14 is mounted for vertical movement. However, if preferred, both electrodes can be mounted for movement, and/or the electrodes can be mounted for relative horizontal movement.
The fusing electrode 12 has a fusing face that forms a cavity 13 for receiving the terminal tube 10 generally as shown in FIGS. 4A-6C and functions apply fusing pressure, heat and current throughout the bottom half of the terminal tube 10 . Also, the cavity functions to confine the flow and expansion of the terminal tube 10 and the wire(s) 16 therein, but is operable to melt the insulating material 18 and cause it to flow toward the ends 23 of the terminal tube 10 , as described below, which enables increased pressure to be applied to the work assembly. In the illustrated embodiment, the cavity 13 is generally semicircular with approximately the same diameter as the outer diameter of terminal tube 10 and extends to approximately half the vertical diameter of terminal tube 10 when the latter is placed therein.
The fusing face of the fusing electrode 14 is shaped to extend toward the cavity 13 . A central section 17 functions to compress the side of the terminal tube 10 , the insulating material 18 , and the wires 16 therein toward the cavity 13 with a greatest pressure being applied towards the center region of the work assembly. The central section 17 is configured to apply pressure, heat, and current to the outer parts of the work assembly during the fusing.
After the terminal tube 10 is placed in the cavity 13 , the fusing electrode 14 is advanced to engage the terminal tube 10 with a slight force of about five pounds. The fusing electrode 14 thus serves to hold the terminal tube 10 in place while the wire(s) 16 and the insulating material 18 are inserted into the terminal tube 10 . Alternatively, the wire(s) 16 may be placed into the terminal tube 10 by hand prior to placing the terminal tube 10 into the fusing electrode 14 . Therefore the terminal tube 10 with the wires 16 would be manually placed into the machine. See FIGS. 7A-7C and 8 A- 8 C. An operator or automatic visual inspection system can then inspect the work assembly to see if all elements are properly positioned and are free from defects. If for any reason, the work assembly elements are not in the proper position for fusing, the wire(s) 16 and/or the insulating material 18 may be removed, the fusing electrode 14 may be backed off, and the terminal tube 10 may be repositioned, if necessary.
Once the terminal tube 10 is repositioned, if necessary, then the fusing actuator switch may be energized. Accordingly, the fusing electrode 14 is driven toward the fusing electrode 12 , generally as shown in FIGS. 9A-9C . Pressure increases on the work assembly making an intimate contact between the fusing electrodes 14 and 12 and the terminal tube 10 . Fusing current and heat are preferably not fully applied during the first 25-45 milliseconds, but are gradually increased from very low to a maximum during which the terminal tube 10 is softened and greatly deformed and much of the air space between parts is eliminated. As seen in FIGS. 9A-9C , the pressure applied by the cavity 13 is applied to the bottom outer half surface of the terminal tube 10 and is directed toward the original axis of the terminal tube 10 . The pressure is applied to the central region of upper outer half surface of the terminal tube 10 and is directed in opposition to the direction of the pressure applied by the cavity 13 . These pressures are generally indicated by the arrows of FIGS. 9A-9C .
Once a predetermined pressure or displacement is reached between the fusing electrodes 12 and 14 , fusing power in the form of AC or DC current is applied through the fusing electrode 14 initially through the terminal tube 10 only, through the fusing electrode 12 . The fusing electrodes 12 and 14 as well as the terminal tube 10 , the wire(s) 16 , and insulation heat to about 1900 degrees F. Because of the shape of terminal tube 10 and the shapes for the fusing electrodes 12 , 14 , fusing current flows from the fusing electrode 14 through both side cylinder portions of deformed tube 10 to the fusing electrode 12 . Thus current and heat is applied throughout the length for the work assembly to enhance the integrity and reliability of the finished joint.
Accordingly, the great heat applied to the work assembly vaporizes much of the insulation about wire(s) 16 , if present, and causes the insulating material 18 to melt and flow away from the heat sources toward the free end(s) 23 of deformed tube 10 and/or toward any remaining microspaces between parts. During this time, current also begins to flow through the copper wire(s) 16 as the insulation burns off to expose the copper which is still under pressure and forced and deformed against other exposed copper wires and the inside of the terminal tube 10 . Also, application of fusing heat and current through the terminal tube 10 causes the inside tin coating 20 to wet some of the exposed copper wires and to flow toward open microspaces between the deformed wires that become forced together. See FIG. 12 . It should be understood that none of the metal parts amalgamate nor become liquid during the fusing process. The metal Materials only soften and yield to pressure to deform against each other creating a mechanical bond or compression joint between parts. For further information about the use of tin in fusing systems, see JOINING COPPER CONDUCTORS USING TIN-FUSING by S. Karpel, QUARTERLY JOURNAL OF THE INT. TIN RESEARCH INSTITUTE, No. 145, 1985, which is incorporated by reference in its entirety.
After heat, electricity, and pressure are removed from the deformed tube 10 , the insulating material 18 re-solidifies. FIG. 13 shows that final termination for a preferred embodiment illustrated in the previous Figures. The deformed tube 10 comprises an elongated bow-shaped termination for a plurality of previously (insulated) wires with great mechanical integrity. One or both of the ends 23 of the deformed tube 10 and a portion 24 of the wire(s) 16 proximal to one or both ends 23 of the deformed tube 10 is coated with the re-solidified insulating material 18 . The coated wire(s) with insulating material 18 thereon are substantially impermeable to fluids, be they gaseous or liquid. As a result, the resulting wired termination may be suitable for insertion in the human body and is further impermeable to bodily fluids.
FIG. 14 shows another preferred embodiment in which the terminal includes a terminal connector 26 extending from the tubular termination. FIG. 15 shows an alternative embodiment in which the terminal connector 26 ′ is substantially closed/sealed at one end 23 . In such circumstances, when the insulating material 18 melts and flows towards each of the ends 23 of the terminal tube 10 , the insulating material 18 may be partially vaporized, thereby building up vapor pressure in the sealed terminal connector 26 ′. The sealed terminal connector 26 ′ may possibly behave like a projective and violently disengage from the fused wire(s) 16 . Referring now to FIG. 16 , an opening 28 may be formed in the sealed terminal connector 26 ′ to relieve pressure buildup of volatized materials.
It is to be understood that the exemplary embodiments are merely illustrative of the invention and that many variations of the above-described embodiments may be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that all such variations be included within the scope of the following claims and their equivalents.
|
A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.
| 8
|
This application claims priority from co-pending U.S. Provisional Patent Application No. 60/308,738 filed Jul. 30, 2001 for Flexible Mapping of Circuits into Packets.
FIELD OF THE INVENTION
This invention relates to communications systems and methods, in particular, to packet communication systems and methods.
BACKGROUND OF THE INVENTION
Circuit emulation (CEM) systems, such as ATM CES, map native circuit frames received from a circuit into packets or cells. Sometimes this mapping is designed to minimize delay, as with ATM CES. Minimization of delay is accomplished by creating small packets, which minimizes the “capture delay”. Capture delay is the time that it takes to acquire enough incoming circuit frames to create a packet. The drawback to minimizing capture delay is that the ratio of overhead (non-data control information) to data can be high, which leads to inefficient use of bandwidth. Other mappings are designed to increase efficiency and minimize overhead by increasing the number of transported frames, while holding constant the amount of overhead data. Reducing the percentage of overhead in this fashion has the disadvantage of increasing the capture delay.
Capture delay is one component in the round trip delay (RTD) for a packet to travel from one unit across the network to a second unit and then for a packet to return back from the second unit across the network to the first unit. The prior art has included means for measuring round trip delay, but these means have required the use of special test packets that were sent periodically. The use of periodic test packets adds to the overhead because these packets do not carry a CEM payload. The use of periodic test packets adds another tradeoff between having recent representative data on RTD and sending a large number of test packets without CEM payloads. The term payload is being use here and in the claims that follow to designate “real data” in contrast with packet headers, various types of overhead for sending control data, and dummy data that is called “filler” or “stuff”. Delivering real data (“payloads”) is the purpose for having a system, and everything else just facilitates that process.
Thus, prior art solutions have forced a fixed choice on the number of payload frames per CEM packet and thus a fixed choice between inefficient use of bandwidth or increasing the capture delay. A further shortcoming is that the prior art has not provided a method of collecting RTD while continuing to carry CEM payloads.
It is therefore an object of the invention to define a flexible mapping of circuits into packets. This method will allow flexibility in these dimensions:
The amount of data from a given circuit can be varied manually or automatically based on the measured end-to-end delay or round trip delay (RTD). The amount of data mapped to each packet is inversely proportional to the measured round trip delay.
If two or more circuits are destined for the same emulation endpoint, their data may be manually or automatically mapped into the same packet.
It is furthermore the object of this invention to provide a simple means of measuring RTD based on timestamps carried in a CEM packet that also conveys CEM payloads.
SUMMARY
This disclosure provides a method for dynamically adjusting the number of data frames placed in a data unit or packet based on one or more recent measurements of round trip delay from the source device to a target device and back. Also disclosed is a method for measuring round trip delay by capturing certain relevant time values and transmitting these values within the packets carrying data frames so that new measurements of round trip delay can be made without the use of control packets that do not carry data frames.
Data structures for use with the disclosed methods are provided for a variety of protocols.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 shows the layout of the CEM Protocol Data Unit (PDU) in accordance with one version of the present invention.
FIG. 2 shows the placement of multiple CEM PDUs in the same packet in accordance with another version of the present invention.
FIG. 3 shows a standard TCP/IP UDP packet to carry the CEM data in accordance with another version of the present invention.
FIG. 4 shows the format of a CEM/IP packet carried over Ethernet without a VLAN tag in accordance with another version of the present invention.
FIG. 5 shows the format of an IP packet carried over Ethernet with an explicit VLAN tag in accordance with another version of the present invention.
FIG. 6 shows a CEM PDU mapped to Multiprotocol Label Switching (MPLS) in accordance with another version of the present invention.
FIG. 7 shows a CEM/MPLS packet mapped to Ethernet, with no VLAN tag in accordance with another version of the present invention.
FIG. 8 shows a CEM/MPLS packet mapped to an Ethernet frame with an explicit VLAN tag in accordance with another version of the present invention.
FIG. 9 shows the state machine for managing the TxTimeDelay timer and the time fields in the PDU in accordance with one version of the present invention.
FIG. 10 shows the state machine to control the number of payload frames in a CEM PDU based on the RTD in accordance with one version of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
CEM Format
The layout of the CEM Protocol Data Unit (PDU) is shown in FIG. 1
The CEM header is 12 bytes in length, and it is used by the CEM application to multiplex and demultiplex circuits, detect packet loss, maintain packet order, and compute packet network transit delay. A variable number of bytes of Time Division Multiplexing (TDM) data may be carried. Table 1 describes the fields of the CEM Header.
TABLE 1
CEM Header Fields
Field
Description
Values
Size
CVER
Circuit Emulation Version
4 bits
CTYPE
Circuit Type (T1, E1, T3, E3, OC3, OC12)
0 = T1, 1 = E1, 2 = T3,
4 bits
3 = E3, 4 = OC3, 5 = OC12
COPT
Bit mask of options
0xAA55
4 bits
TxTime
TxTime is valid
1 = valid, 0 = invalid
1 bit
EchoTxTime
EchoTxTime is valid
1 = valid, 0 = invalid
1 bit
TxTimeDelay
TxTimeDelay is valid
1 = valid, 0 = invalid
1 bit
More
More CEM frames after this one
1 = more, 0 = this is the last
1 bit
CFRAMES
Number of Native Circuit Frames contained in
1 to 15, 0 = 16 frames
4 bits
the packet
CEM LABEL
Circuit Emulation Label
16 bits
CEM SEQUENCE#
Sequence Number for packet loss detection
0 to 65535
16 bits
and reordering
TxTimeDelay
Clock ticks between receipt of Transmit
# of 125 μs ticks
16 Bits
Timestamp and transmission of this packet.
This is used to account for holding delay.
TxTime
Transmit Timestamp
In units of 125 μs ticks
16 Bits
EchoTxTime
The last captured TxTime from the Far Side
In units of 125 μs ticks
16 Bits
Multiple CEM PDUs can be placed in the same packet, as shown in FIG. 2 . For the PDUs shown in FIG. 2, the “More” bit in the COPT field would be set to “1” for CEM PDUs # 1 and # 2 and to “0” for PDU # 3 .
CEM Mappings
CEM Over IP Format
The mapping of CEM to IP uses a standard TCP/IP UDP packet to carry the CEM data. The layout of this packet is shown in FIG. 3 .
FIG. 4 shows the format of a CEM/IP packet carried over Ethernet with no VLAN tag. FIG. 5 shows the format of an IP packet carried over Ethernet with an explicit VLAN tag.
CEM Over MPLS
A Multiprotocol Label Switching (MPLS) label is 2 bytes in length. FIG. 6 shows a CEM PDU mapped to MPLS.
FIG. 7 shows a CEM/MPLS packet mapped to Ethernet, with no VLAN tag. Those of skill in the art understand the use of the VLAN tag for use in an architecture for Virtual Bridged LANS, such as found in IEEE Standard 802.1Q-1998 IEEE Standards for Local and Metropolitan Area Networks: Virtual Bridged Local Area Networks approved Dec. 8, 1998 by the IEEE-SA Standards Board.
FIG. 8 shows a CEM/MPLS packet mapped to an Ethernet frame with an explicit VLAN tag.
CEM Over Other Protocols
It will be apparent to someone skilled in the art that the CEM PDU shown in FIG. 1 may be mapped to other protocols. For example, the mapping shown in FIG. 3 may be combined with standard mappings of IP to ATM or Frame Relay to provide the transport of CEM over those protocols.
Measurement of RTD
The current invention measures RTD through the use of timestamps embedded in the CEM Packet.
General Processing Flow
A process to measure roundtrip delay from Unit A to Unit B and back to Unit A comprises:
Step 104 —Unit A generates a circuit emulation packet (CEM PDU) and places the value of local time into the TxTime field (transmit time) into a field within the CEM PDU.
Step 108 —Unit A transmits the packet to Unit B through a packet network.
Step 112 —Unit B receives the transmitted packet and records the TxTime field from the received packet and Unit B starts a timer to measure TxTimeDelay.
Step 116 —Unit B generates a CEM PDU and fills the TxTime field with local time, places the TxTimeDelay timer value in the TxTimeDelay field and copies the stored TxTime into EchoTx Time to send back the time received in the packet from Unit A. The TxTimeDelay contains the holding delay that occurred between the receipt of the packet at Unit B and the preparation of the packet for transmission to Unit A.
Step 120 —Unit B transmits the packet to Unit A through the packet network.
Step 124 —Unit A receives the transmitted packet and records the TxTime field from the received packet and Unit A starts a timer to measure TxTimeDelay.
Step 128 —Unit A marks the local time then subtracts from local time the EchoTxTime and the TxTimeDelay obtained from the packet received from Unit B. This provides a Round Trip Delay. The one-way delay can be approximated as one half of the RTD time.
The actions at Unit A and Unit B are symmetric. As the process continues, the next packet back to Unit B will have enough information for Unit B to calculate a Round Trip Delay. Note that there is not any requirement that the local time clock in Unit A be synchronized to the local time clock in Unit B.
State Machine Diagram
FIG. 9 shows an implementation of a state machine for managing the TxTimeDelay timer and the time fields in the PDU.
State Machine Table
Table 2 describes the state machine depicted in FIG. 9 .
TABLE 2
RTD State Machine
State
Event
Idle
Timing
Received
1. Record TxTime in
1. Ignore TxTime
CEM PDU
EchoTxTime
2. Set
TxTimeDelay = 0
3. →Timing
Time to Send
1. Set EchoTxTime and
1. Record
CEM PDU
TxTimeDelay invalid in packet
EchoTxTime and
TxTimeDelay in
packet and set valid
2. →Idle
Notes:
1. The TxTime value in the packet will always be valid.
2. In the timing state the state machine is maintaining a timer until the next CEM PDU is to be sent. The TxTime of any packets received in this state is ignored. Thus, only one TxTimeDelay timer is needed per circuit.
RTD Measurement Example
Table 3 shows an example of RTP measurement.
TABLE 3
RTD Example
Unit A
Unit B
Unit A
Time
Local
Local
Curr
New
Recv'd
TxTime
Recv.
Index
Time
Event
Time
State
Event
State
TxTime
Delay
Event
Time
RTD
0
22
342
Idle
Receive #6
Timing
20
0
1
23
343
Timing
Timing
20
1
Receive #330
23
23 − 16 − 3 = 4
2
24
Send #7
344
Timing
Timing
20
2
3
25
345
Timing
Send #331
Idle
20
3
4
26
346
Idle
Receive #7
Timing
24
0
5
27
347
Timing
Timing
24
1
Receive #331
27
27 − 20 − 3 = 4
6
28
Send #8
348
Timing
Timing
24
2
7
29
349
Timing
Send #332
Idle
24
3
8
30
350
Idle
Idle
24
—
9
31
351
Idle
Idle
24
—
Receive #332
31
31 − 24 − 3 = 4
10
32
Send #9
352
Idle
Idle
24
—
11
33
353
Idle
Send #333
Idle
24
—
12
34
354
Idle
Receive #8
Timing
28
0
13
35
355
Timing
Receive #9
Timing
28
1
Receive #333
35
No calculation
14
36
Send #10
356
Timing
Timing
28
2
15
37
357
Timing
Send #334
Idle
28
3
16
38
358
Idle
Receive #10
Timing
36
0
17
39
359
Timing
Timing
36
1
Receive #334
39
39 − 28 − 3 = 8
18
40
Send #11
360
Timing
Timing
36
2
19
41
361
Timing
Send #335
Idle
36
3
20
42
362
Idle
Receive #11
Timing
40
0
21
43
363
Timing
Timing
40
1
Receive #335
43
43 − 36 − 3 = 4
The following time indices are of interest.
Time indices 0 , 4 , 16 and 20 show normal reception of a packet at Unit “B”. The TxTime field is recorded, the TxTimeDelay timer is started and the state machine moves to the “Timing” state.
Time indices 3 , 7 , 15 and 19 show normal transmission of a packet from Unit “B”. The previously received value of the TxTime field is placed in the EchoTxTime field of the outgoing packet, the TxTimeDelay timer is stopped and the state machine transitions to the “Idle” state.
Time index 11 shows Unit “B” sending a packet without a valid time measurement. The TxTimeDelay and EchoTxTime bits in the COPT field are set to 0 to reflect that this packet may not be used at Unit “A” to calculate RTD at time index 13 .
Time index 13 shows packet # 9 arriving at Unit B. Since Unit “B” is already in the “Timing” state, the packet is ignored as far as the RTD state variables are concerned.
Time indices 1 , 5 , 9 , 17 and 21 show a normal calculation of RTD at Unit “A”. The calculated value of RTD is 4 for each of these except for time index 8 . Time index 8 properly shows a value of 8, reflecting the delayed arrival of packet # 8 at Unit “B” at time index 12 . Note the taking half of the RTD as an estimate of one way delay is only an approximation since the delays in this case were not symmetric.
Automatic Control of Flexible Mapping
Control of Mapping Multiple Circuits
When multiple circuits are destined for the same far end point, they will have the same IP destination address or MPLS Label. All such circuits can be mapped into the same packet using multiple CEM PDUs, with the COPT More flag set appropriately. Thus as illustrated in FIG. 2, a single transmission packet to be transmitted from device A to device B can contain a set of CEM PDUs that are all destined for Device B.
Control of Frames Per PDU (FPP)
As mentioned above, there is a trade-off in sending many partially loaded CEM PDU packets and thereby making inefficient use of the network, or waiting until the CEM PDU can be loaded with many payloads before sending. While the latter mode would send fewer packets, it would increase the average RTD because payloads would have to wait for a CEM PDU to become “full” and depart.
The present invention dynamically changes the balance between efficiency and responsiveness by altering the number of payload frames in a CEM PDU based on the RTD for recent transmissions. One-way delay may also be used, but it is not usually available directly.
FIG. 10 shows the state machine. In a preferred embodiment of the present invention, there are three states, each with its own FPP value (Frames per Packet). This invention can be extended to any system that dynamically changes from one FPP value to another based on current conditions. Thus, the number of states can be any number two or larger. Two states would probably be too coarse. It is currently felt that the optimal number of states would be from 3 to 5 states to avoid having an unduly complex system. This disclosure will explain the concept through the use of a three state example.
The three states are:
Low—This is the steady state when the current RTD is low as defined by the threshold L.
Medium—This is the steady state when the current RTD is medium as defined by the thresholds L and M.
High—This is the steady state when the current RTD is high as defined by the threshold M.
Note that there are no timers in this state machine. Since the number of frames per CEM PDU is contained within the PDU, the FPP could change on every single PDU without impairing the operation of the system. Hysteresis (or control deadbands), holdoff timers and/or smoothing of the RTD samples could be introduced to prevent minor changes in RTD from triggering changes in state and FPP.
Table 4 shows the state transitions for each range of RTD.
TABLE 4
State Machine for Control of FPP
State
RTD Status
Low
Medium
High
RTD < L
No change
1. Set FPP = C L
1. Set FPP = C L
2. →Low
2. →Low
L <= RTD < M
1. Set FPP =C M
No change
1. Set FPP = C M
2. →Medium
2. →Medium
RTD >= M
1. Set FPP = C H
1. Set FPP = C H
No change
2. →High
2. →High
Typical values for the values are:
L = 10 ms
M = 50 ms
C L = 20
C M = 10
C H = 1
For the convenience of the reader, applicant has added a number of topic headings to make the internal organization of this specification apparent and to facilitate location of certain discussions. These topic headings are merely convenient aids and not limitations on the text found within that particular topic.
Those skilled in the art will recognize that the methods and apparatus of the present invention has many applications and that the present invention is not limited to the specific examples given to promote understanding of the present invention. Moreover, the scope of the present invention covers the range of variations, modifications, and substitutes for the system components described herein, as would be known to those of skill in the art.
In order to promote clarity in the description, common terminology for components is used. The use of a specific term for a component suitable for carrying out some purpose within the disclosed invention should be construed as including all technical equivalents which operate to achieve the same purpose, whether or not the internal operation of the named component and the alternative component use the same principles. The use of such specificity to provide clarity should not be misconstrued as limiting the scope of the disclosure to the named component unless the limitation is made explicit in the description or the claims that follow.
Acronyms
CEM
Circuit Emulation
CES
Circuit Emulation Service
FPP
Frames Per PDU
MPLS
Multiprotocol Label Switching - described in IETF RFC3031.
PDU
Protocol Data Unit
RTD
Round Trip Delay
TCP/IP
Transmission Control Protocol/Internet Protocol-a network
control protocol for host-to-host transmissions over a packet
switching communication network.
UDP
User Datagram Protocol - described in RFC 768.
VLAN
Virtual Local Area Network
|
A system for optimally mapping circuits into packets based on round trip delay (RTD), and a system for measuring RTD for use in packet communications systems such as circuit emulation (CEM) systems is disclosed. The measured RTD value can be used in a system that adjusts packet size to reduce capture delay to partially offset an increase in RTD. As the use of smaller packets increases the overhead burden on the packet communication system, the packet size can be increased to reduce the overhead burden when the size of the current RTD becomes appropriately short. The disclosure also teaches the placement of data from two or more circuits destined for the same emulation endpoint into the same transmission packet in order to improve system performance. The abstract is a tool for finding relevant disclosures and not a limitation on the scope of the claims.
| 7
|
RELATED APPLICATION
[0001] This application is a continuation-in-part application of U.S. Non-Provisional patent application Ser. No. 14/645,013, filed Mar. 11, 2015, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of energy production, conservation, and transference as a combined heat and power system; specifically, a portable isothermal compressed gas energy storage and generator system is proposed that works in conjunction with a plural of reciprocating novel generators and renewable energy input sources to produce excess energies during peak hours to alleviate intermittency periods and store not only high density of electrical energy but also high ratio of gas as compressed heat can be transferred from gas storage to generators to electrical storage for electric user to access during peak or off-peak periods to alleviate energy storage issues and conserve energy for longer periods.
[0003] This design incorporates a centered double-sided, dual-acting pneumatic piston drive to simultaneously trigger distal end generators per cycle. It also illustrates the capacity to repetitively align distal end sleeve assemblies behind existing rows of generators to enable pneumatic-induced kinetic force applicator to simultaneously trigger an array of generators per cycle.
BACKGROUND OF THE INVENTION
[0004] No identified prior art describes a portable compressed gas energy storage system comprising a portable auxiliary power source, an operational rechargeable battery (Battery 1 ), a rechargeable battery to store generative energy (Battery 2 ), and a gas drive system that includes a plural of linear generators at each distal end of the separate piezoelectric housing used for reciprocating piezoelectric energy production; wherein a plural of double-sided, dual acting pneumatic drive pistons are positioned midpoint or in the middle or center of the distal ends, wherein each rod end of the plural of dual-sided, dual acting pneumatic drive pistons interconnect with a drive bar that are interconnected to the head of each drive piston rod that are pointed towards or facing each distal end of the housing; wherein the piston rods are implemented as kinetic force transfer units; wherein the two opposing piston rods of the dual-sided, dual acting pneumatic drive pistons are sharing at least one pneumatic chamber in order for pressure to simultaneously traverse or drive opposing rods out of the piston housing cylinder and up the drive path of the barrel housing; wherein pneumatic cylinder pistons are adjacent to one another; wherein these pneumatic pistons apply pneumatic force to piston rods that traverse up and down the distal ends of the barrel; wherein pressure (gas), pneumatic pistons and drive bar are claimed as the drive system; wherein the drive bars that interconnects both piston rods of the pistons engages with the linear generators when traversing back and forth simultaneously because of manual or automatic relay switches that work with an automatic or manual relay or control module to regulate the air or gas output stored in the gas compressor chamber using valves and air hoses to supply pressure that drives the pneumatic pistons that are located at the midpoint of the drive system or barrel housing; wherein an assembly is positioned at each distal end of the barrel housing that houses a manual or automated relay controller and a plural of linear generators; wherein the assembly receives kinetic pressure from the reciprocating pneumatic drive system; wherein pressure is released from the relay to an intake of valve of the double-sided, dual-acting pneumatic pistons to traverse the drive bars that interconnect with the piston rods into linear generators; wherein the drive bar engages the generators in order to transfer motion in the form of kinetic energy to the respective series of linear generators; wherein the motion of the drive bar from midpoint to a distal end simultaneously applies kinetic force to not only the series of linear generators but also applies kinetic force to distal ended manual or automatic relay controllers that connect with automatic or manual relay or control module located outside the piezoelectric housing that regulate pressure (heat) directional flow to trigger the opposing movement of pneumatic pistons; wherein manual relay or control module works with relay controllers, while optional automatic relay or control module work with a preferred time set forth in order to automatically reset the relay or control module; wherein relay or control modules regulate the pressure output stored instead of using distal end relay controllers to input and discharge pressure to and from pneumatic pistons using air hoses interconnected to the relay or control module and to valves on the pneumatic pistons; wherein, in the separated piezoelectric housing, pneumatic pistons that are midpoint to the plural of linear generators that are positioned at each distal end of the housing apply pneumatic force to the opposing piston rods that interconnect with the pneumatic pistons that provide pneumatic-induced motion to the interconnected drive bars that makes contact with linear generators at each distal end; wherein the drive bars simultaneously apply kinetic force to the respective distal end generators and relay controllers to trigger a manual relay or control module if applied; wherein a compressed gas source operated by battery 1 or a first electrical energy storage unit receiving energy from a portable auxiliary power source, namely renewables or other sources of electrical load or supply, supplies operational energy to battery 1 that supplies energy to the motorized pump of the gas compressor and valve system that works with distal ended relay controllers that connect to outside relay or control module that regulate the gas directional flow and use kinetic energy to facilitate movement and direction of the pneumatic pistons in order to push the drive bar back and forth until either the volume of the compressed gas chamber is low, power sources are depleted or the electrical energy storage units are full to capacity, the device is turned off or a killswitch command is sent from battery sensors to control modules to cease operations; wherein linear generators, also known as linear magnetic induction units, are positioned along the distal ends of the barrel housing such that upon impact with the front frames of the drive bar, said magnetic induction units shall generate electricity, which is converted by a transformer, then transferred and stored to battery 2 or electrical energy storage unit 2 for storage; wherein a transfer control can be used to switch between stored AC, direct AC and direct DC output when stored AC is not presently optional.
[0005] In this and many other respects, the Compressed Gas Energy Storage microgrid apparatus or system departs from the conventional concepts and designs of the prior, traditional, or existing compressed gas energy storage system
SUMMARY OF THE INVENTION
[0006] The a combined heat and power system, namely a combined renewable energy and compressed gas energy storage and generation portable isothermal microgrid system, is a reciprocating bar-based barrel that uses a drive bar to transfer direct kinetic energy to piezoelectric components to then store the electrical production, all of which can be used in a microgrid configuration, that uses renewable energy, namely solar, wind, water or hydro, or other sources of electric supply to sequentially generate initial electrical energy that is stored, store pneumatic energy as compressed gas, generate high density electrical energy using stored gas against piezoelectric generators, and finally store the resulting high density electrical energy into a second battery that interconnects with renewable energy storage for bidirectional flow electrical balancing to prolong electrical recharging of storage through using multiple electrical generative sources; all of which comprises of a barrel housing with a modified drive system within the barrel housing setting where a drive bar traverses back and forth in order to transfer kinetic energy to a plural of piezoelectric components, namely linear generators and relay controllers located at distal ends of barrel housing in a mounted drive assembly that allows kinetic force application, to promote simultaneous electrical discharge and pressure (gas) discharge to promote the pneumatic rods to traverse towards opposing distal ends of the piezoelectric barrel housing. As a direct kinetic energy transferor, it uses a bar to apply pressure (gas)-induced reciprocating kinetic force application onto a plural of distal end piezoelectric components. The center of the piezoelectric barrel housing, also known as the midpoint of the distal ends of the barrel housing or drive system, is outfitted with double-sided, dual-acting pneumatic pistons that house rods that uses pressure to apply force to interconnected distal end drive bars to trigger the current discharge of linear generators from both distal ends simultaneously. The pneumatic pistons are being supplied pressure from a compressed gas source or chamber, which pushes on internal components of the pneumatic piston—rod—which in turn pushes in a reciprocating manner the drive bar toward opposing distal ends or drive assembly housing linear generators and relay controllers.
[0007] An object of the invention is to provide a housing that includes a modified drive system of the barrel housing that includes linear generators at distal ends, which are transferred linear or kinetic energy from a drive bar from the midpoint area of the barrel housing.
[0008] Another object of the invention is to provide the drive system with a force application drive bar that interconnects the piston rods that are supplied kinetic energy by the pneumatic pistons positioned at distal ends to apply kinetic force in a reciprocating manner to a drive assembly or plural of linear generators and relay controllers positioned at each distal ends.
[0009] A further object of the invention is to include pneumatic pistons at the midpoint of the distal ends of the piezoelectric housing, since the double-sided, dual acting pneumatic pistons house piston rods that use stored pressure (gas) to generate pneumatic movement. The compressed gas source or chamber will supply pneumatic force to the pneumatic pistons in order to aid the pressure (gas) in pushing the drive bar towards respective piezoelectric components, namely a plural of linear generators and relay controllers that are located at distal ends of the barrel. The drive bar engages with or applies kinetic pressure to the action relay controller that uses kinetic pressure from drive bar to send a command to the relay or control module that regulates the gas directional flow that promote movement of pistons. Relays controllers, located at each distal end, enable newly added pressure to pistons. Optional design of the automatic relay or control module can be pneumatic timing discharge-based, or pneumatic discharge that operates on timing sequence to regulate or direct pressure in or out of pistons using air hoses, instead of using distal end relay controllers to input and discharge pressure to and from pneumatic pistons using air hoses interconnected to the relay or control module and to valves on the pneumatic pistons. Pistons located at the midpoint of the distal ends are receiving newly added pressure input through air hoses supply gas to interconnect to piston valves or stems to extend their piston rods.
[0010] An additional object of the invention is to supply an auxiliary power source, namely renewables or other sources of electrical supply, to operate the compressed gas source for remote or portable power station purposes. The compressed gas source will supply pneumatic force to the pneumatic pistons in order to pushing the opposing, distal end drive bars towards both linear generators and relay controllers that are located at distal ends of the barrel housing. Each drive bar engages with the automatic or manual action controllers, which sends a command to the relay or control module to regulate the directional flow of compressed gas at a time towards one pair of midpoint pneumatic pistons or the other. Additionally, the relay or control module can utilize motion detection sensors or come equipped with a pneumatic timer to autonomously switch the directional flow of compressed gas on a timer—sequential or simultaneous manner—towards one pair of centered pneumatics pistons without the usage of automatic or manual action controllers that rely on kinetic force applications from the drive bar.
[0011] A further object of the invention is to generate high energy using a plural of magnetic induction generators for energy production purposes. Linear magnetic induction generators produce electricity upon movement of magnet back and forth inside of induction coil. Generators can include either a spring only or a first and optional spring configuration to promote push down and reset of the magnetic induction bar or magnetic induction process that results in a discharge of a current. First spring configuration has the spring positioned on one side of the metal bar to facilitate spring release and retraction processes, while the optional first and optional second spring configuration has the first spring located at the opposing side of the magnet and metal bar. Magnet can traverse back and forth within induction coil. Force is applied to the linear magnetic induction generators by the traversing kinetic motion of the drive bar. The bar applies force to the magnet set atop a compressed spring that facilitates motion between the magnetic field of the magnet and conductive coil to emit an AC electrical output. Transformers are used in conjunction with the magnetic induction generators to convert AC to DC power. A transfer control can be used to switch between stored AC, direct AC and direct DC output when stored AC is not presently optional. The linear generators work in conjunction with the system auxiliary power, namely renewables or other sources of electrical supply.
[0012] An additional object of the invention is to provide a design where multiple generators can be triggered simultaneously to produce high energy densities per reciprocating cycle. A singular pneumatic pressure input source can allow an array or series of linear generators to be influenced or triggered to simultaneously produce an electric current discharge or discharged electric current per spring reciprocating cycle. The linear generators can be aligned in an array—rows and columns—, to trigger each other, where distal end housing comprising of a plural of linear generators can be aligned in an array—columns and rows—at the rear of the prior row of linear generator-based distal end sleeve housing; wherein the rear stem or bar of the prior linear generators are elongated as a result of kinetic force applied to push down the metal bar of the linear generator; wherein the rear stems or bars can rest on a secondary drive bar or magnetic divider that rest on magnets of a secondary row of linear generators so applied kinetic force is transferred from the first row of linear generators to the second row of linear generators and other rows of linear generators following thereafter.
[0013] An additional object of the invention is to provide two electrical energy storage units that store electricity. The first electrical energy storage unit stores electricity generated from the auxiliary power source and supplies it to the motorized pump of the compressed air source; wherein the second electrical energy storage unit stores electricity generated from the linear generators and supplies electric user power. The first and second electrical energy storage units can be interconnected.
[0014] A further object of the invention is to provide access to filtered water when the system is using an ambient gas source. Moisture from an ambient gas source builds up over time within the compressed gas storage chamber as the high ratio of gas within the volume of the compression chamber heats up during compression, releasing moisture, and likewise cools down during expansion; wherein the moisture can be directed into an interconnected portable water filtration system to supply filtered water that accumulates over time, enabling the system to not only relate to the field of energy production, conservation, and transference but also relate to the field of water collection, conservation, and transference.
[0015] These together with additional objects, features and advantages of the compressed gas energy storage system or apparatus will be readily explained upon reading the following detailed description of illustrative embodiments of the portable air driven generator and storage system when taken in conjunction with the accompanying drawings.
[0016] In this respect, before explaining the current embodiments of the portable air driven generator and storage system in detail, it is to be understood that the portable air driven generator and storage system is not limited in its applications to the details of construction and arrangements of the components set forth in the following description or illustration. The concept of this disclosure may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the portable air driven generator and storage system.
[0017] It is therefore important that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the microgrid portable air driven generator and storage system. It is also to be understood that the phraseology and terminology employed herein are for purposes of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the invention.
[0019] FIG. 1 illustrates a cross-sectional view of the embodiment of the system configuration—electric production, conservation, and transference as well as pneumatic gas conversion into filtered water—of the present invention.
[0020] FIG. 2 illustrates a detailed view of the pneumatic gas configuration only.
[0021] FIG. 3 illustrates a detailed illustration of the pneumatic gas system configuration and sequence, not only illustrating the directional pressure (heat) flow using gas hoses and valves and the componentry that are influenced by the stored gas before the gas is directed out through piston valves but also illustrating pistons with multiple chambers that can be configured to work in the system. In the process of directional gas flow that occurs in pistons that use two gas storage chambers—a front and a rear that is separated by a rod wall—to traverse the piston rod wall in one direction, the front gas storage chamber (chamber 1 is supplied pressure, making the opposing gas storage chamber (chamber 2 ) of the piston direct out pressure back to the valve located at the relay or control module by using air hoses used to direct pressure in and out. The wall of a rod separates the single large gas chamber of the piston into two adjacent gas storage chambers—front chamber and rear chamber—in order for pressure (heat) to be directed in or out one side of the gas storage chamber, which will direct out pressure in the adjacent gas storage chamber to traverse the piston rod and rod wall in opposing directions using the sequential process of applying pressure into chamber 1 or chamber 2 of the piston, depending on the direction that the drive bar is traversing to trigger manual relay controllers or depending on a pneumatic timing command sent from the relay or control module. One of the manual relay controllers can be designed with an extended switch arm to enable the switch to be position at the rear area of the opposing drive bar in order to be triggered, thereby changing the directional flow of pressure to traverse the drive bar.
[0022] FIG. 4 illustrates a detailed illustration of the movement of the pneumatic pistons when gas input occurs and when gas discharging occurs. Air hoses interconnect with sides or gas chambers of pistons using valves as the air hoses work as both gas admittance and simultaneously gas release units, depending on the piston gas chamber that gas is inputting and being released, as air hoses direct pressure controlled by the relay to enter one side of the piston gas chamber and release pressure using the air hoses that direct the released pressure to a release valve located at the relay or control module.
[0023] FIG. 5 illustrates a cross-sectional view of the electrical configuration only, illustrating the electrical input from the renewable energy source, the units that the battery operates, and the multiple currents—from stored AC to direct AC and DC—that the system can produce for electric users.
[0024] FIG. 6 illustrates a cross-sectional illustration of the full configuration of system as well as the electrical sequence, illustrating the directional flow of electricity produced from the push-down process of the plurality of linear generators positioned at each distal end of the barrel housing.
[0025] FIG. 7 illustrates a detailed illustration of the magnetic induction unit, illustrating the multiple linear generator designs that can work with a transformer to provide direct DC or work without a transformer to provide direct AC.
[0026] FIG. 8 illustrates a detailed illustration of the existing piezoelectric barrel housing, an illustration of the additional magnetic induction sleeves that can be interconnected to the existing piezoelectric housing and componentry of both designs, illustrating the drive system comprising of gas source, centered pistons and distal end drive bars that apply kinetic pressure to promote the push-down process of distal end piezoelectric-based influenced assembly units like a plurality of linear generators and relay controllers, as well as a plurality of additional generative cartridge sleeves per distal end to promote higher energy density output when kinetic force is applied by the drive bars.
[0027] FIG. 9 illustrates a detailed illustration of the barrel housing, illustrating the influenced assembly, namely the distal end sleeves that house piezoelectric components like the plurality of linear generators and relay controllers.
[0028] FIG. 10 illustrates a detailed illustration of the array of distal end housing comprising of a plural of linear generators that can be aligned in a column or row to the rear of a prior linear generator to use the rear stem of the prior linear generator to trigger by pushing down the magnet of the linear generator positioned behind it. A singular pneumatic pressure input source can allow an array or series of linear generators to be influenced or triggered to simultaneously produce an electric current discharge or discharged electric current per sequence of piston rod push and pull event.
[0029] FIG. 11 illustrates an embodiment of proposed application that the portable microgrid system can be adopted to, namely an electric vehicle-to-grid application, where portable electricity can be applied to an electric vehicle and electric grid.
[0030] FIG. 12 illustrates a detailed illustration of the movement of the pneumatic pistons when using a pneumatic timing relay or control module to sequentially direct gas or pressure flow to each air hose, as an alternative to using the manual relay controllers that rely on kinetic pressure from the drive bar.
[0031] FIG. 13 illustrates a detailed illustration of the movement of the pneumatic pistons when using a motion detection relay switch connected to the relay or control module, as an alternative to using the manual relay controllers that rely on kinetic pressure from the drive bar.
[0032] FIG. 14 illustrates a detailed illustration of the portable water filtration system that connects to a port on the compressor gas chamber that filters collecting moisture and converts it into drinkable water.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The following detailed description is merely exemplary in nature and is not intended to limit the scope of the invention. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations in the art of compressed gas energy storage system to practice the disclosure and are not intended to limit the scope of the appended claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
KEY TO NUMERICAL REFERENCES BELOW OR IN THE DRAWINGS
[0000]
100 —Invention—Reciprocating Bar-Based Barrel Direct Energy Transferor Piezoelectricity
109 —Auxiliary power source (Renewable energy source or other source of electric supply)
101 —Housing
108 —Sleeve (Housing)
102 —Undefined length
103 —Undefined internal length or width or depth
105 —Inner surface
106 —Drive bar
118 —Housing of the drive bar
107 —Distal end (Invention)
128 —Inverter
130 —First electrical energy storage unit—capacitor or battery (Gas source)
131 —Second electrical energy storage unit—capacitor or battery (Electric user)
134 —Transfer control
135 —Electrical wire
122 —Pneumatic piston
104 —Piston rod
120 —Rod Wall
123 —Spring (Optional-located within 122 )
124 —Piston (Internal)
133 —Valves
126 —Gas source
111 —Compressor motor or pump
125 —Gas chamber
127 —Air hose
129 —Relay or control module (Automatic or manual)
171 —Motion detection sensor switch (Optional to work with relay)
172 —Pneumatic timing release relay or control module (Optional)
132 —Action relay controllers (Wireless or wired)
136 —Water filtration unit
173 —Gravel
174 —Sand
175 —Charcoal
176 —Cheesecloth or coffee filter
177 —Filtered water
137 —Port
138 —Moisture
139 —Pressure (Heat)
140 —Magnetic induction generators
141 —Magnet
142 —Induction coil
143 —First spring
146 —Second spring (Optional)
144 —Transformer
145 —Metal Bar
147 —Magnetic shielding wall divider
170 —Electric user
[0081] Detailed reference will now be made to a preferred embodiment of the present invention, examples of which are illustrated in FIGS. 1-14 . The compressed gas energy storage system, namely a reciprocating bar-based barrel direct energy transferor piezoelectricity system 100 (hereinafter “invention”) comprising of a barrel housing with a plural of traversing drive bars as the direct energy transferor and piezoelectric componentry, includes a barrel housing 101 of an undefined length 102 and undefined internal length or width or depth 103 . That being said, the barrel housing 101 is of hollowed construction, is rectangular in shape, includes distal ends 107 that interconnect using side rails, and has clearance space in between the distal ends. Each distal end 107 is made up of multiple sleeves 108 to house piezoelectric components as well as sleeves 108 to include linear generators 140 and relay controllers 132 extending lengthwise along an inner surface 105 with which a drive bar 106 that is interconnected with the piston rods 104 of pneumatic pistons 122 that are centered in the clearance space 105 between the distal ends 107 of the housing 101 that engages the linear generators 140 and traverses each distal end drive bar 106 back and forth between distal ends 107 .
[0082] The barrel housing 101 includes a plural of linear generators 140 at the distal ends 107 positioned in housing sleeves 108 , and draw kinetic energy from the drive bar 106 when in contact therewith. It shall be noted that the invention 100 is designed in such a way that the drive bar 106 is mobile and traverses back and forth between the distal ends 107 in order to transfer kinetic energy to the linear or magnetic induction generators 140 for electrical production when arriving at the distal ends 107 by the use of a compressed gas source 126 to supply pressure (heat) 139 . That being said, the housing of the drive bar 118 applies kinetic force stored therein when communicated with the linear or magnetic induction generator 140 ; so upon contact, and upon moving away from said linear or magnetic induction generator 140 and moving towards an opposing distal end, said housing of drive bar 118 is imparted new kinetic force by compressed gas source 126 that traverse pneumatic pistons 122 in order to apply new level of kinetic force therein for transference to the piezoelectric components positioned in housing sleeves 108 , namely relay controllers 132 and linear or magnetic induction generators 140 at the opposing distal end 107 , etc.
[0083] The plural of magnetic induction generators 140 produce electricity, which is transferred to the second electrical energy storage unit 131 .
[0084] Pneumatic pistons 122 , positioned between or midpoint of distal ends 107 of piezoelectric housing, work in unison with interconnected piston rods 104 and drive bar 106 to apply applicable force to traverse each drive bar 106 back and forth along the inside of the barrel housing 101 . The centered double-sided, dual-acting pneumatic pistons 122 comprise of a plural of piston rods 124 that can traverse in opposing directions when pressure 139 is introduced into their gas chambers 125 can include a spring 123 coupled with a piston 124 . Regulated by relay controllers 132 that send a command to the relay or control module 129 that regulates the directional flow of gas 126 into midpoint pneumatic pistons 122 , the piston 124 is connected to a gas chamber 125 , which supplies compressed gas 126 to all of the pistons 124 via compressed air hoses 127 . As an alternative to using relay controllers 132 , the relay or control module 129 can utilize motion detection sensor switches 171 or can use a pneumatic timing release relay or control module 172 to autonomously switch the directional flow of compressed gas 126 on a timer or sequential manner towards one pair of centered pneumatics pistons 122 without the usage of automatic or manual action controllers 132 that rely on kinetic force applications from the drive bars 106 . Located at each distal end 107 , motion detection sensor switches 171 select the drive bar 106 region to monitor movement using an emitted light 178 to compare sequential images, changes or interruption in light pattern; and if enough of the light 178 have changed between those frames, the software determines something moved and send the relay 129 an alert to trigger motion of the pneumatic pistons 122 by sending command to relay 129 to release gas as pressure into targeted air hoses 127 . Pneumatic timing release relay or control module 172 releases gas 126 as pressure 139 to air hoses 127 in a sequence based on timing action that is halted by removing voltage from the coil 142 with time; when voltage is applied to the coil 142 , the contacts energize and de-energize alternatively, making on and off cycle timing lengths adjustable so the time release can reoccur or happen again. Air hoses 127 interconnect relay or control modules 129 with valves 133 of pneumatic piston 122 and its internal piston 122 or chambers 125 as the air hoses 127 work as both gas admittance and simultaneously gas release units, depending on the piston gas chamber 125 distal end 107 that gas 126 working as pressure 139 is being directed—inputted and released—as air hoses 127 direct pressure 139 controlled by the relay 129 to enter one side of the piston gas chamber 125 and release pressure 139 using the air hoses 127 that direct the released pressure 139 to a release valve 133 interconnected with the relay or control module 129 .
[0085] The gas chamber 125 is supplied compressed gas from a compressed gas source 126 and stores it as pressure (heat) 139 . Moisture 138 from a gas source 126 builds up over time within the compressed gas storage chamber 125 as the high ratio of gas within the volume of the compression chamber heats up during compression, releasing moisture 138 , and likewise cools down during expansion. The water filtration unit 136 , which can consist of a rectangular, bottleneck housing 101 with filtration layers like gravel 173 , sand 174 , charcoal 175 and a cheesecloth or coffee filter 176 to filter water contaminants, can interconnect with an intake/outtake port 137 of the gas storage chamber 125 so moisture 138 can be directed into the water filtration system 136 to supply filtered water 177 that accumulates over time, enabling the system 100 to not only relate to the field of energy production, conservation, and transference but also relate to the field of water collection, conservation, and transference.
[0086] The magnetic induction generators 140 produce electricity by absorbing kinetic pressure from the drive bar; wherein the kinetic pressure is transferred into movement of a magnet 141 back and forth inside of an induction coil 142 . Each magnet 141 magnetizes a metal bar 145 that works with a first spring 143 to reset the metal bar 145 back to its original position and reciprocate the kinetic pressure. Magnets can be separated by magnetic shielding divider or wall 147 to prevent magnetic interference. The generator can include an optional second spring 146 if necessary, to assist in reciprocating the weight of the combined magnet and metal bar. The first spring 143 is located on a side of the magnet 141 opposite of the optional second spring 146 . The first spring 143 connects the magnet 141 to the distal end 107 of the barrel housing 101 such that the magnet 141 can travel back and forth within the induction coil 142 . The optional second spring 146 extends away from the adjacent distal end 107 of the housing 101 . The magnet 141 or first spring 143 is responsible for hitting against the drive shaft or bridge bar 106 . It shall be noted that the magnet 141 produces electricity as it traverses back and forth inside the induction coil 142 therein.
[0087] The movement of the magnet 141 back and forth within the induction coil 142 is accomplished by virtue of the first spring 143 and the optional second spring 146 in communication between the drive bar 106 and the distal end 107 of the housing 101 . It shall be noted that as the drive bar 106 traverses back and forth inside of the barrel housing 101 , the housing of the drive bar 118 applies kinetic pressure to the first spring 143 to extend and retract, which causes the magnet 141 to magnetize the metal bar to move back and forth inside of the induction coil 142 thereby producing electricity each time the housing of the drive shaft bar 118 traverses to each distal end 107 . The AC electricity that is produced by the linear or magnetic induction generators are converted to DC by transformers 144 . A transfer control 134 can be used to switch between stored AC, direct AC and direct DC output when stored AC is not presently optional.
[0088] The linear or magnetic induction generators 140 can be aligned in an array—rows and columns—, to trigger each other within their respective stationary sleeves 108 , where distal end housing 101 comprising of a plural of linear generators 140 can be aligned in an array—columns and rows—at the rear of the prior row of linear generator-based distal end sleeve housing 101 ; wherein the rear stem or metal bar 145 of the prior linear generators 140 are elongated as a result of kinetic force applied to push down the metal bar 145 of the linear generator 140 ; wherein the rear stems or metal bars 145 can rest on a secondary drive bar 106 performing as a magnetic divider 147 that rest on magnets 141 of a secondary row of magnetic induction generators 140 so applied kinetic force is transferred from the first row of linear generators 140 to the second row of magnetic induction generators 140 and other rows of linear generators 140 following thereafter. A singular pneumatic pressure input source 139 can allow an array or series of linear or magnetic induction generators 140 to be influenced or triggered to simultaneously produce an electric current discharge or discharged electric current per spring reciprocating cycle.
[0089] The first energy storage 130 can be interconnected with the second energy storage 130 ; wherein electricity produced by the magnetic induction generators 140 can be transferred by a wire 135 to supply electricity to the second electrical energy storage unit 131 —capacitor and/or battery—and then an inverter 128 for electric user energy conversion purposes; while the first electrical energy storage unit 130 stores energy from a portable auxiliary power source 109 , namely a renewable energy source or other source of electric supply, to supply power to the on demand motor 111 of the compressed gas source 126 . That being said, the compressed gas source 126 is commonly a gas compressor that requires electricity from first battery 130 in order to operate a motor 111 to facilitate the compression and storage of gas.
[0090] The stored gas source 126 which is transferred as pressure (heat) 139 by air hoses 127 using input and discharge valves 133 to and from the gas chamber 125 , which then transfers the compressed gas 126 as pressure (heat) 139 back to the piston diaphragm 124 of the pneumatic pistons 122 . Double-sided, dual-acting pneumatic pistons 122 comprise of a plural of piston rods 124 that can traverse in opposing directions when pressure 139 is introduced into their gas chambers 125 can include a spring 123 coupled with a piston 124 . Pneumatic pistons 122 are positioned at the center of the distal ends 107 of the housing 101 as a drive assembly to reciprocatingly convert high ratio of stored pressure (heat) 139 stored within the gas chamber 125 to enable the mechanical motion of the piston rods 124 as air hoses 127 connect to input and discharge valves 133 of pneumatic pistons 122 , which is namely a pneumatic force component with an internal that includes a gas storage chamber 125 with valves 133 located at each distal end 107 that use a piston rod wall 120 in the gas storage chamber 125 as a pressure (heat) divider for each distal end 107 of the gas storage chamber 125 with input and discharge valves 133 , allowing chamber 1 to be the numerical reference for the front gas storage chamber 125 of the piston and chamber 2 to be the numerical reference for the opposing gas storage chamber 125 of the piston 122 . The relay or control module 129 directs pressure 139 to respective air hoses 127 to supply pressure 139 to respective distal end gas storage chambers 125 of the piston 122 to traverse the piston rod 104 . As the front gas storage chamber (chamber 1 ) 125 is supplied pressure, making the opposing gas storage chamber (chamber 2 ) 125 of the piston 122 discharge pressure 139 back to the release valve 133 located at the relay or control module 129 by using air hoses 127 to input and discharge pressure 139 . The wall of a rod 120 separates the single gas chamber 125 of the piston 122 into two adjacent gas storage chambers 125 in order for pressure (heat) 139 to input one side of the gas storage chamber 125 , which will discharge pressure 139 in the adjacent gas storage chamber 125 to traverse the piston rod 124 or rod wall 120 . The volume of gas source 126 compresses on one end of the piston rod 124 or rod wall 120 while expanding it as pressure (heat) 139 on the opposing end to traverse the rod 124 back and forth in a push and pull manner in a certain direction. Pneumatic pistons 122 are designed with a gas input and discharge valves 133 that are supplied gas 126 as pressure 139 by air hoses 127 that make up the valve system comprising of electromagnetic solenoids and standard valves 133 that is interconnected with the gas storage source 126 . Each gas storage chamber 125 is designed with either a valve 133 for gas input/discharge processes or a combined gas storage chamber 125 and spring 123 configuration where pressure 139 is applied to one end of the piston 124 , facilitating the spring 123 to first retract then extend back to its original position. The pressure 139 input on one side of the piston 124 enables pressure (heat) 139 to be discharged on the other end of the piston 124 if the pneumatic piston has two gas chambers 125 with two valves 133 , or if the pneumatic piston 122 has a pressure (heat) 139 and spring 123 configuration, then a single valve 133 can be used to input and discharge gas 126 to move the rod 104 forth while the spring 123 is used to apply opposing force as it retracts and extends, thereby applying opposing force from using the inner surface 105 of the pneumatic piston 122 . There will be sequential pressure discharging on one side of the pneumatic piston rod 104 to traverse or push and pull the piston rod 104 to achieve sequential movement in the opposite direction. The rod 104 or rod wall 120 is linked to the internal piston 124 . The piston 124 interconnects with piston rods 104 that interconnect with the drive bar 106 . Pressure (heat) 139 released or regulated to centered pneumatic pistons 122 by relay or control module 129 that uses manual or automatic activation relay controllers 132 that are positioned at each distal end of the barrel housing 101 to release pressure 139 that will move piston rod 104 a certain length 102 until the pressure (heat) 139 is discharged out a discharge valve 133 to facilitate the sequence of pressure input and discharge provided by either stored compressed heat gas source 126 or other acting on the piston 124 to achieve movement in the opposing direction to traverse the rod 104 , thereby traversing the drive bar 106 to promote pneumatic force storage manipulation onto distal end drive assembly of the housing 101 that includes a relay controller switch 132 and a plural of linear generators or a pneumatic timing release relay or control module 172 and no relay controller 132 . Opposing each other, each side of the gas storage chamber 125 that are located within the pneumatic pistons 122 that are located at the center or midpoint of each distal end 107 of the piezoelectric housing 101 is directed pressure 139 to traverse the rod walls 120 of each plural of double-sided, dual-acting pneumatic pistons 122 simultaneously. The specification of the piezoelectric housing 101 includes midpoint double-sided, dual-acting pneumatic pistons 122 that have opposing piston rods 104 that face each distal end 107 . With internal numerical references (chamber 1 ) and (chamber 2 ) of the pneumatic piston 122 , when traversing the rod wall 120 of the piston in one direction, this process requires pressure 139 directed by air hoses 127 that are interconnect with valves 133 to simultaneously fill not only the gas storage chambers 125 (chamber 2 ), which will carry the discharged pressure 139 out of the system 100 using air hoses 127 to release the pressure 139 out of the relay exit valve 133 in order to prepare for the respective discharge of pressure 139 out of the originally-filled gas storage chamber 125 (chamber 2 ) in order to fill the opposing gas storage chamber 125 (chamber 2 ) so the piston 124 will motion in a reciprocating manner to move and then reset itself to its original position as pressure 139 is input and discharged out the release valve 133 of the relay or control module 129 using either optional pneumatic timing release relay or control module 172 or manual relay controllers 132 with conventional relay or control module 129 .
[0091] It shall be noted that each midpoint between the distal ends 107 of the housing 101 may include at least one double-sided, dual-acting pneumatic piston 122 , while the distal end 107 of the housing 101 may include at least one magnetic induction generator 140 per distal end 107 .
[0092] The invention 100 may include manual action controllers 132 that are positioned at both distal ends 107 of the housing 101 . The manual action relay controllers 132 operate manually thru piezoelectric means when force is applied to their trigger which sends a command to the relay or control module 129 that regulate the released direction of the compressed gas 126 to pneumatic pistons 122 located at midpoint between the distal ends 107 . Optional automatic relay or control module 129 that works on a timing release relay or control module 172 instead of using distal end relay controllers 132 to input and discharge pressure 139 to and from pneumatic pistons 122 using air hoses 127 interconnected with the relay or control module 129 and to valves 133 on the pneumatic pistons 122 . Pneumatic timing release relay or control module 172 releases gas 126 as pressure 139 to air hoses 127 on a timing release control based on timing action that can continue to do over until ceased by removing current from its coil 142 with time.
[0093] The essential characteristics of the compressed gas and storage invention or apparatus is as followed: a combined heat and power system, the reciprocating bar-based barrel direct energy transferor is designed to work in conjunction with external auxiliary power sources renewable energy sources or other sources of electric supply to generate compressed gas; wherein the compressed gas resource can then be utilized to apply kinetic pressure to an alignment or plural of linear or magnetic induction generators to produce high energy densities and store the electricity for electric users, enabling the device to function as a portable generator and power station since its design allows it to store the energies of independent renewable auxiliary energy sources and apply a fraction of the accumulated energy to generate compressed gas with high volumes of pressure to trigger a plural of novel generators that are standing by at each distal end. In summation, the gas driven generator and storage system collects renewable energies, generates electricity and stores power in all sizes, making it appropriate for multiple applications, including handheld power, home power, regional power and EV-to-grid.
[0094] The barrel housing configuration includes a bar that uses compressed gas to traverse back and forth in order to transfer kinetic pressure to a drive assembly configuration of linear or magnetic induction generators and relay controllers provided at distal ends of barrel housing. The interior of the housing is outfitted with double-sided, dual-acting pneumatic piston positioned at the center or midpoint between the distal ends of the housing, where the pistons house rods that simultaneously traverse a plural of drive bars into linear generators to produce electricity as pressure is supplied and discharged to the internal gas chambers of the pistons to traverse the opposing piston rods simultaneously towards their distal end generators. This design will enable the pneumatic pistons to utilize compressed gas to facilitate movement of the piston rods. A drive bar is used as a bridge to interconnect one piston rod to the other. The drive bars allow for the two pneumatic pistons positioned at midpoint between the distal ends of the piezoelectric housing to work in sequential unison when applying kinetic force to distal ended linear or magnetic induction generators.
[0095] In addition, the linear or magnetic induction generators can be aligned in an array—rows and columns—, to trigger each other, where distal end housing comprising of a plural of linear generators can be aligned in an array—columns and rows—at the rear of the prior row of linear generator-based distal end sleeve housing. The rear stem or bars of the prior linear generators are elongated as a result of kinetic force applied to push down the metal bar of the linear generator. The rear stems or bars can rest on a secondary drive bar or magnetic divider that rest on magnets of a secondary row of linear generators so applied kinetic force is transferred from the first row of linear generators to the second row of linear generators and other rows of linear generators following thereafter; wherein a single pneumatic pressure input source will allow an array or series of linear generators to be influenced or triggered to simultaneously produce an electric current discharge or discharged electric current per spring reciprocating cycle.
[0096] The derived electricity from the generators, along with the initial operational energy, which is an auxiliary power source, namely a renewable energy source or other source of electric supply, are then stored into electrical energy storage units. The pneumatic pistons are supplied compressed gas from a compressed gas source, which receives electricity from the first electrical energy storage unit, namely the electrical energy storage unit that receives the initial operational energy, which is an auxiliary power source. In return, upon activation, the pneumatic pistons utilize the compressed gas to apply work to interconnected drive bar inside the barrel housing to awaiting piezoelectric components, namely a plural of linear generators and relay controller that are connected to the relay or control module that regulate gas directional flow. The traversing of the drive bars will continue until either the system activation switch is turned off, or the electrical energy storage units are filled to capacity or the electrical energy storage units are depleted or if the compressed gas resource depletes.
[0097] With respect to the above description, it is to be realized that the optimum dimensional relationship for the various components of the invention 100 , to include variations in size, materials, shape, form, function, and the manner of operation, assembly and use, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the compressed gas energy storage invention 100 .
[0098] It shall be noted and readily recognized that numerous adaptations and modifications which can be made to the various embodiments of the present invention which will result in an improved invention, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents.
|
A combined heat and power system, namely a portable combined heat and power microgrid system with the capacity to convert air to electricity, since the system imparts excess energy derived from multiple electrical energy sources, namely renewables or other sources of electrical supply like gas-induced electrical generation, to produce and store energy as compressed heat that is then redirected to generate reciprocating energy utilizing a barrel housing or setting to promote direct kinetic energy transfer method onto an array of rowed piezoelectric generators that use sequential direct kinetic energy transference to produce electricity and store it in a second electrical storage unit that can be interconnected to the operational electrical storage unit to not only promote redirect electrical flow during peak or off-peak to extend systemic operations but also to promote high volumes of energy from multiple energy sources for electric user purposes, enabling communication with high density energy when stored.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a U.S. Nationalization of, and claims priority to co-pending PCT Patent Application No. PCT/US2014/54887, filed on Sep. 10, 2014, which claimed priority to then co-pending U.S. Provisional Patent Application Ser. No. 61/876,422, filed on Sep. 11, 2013, the content of which is incorporated by reference herein.
TECHNICAL FIELD
[0002] The novel technology relates generally to materials science, and, more particularly, to a high surface area graphene composite material.
BACKGROUND
[0003] Because of the increasing demand of electrical/hybrid vehicles, tremendous effort has been devoted to the development of energy storage devices with high-energy density and good durability. Conventional energy storage devices, for example, batteries, have limitations such as short cycle life, relatively slow charging/discharging currents (i.e. low power), and slow response to fast charging/discharging. Electrochemical supercapacitors have attracted much attention due to their excellent cycling performance, higher power density, and fast response. Supercapacitors are typically one of two types. The first is the interfacial double-layer capacitance with electric charge storage on high-surface-area carbon materials. The second is pseudocapacitance, which is associated with the redox reaction of metal oxides or conducting polymers. Among the pseudocapacitance candidate materials, much effort has been dedicated to the construction of supercapacitors using polyaniline (PANI). PANI has been considered as one of the most promising and versatile conducting polymers for supercapacitor applications because of its high capacitance, low cost, and easy synthesis. Although PANI possesses high theoretical capacitance of 2000 F/g, compared to many other microporous/mesoporous materials, PANI generally has a relatively low surface area, which limits the accessible surface area of PANI for electrolyte ions. PANI also suffers from poor cycling stability caused by swelling and shrinking of the polymer backbone during charging/discharging. These drawbacks greatly hinder the use of PANI as the supercapacitor electrode in practical applications. Thus, there remains a need for improved PANI materials for use in electrode and electrochemical applications. The present novel technology addresses this need.
SUMMARY
[0004] The present novel technology relates to graphene-based composite materials. One object of the present invention is to provide improved graphene-based composite materials for electrochemical capacitors. Related objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic illustration of the process of the preparation of covalently grafted polyaniline-graphene nanocomposit material according to a first embodiment of the present novel technology.
[0006] FIG. 2A is a first photomicrograph of the covalently grafted polyaniline-graphene nanocomposit material of the present invention.
[0007] FIG. 2B is a first photomicrograph of a noncovalently bonded polyaniline-graphene nanocomposit material.
[0008] FIG. 2C is a second photomicrograph of the covalently grafted polyaniline-graphene nanocomposit material of the present invention.
[0009] FIG. 2D is a third photomicrograph of the covalently grafted polyaniline-graphene nanocomposit material of the present invention.
[0010] FIG. 3A is a graphical representation of intensity vs. Raman shift for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0011] FIG. 3B is a graphical representation of intensity vs. Binding energy for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0012] FIG. 4 is a graphical representation of weight percentage vs. temperature for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0013] FIG. 5A is a first TEM photomicrograph of graphene oxide.
[0014] FIG. 5B is a first photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0015] FIG. 5C is a second photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0016] FIG. 5D is a third photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0017] FIG. 5E is a fourth photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0018] FIG. 5F is a fifth photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0019] FIG. 5G is a sixth photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0020] FIG. 5H is a seventh photomicrograph of a covalently graphed polyaniline-graphene composite material.
[0021] FIG. 6A is a graphical representation of N 2 absorption volume vs. relative pressure for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0022] FIG. 6B is a graphical representation of derivative pore volume vs. pore size for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0023] FIG. 7A is a graphical representation of specific current vs. potential for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0024] FIG. 7B is a graphical representation of Z″ vs. Z′ for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0025] FIG. 8A is a graphical representation of galvanostatic discharge curves for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0026] FIG. 8B is a graphical representation of specific capacitance as a function of total weight for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0027] FIG. 8C is a graphical representation of specific capacitance vs. current density for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0028] FIG. 8D is a graphical representation of capacitance retention as a function of cycling for covalently graphed polyaniline-graphene composite material and aniline-functionalized graphene oxide material.
[0029] FIG. 9 is a graphical overlay of the structure of the covalently graphed polyaniline-graphene composite material on a photomicrograph of the same.
[0030] FIG. 10 is a schematic diagram of a supercapacitor system employing the composite material of FIG. 1 as an electrode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] For the purposes of promoting an understanding of the principles of the invention and presenting its currently understood best mode of operation, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, with such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0032] Recently, graphene, a single-atom-thick honeycomb structure of sp2-hybrized carbon atoms, has attracted attention due to its high surface area, mechanical strength, conductivity, and stability. These properties render graphene extremely promising for electrochemical energy storage, especially supercapacitors. A great deal of interest has been paid to graphene oxide (GO). GO can be produced by the chemical treatment of graphite through oxidation and subsequent exfoliation in water into single-layer sheets by mechanical agitation. The polar oxygen-containing functional groups (epoxide hydroxyl, carboxyl, and the like) render GO strongly hydrophilic and dispersible. Existing surface functionalities on GO can contribute to some pseudocapacitance as supercapacitor electrodes. Moreover, the existence of various functionalities on GO allows further modification to fabricate composite materials for different applications. For instance, graphene/PANI nanocomposites have been prepared by mechanical mixing, in situ electropolymerization, noncovalent functionalization, and a covalent grafting method via acyl chemistry. The synergistic effect between PANI and graphene/GO can significantly enhance the performance of the resulting composites. However, without carefully controlling the synthetic route, a phase separation between PANI and graphene/GO may occur, which greatly decreases this synergistic effect.
[0033] As illustrated in FIGS. 1-10 , the present novel technology relates to a simple three-step route to achieving covalently-grafted polyaniline (PANI)/graphene oxide (GO) nanocomposites 10 . The synthesized composites 10 typically have a uniform hierarchical morphology of the PANI thin film 15 as well as short nanorods 20 densely grown on the GO sheets 25 , in contrast to the nonuniform morphology of noncovalently-grafted PANI/GO. Due to the introduction of GO, the covalently-grafted PANI/GO composites 10 typically exhibit higher surface area and larger pore volume compared with PANI alone. These features enable the increased exposure of PANI to the electrolyte ions, resulting in a more accessible PANI surface for redox reaction species and faster ion transport. The PANI utilization is thus increased, resulting in excellent electrochemical performance (capacitance 442 F/g of PANI/GO (6:1) vs. 226 F/g of pure PANI) and improved cycling stability (83% @ 2000 cycles of PANT/GO (6:1) vs. 54.3% @ 1000 cycles of pure PANI) in electrochemical capacitors utilizing the same. Excellent electrochemical performance demonstrates the advantage of the PANI/GO composites 10 prepared via this covalent grafting method.
[0034] In the present novel technology, a facile chemical route is utilized to prepare covalently-grafted PANI/GO nanocomposites 10 using in-situ polymerization of aniline initiated on aniline-functionalized GO sheets. This technique involves first the functionalization of GO with p-phenyldiamine via a diazonium reaction, followed by an in-situ polymerization of aniline in the presence of aniline-functionalized GO, an acid dopant, and an oxidant ammonium persulfate (APS). The prepared covalently-bonded PANI/GO composites exhibited a hybrid morphology, which consists of PANI thin film grown on GO nanosheets with densely vertically-grown PANI nanorods on the GO. The unique structure of this composite material is expected to maximize the synergistic effect between PANI and GO, leading to enhanced performance in supercapacitor electrodes.
[0035] The three-step technique 90 for the preparation of covalently-grafted PANI/GO nanocomposites 10 from natural graphite flakes and an aniline monomer is illustrated in FIG. 1 . GO was first prepared by the oxidative exfoliation 100 of natural graphite flakes using a modified Hummer's method. Then the surface of the GO 25 was functionalized 110 with aniline groups via a diazonium reaction. The surface functionalization of carbons with aryl diazonium salts has been demonstrated previously. Finally, covalently-grafted PANI/GO nanocomposites 10 were synthesized by in-situ polymerization 120 of aniline in the presence of aniline-functionalized GO, an oxidant, and an acid dopant at room temperature for 8 hours. Several covalently-grafted PANI/GO composites 10 were synthesized with different aniline/GO weight ratios, ranging from 1:1 to 10:1. In comparison, noncovalently-grafted PANI/GO was also prepared under the same conditions, except pristine GO was used. Scanning Electron Microscopy (SEM) was carried out to examine the morphology of both the covalently-grafted composites 10 and the noncovalently-grafted PANI/GO composites (aniline/GO ratio of 10:1). The covalently-grafted PANI/GO 10 exhibited a homogeneous hierarchical morphology of a layered structure and vertically grown nanorods densely packed on the graphene plane ( FIGS. 1A, 1C, 1D ). Although there exists a small portion of similar hybrid morphology in noncovalently-grafted PANI/GO, the phase separation between PANI and GO is demonstrated by the presence of the PANI aggregates (as the arrow indicates in FIG. 1B ). The formation of a different morphology can be explained by the classic nucleation theory. According to classic nucleation theory, homogeneous nucleation occurs when a supersaturation of nuclei at a critical size is achieved. As the PANI grows into a critical size, the nucleation between oligomer/polymer nuclei may occur, followed by further aggregation and precipitation of PANI aggregated particles. In the case of the polymerization 120 of aniline on nonfunctionalized GO 25 , a small portion of PANI nuclei might have been initially formed near the surface of the GO 25 due to the static attraction force and van der Waals force; although, many more nuclei were involved in the solution. Thus, as the polymerization proceeded, nucleation occurred simultaneously on the PANI nuclei that were formed either near the GO or in the solution, leading to the formation of two distinct morphologies ( FIG. 1B : PANI/GO hierarchical structure and PANI aggregates). While synthesizing the covalently-grafted PANI/GO 10 , the polymerization 120 of aniline was initiated on the aniline-functionalized GO surface 25 , resulting in a large number of active nucleation sites. Further nucleation mostly took place on these active nucleation sites, resulting in the morphology of the layered structure and a much more uniform distribution of vertically grown PANI nanorods 20 .
[0036] To validate successful functionalization, GO 25 , PANI 15 , aniline-functionalized GO, and covalently-grafted PANI/GO composites 10 were characterized by Raman spectroscopy and X-ray photoelectron spectroscopy (XPS). The Raman spectrum of the as-prepared GO displays two prominent peaks at 1330 and 1590 cm −1 . The G band at around 1590 cm −1 can be ascribed to sp 2 carbons, and the D band at about 1320 cm −1 is indicative of the disordered aromatic structure of the sp 2 carbons. This disorder can be caused by surface defects, edges, or by the formation of sp 3 bonds, as observed in graphene functionalization. The intensity ratio of the D and G band, I D /I G , is commonly used to determine the defect quantity in graphene materials. In pristine GO, the I D /I G was calculated to be about 0.89. After the diazonium reaction, the I D /I G of aniline-functionalized GO increased to 0.95, indicative of the sp 2 carbon functionalization as a result of the covalent attachment with the aniline groups. Pristine PANI has characteristic peaks at around 800, 1160, 1325, 1466, and 1589 cm −1 , which can be attributed to ring deformation of the benzene/quinoid rings, C—H bending of the benzene ring, protonated C—N stretching, C=N stretching, and C═C stretching of the benzene/quinoid ring, respectively. In PANI/GO composites 10 , only three characteristic peaks of PANI at 1165, 1328, and 1592 cm −1 are present. The missing two peaks could be caused by the overlapping of two major peaks of PANI at 1325 and 1589 cm −1 with those of GO around 1330 and 1590 cm −1 . It is possible that the Raman peaks of PANI superimposed on the GO structures is due to the strong interaction between the PANI polymer backbone and the GO nanosheets via π-π stacking. Further, the atomic composition of the samples as analyzed by XPS and the comparative results are shown. Compared to pristine GO, the presence of N (1.8%) in aniline-functionalized GO evidenced successful diazonium functionalization. In addition, a large peak of N is can also be observed in the XPS spectrum of the PANI/GO composites 10 , suggesting the presence of PANI. The N composition in the resulting composites 10 determined by XPS can be used to estimate the weight percentage of PANI (Table Si). For example, about 44.3 wt % and 93.5 wt % PANI was determined in the composites prepared with the aniline-to-GO ratio of 1:1 and 10:1, respectively. This is consistent with the weight ratios that were used in the synthesis.
[0037] The thermal stability of GO and covalently-grafted PANI/GO composites 10 was examined by thermogravimetric analysis (TGA), shown in FIG. 3 . GO is thermally unstable in air above 100° C., which is due to the removal of water residues and pyrolysis of existing oxygen-contain groups. Polyaniline generally exhibits two stages of decomposition. The decomposition before 290° C. is likely due to the loss of moisture and dopant (i.e. HCl). PANI main chains start to decompose above 290° C. The covalently-grafted PANI/GO composites showed typical decomposition stages of weight loss similar to PANI, indicating the successful polymerization of PANI on GO surfaces. Interestingly, the covalently-grafted composites exhibited better thermal stability, which could be attributed to the strong interaction resulting from the π-π stacking force between the GO basal plane and the PANI backbone, and the covalent bonding between the GO and PANI end chains. All of the covalently-grafted composites exhibited slightly better stability ( FIG. S2 ). In contrast, the TGA curve of the noncovalently-grafted composites was similar to that of pure PANI, probably due to the weak synergistic effect resulting from the phase separation between GO and PAN'.
[0038] The morphology of the composites synthesized from different ratios was further investigated by SEM and transmission electron microscopy (TEM), as shown in FIG. 4 . The TEM images of GO ( FIG. 4A ) and PANI ( FIG. 4H ) showed flat graphene sheets with some wrinkles and aggregated nanofiber morphology, respectively. A hierarchical structure of layered nanosheets and aligned short PANI nanorods was observed in all samples, consistent with the SEM results in FIGS. 1A, 1C, 1D . It can be seen that length and diameter of the nanorods increased with the PANI content in the composites ( FIGS. 4B-G ). This can be explained by the nucleation theory mentioned above. A large number of active surface nucleation sites were first formed on the aniline-terminated surface. The nucleation mainly occurred on these nucleation sites. The polymerization of aniline continues to propagate on the existing PANI nuclei. Once the aniline in the solution was consumed, the polymerization ended. At a lower aniline/GO ratio (i.e. 1:1), a thin film of PANI on the GO nanosheets forms due to the low aniline/GO ratio and the strong interaction between PANI and GO. At a higher aniline/GO ratio (4:1, 6:1, 8:1), further nucleation may take place on the existing PANI thin film, resulting in the vertically-aligned PANI nanorods. This variation in morphology may lead to the different pore structures of these composites.
[0039] To assess the porosity of the covalently-grafted PANI/GO composites, N 2 adsorption-desorption isotherms were measured by a surface area analyzer at 77 K. The N 2 adsorption-desorption isotherms and the pore size distribution of the as-prepared composites with different PANI contents are shown in FIG. 5 . The pure PANI possesses a broad pore size distribution ranging from 0.8 nm to 36 nm. PANI shows a specific surface area of 38 m 2 /g, pore volume of 0.32 cm 3 /g, and an average pore size of 57.6 nm. Compared to PANI, the covalently-grafted composites exhibit a similar range of pore size, while showing a much higher surface area and larger pore volumes ( FIG. 5 , Table 1). The total pore volume and the micropore volume increase, and the average pore size decreases as the GO nanosheets are incorporated. The PANI/GO composites (1:1) have a specific surface area of 127 m 2 /g, a pore volume of 0.56 cm 3 /g, and an average pore size of 37.5 nm. It is expected that the large pore volumes of the composites allow rapid electrolyte ion transport, while the high surface area provides the composites with more surface active sites for pseudocapacitance.
[0040] To evaluate the advantages of using covalently-grafted PANI/GO nanocomposites 10 as a supercapacitor electrode 150 , the electrochemical properties of PANI, GO, and PANI/GO were characterized by cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS), and a galvanostatic charge/discharge test. FIG. 6A shows cyclic voltammograms (CVs) of the PANI and covalently-grafted PANI/GO (8:1) in 1 M H 2 SO 4 with various scan rates in the range of −0.1 to 0.8 V vs. Ag/AgCl. As shown in FIG. 6A , the capacitance of GO is very small compared to PANI and PANI/GO, due to the low surface area of GO caused by the restacking between the GO sheets. The typical PANI redox peaks (about 0.1 and 0.6 V) are clearly seen in FIG. 6 . Both the PANI and PANI/GO composite electrodes exhibit similar pairs of redox peaks, which can be ascribed to the faradaic transition between the different oxidation states of PANI (leucoemeraldine, emeraldine, and pernigraniline). The shape of the CV curve of the PANI/GO composites also indicates that the composites can provide both faradic capacitance and double-layer capacitance, which results from the unique hierarchical structure of the composites. Clearly, the CV curve of the PANI/GO composites is much larger than that of the pure PANI, indicating a higher specific capacitance. To obtain a comprehensive understanding of the capacitive response of the PANI/GO composites, an electrochemical impedance test was conducted and the results are shown in FIG. 6B . The small diameter of the semicircle of the PANI/GO composites in the high frequency region represents the low charge transfer resistance at the interface between the electrode and electrolyte. The nearly vertical arm of the AC impedance in the low frequency region indicates an excellent capacitive behavior, representative of fast ion diffusion and adsorption in/on the electrode material. The low resistance and fast ion diffusion can be attributed to the enhanced specific surface area and the pore structure of the PANI/GO composites which may render this composite material very promising as a supercapacitor electrode.
[0041] The three-electrode 150 configuration can exaggerate the performance of supercapacitors 160 to some extent. A two-electrode 150 test configuration, instead, is the best method to evaluate the real performance of a supercapacitor system 140 . Thus, galvanostatic charge-discharge measurements were also taken in a two-electrode 150 system at various current densities for different PANI/GO composites 10 . The influence of the aniline/GO ratio on the specific capacitance was studied by galvanostatic charge/discharge at a current density of 2 A/g. The nonlinear charge/discharge curves indicate the pseudocapacitive behavior of the composites. All PANI/GO composites showed a higher capacitance compared to pure PANI (185 F/g), with the highest capacitance (379 F/g) found in the composites prepared at an aniline/GO ratio of 6:1 (81.3 wt % PANI). The specific capacitance of the PANI/GO composites was determined to increase with the GO content in the composites, maximize, and then decrease. The increase in the capacitance is mainly due to the larger surface area of the composites. The further decrease is probably caused by the decrease in the PANI content. For example, although PANI/GO (4:1) exhibited a slightly higher surface area (115 m 2 /g) than the PANI/GO (6:1) (105 m 2 /g), the lower PANI content in the composites (70.1 wt % PANI) is likely to reduce the overall pseudocapacitance. Galvanostatic charge-discharge measurements were also taken at various current densities for the PANI and PANI/GO (6:1) electrodes 150 . The corresponding specific capacitance values from the discharge curves based on the mass of active materials is summarized and shown. At a current density of 1 A/g, the specific capacitance of PANI and PANI/GO (6:1) is 226 and 422 F/g, respectively. Even at a high current density of 10 A/g, the PANI/GO (6:1) composite electrodes still maintain a specific capacitance of 265 F/g. The specific capacitance of PANI/GO composites 10 against PANI weight can be estimated based on the weight percentage of PANI in the composites 10 . Considering most GO sheets were fully coated by PANI, the capacitance contributed by the GO is neglected here. The specific capacitance of PANI/GO 6:1 (70.1 wt %) against the weight of PANI is calculated to be about 603 F/g at a current density of 1 A/g. For PANI/GO 1:1 (44.3 wt %), the specific capacitance based on the weight of PANI is 783 F/g, which is comparable to the thin PANI film deposited on the graphene hydrogels. IR drop can significantly reduce the energy density and power density of a supercapacitor electrode. Much lower IR drops were observed for the covalently-grafted PANI/GO composites during the charge/discharge tests, indicating low contact resistance and diffusion resistance ( FIG. S7 ). An energy density of 9.6 Wh/kg (1 A/g) and a power density of 3468 W/kg (10 A/g) can be delivered by PANI/GO (6:1) composites, as compared to 4.5 Wh/kg (1 A/g) and a power density of 2945 W/kg (10 A/g) in pure PANI. The higher energy density and power density can be attributed to the increased surface area and pore volume in the composites, allowing a more accessible surface area to the redox species and a faster ion transport within the electrode. The PANI/GO composite electrodes also exhibited good cycling stability. PANI supercapacitors usually suffer from a short cycle life due to the swelling and shrinking of the polymer network during charging and discharging processes. As shown in FIG. 7D , the capacitance retention of PANI decreased to only about 54.3% after 1000 charge/discharge cycles at a current density of 2A/g. In comparison, our PANI/GO (6:1) composite electrodes showed a capacitance retention as high as 8 3 % over 2000 cycles under the same charge/discharge condition. The excellent cycle life could be attributed to the large surface area and pore volume from the unique hierarchical structure, which can accommodate the swelling and shrinking of the polymer network during cycling. The covalent bonding and the strong π-π interaction between the GO and PANI may also play a role in maintaining the electrochemical stability of PANI. Excellent electrochemical performance demonstrates the advantage of the PANI/GO composites prepared via this covalent grafting method.
[0042] Regarding the three-step synthesis 90 to prepare covalently-grafted PANI/GO nanocomposites 10 from natural graphite and aniline at room temperatures, covalently-grafted composites 10 formed a uniform hierarchical morphology of PANI nanorods grown on planar GO sheets, in contrast to a nonuniform morphology of nongrafted composites. Compared to pure PANI, the PANI/GO composites 10 possessed a much larger specific surface area and pore volume, which increased the accessible surface area for the redox reaction and allowed faster ion diffusion. This unique hierarchical morphology maximized the synergistic effect between PANI and GO, leading to an enhanced performance as a supercapacitor electrode. The PANI/GO composites prepared with an aniline/GO ratio of 6:1 showed the highest capacitance of 422 F/g at a current density of 1 A/g. The capacitance can be retained at about 83% after 2000 cycles. These covalently-grafted PANI/GO composite materials 10 may be useful for broad applications including energy storage, sensors, biosensors, and catalysis. This facile covalently-grafting method may be utilized to fabricate many other high-performance composites.
EXAMPLES
[0043] Synthesis of GO: GO was prepared by a modified Hummer's method. To completely oxidize the graphite, a pre-oxidization was needed prior to the Hummer's method. Graphite flakes (2 g) were mixed with concentrated H 2 SO 4 (10 mL), K 2 S 2 O 8 (1 g), and P 2 O 5 (1 g). The resulting mixture was constantly stirred, heated at 80° C., and then gradually cooled down to room temperature. The pre-oxidized graphite was filtered, washed with DI water, and dried in an oven at 80° C. This pre-oxidized graphite was then subjected to oxidation by the Hummers' method. The pre-oxidized graphite (2 g), sodium nitrate (1 g), and sulfuric acid (46 mL) were mixed and stirred for 15 min in a 500 mL flask immersed in an ice bath. Potassium permanganate (6 g) was slowly added to the above suspension solution and cooled for another 15 min. Then, DI water (92 mL) was added slowly to the suspension, causing a violent effervescence. The temperature was maintained at about 95-98° C. for 15 min. The suspension was diluted with warm DI water (280 mL) and treated with 30% H 2 O 2 (10 mL) to reduce the unreacted permanganate. Finally, the resulting suspension was washed by centrifugation with HCl and copious DI water to remove residual salts. Then, the GO dispersion solution was subjected to another centrifugation at 5000 rpm for 5 min to remove the unexfoliated GO. The purified GO was dispersed in DI water at a concentration of 1 mg/mL and sonicated for 1 h to exfoliate the GO. The resulting GO colloid solution is able to remain stable for a few months.
[0044] Aniline functionalization of GO: P-phenylenediamine (8 mmol) and H 2 SO 4 (8 mmol) was dissolved in the GO solution (500 mL). A 5 mL solution containing NaNO 2 (8 mmol) was added dropwise to the solution. The solution was stirred and heated at 65° C. for 4 h. The resulting aniline-functionalized GO was centrifuged, washed with DI water, and freeze dried. Synthesis of covalently-grafted PANI/GO nanocomposites: The aniline-functionalized GO (100 mg), the aniline monomer (at different aniline/GO ratios), and the HC 1 was dispersed in DI water (100 mL). A solution of the oxidant, (NH 4 ) 2 S 2 O 8 (APS), was rapidly added into the above dispersion. The molar ratio of aniline:APS:HCl was kept at 1:0.5:2. The solution was vigorously shaken for 10 s and left undisturbed to react for 24 h. After the reaction was completed, the precipitated product was filtered, washed with DI water, and dried. For comparison, the nongrafted PANI/GO composites were synthesized following the same procedure, except that pristine GO was used.
[0045] Characterization: The morphology of the graphene and the graphene-PANI nanocomposites was characterized by TEM and SEM. Raman spectra were also taken by spectrometer with laser excitation at 785 nm. The XPS spectra were recorded by an X-ray photoelectron spectrometer. TGA curves were also obtained using. The N 2 adsorption/desorption isotherms were measured at 77 K. The Brunauer-Emmett-Teller (BET) specific surface area was calculated using adsorption data at the relative pressure range of 0.05-0.2. The micropore volumes were estimated from the amount adsorbed at a relative pressure (P/Po) of 0.25. The total pore volumes were estimated from the amount adsorbed at a relative pressure (P/Po) of 0.99. The pore size distribution, average pore size, and DFT pore volumes were calculated based on the NLDFT model on carbon at 77 K assuming the slit pore geometry. The standard error of the fitting using the NLDFT model was less than 2%.
[0046] Electrode fabrication and electrochemical tests: For the three-electrode electrochemical test, the supercapacitor electrode was prepared by casting the slurry containing 80% active materials, 10% SuperP, and 10% Polyvinylidene fluoride (PVDF) in 1-methyl-2-pyrrolidone (NMP) onto the surface of a glassy carbon electrode. After drying the electrode in an oven at 60° C., the electrochemical measurements were carried out in 1 M H 2 SO 4 . A platinum sheet and a saturated Ag/AgCl electrode were used as the counter and the reference electrode, respectively. Cyclic voltammetry was performed for the two-electrode configuration. The slurry containing 80% active materials, 10% SuperP, and 10% PVDF in NMP was pasted onto the Pt foil. The electrodes were dried in a vacuum oven at 60° C. for 24 h. A filter membrane, immersed in 1 M H 2 SO 4 for 1 h, was used as the separator. Then the cell was tightly clamped. The galvanostatic charge/discharge tests were performed on a battery test station. The material-based specific capacitance was calculated from the discharge curves by the following relation: C=2It/(mV), where I is the charge/discharge current, t is the discharge time, m is the mass of the active materials on each electrode, V is potential after the deduction of the IR drop. The energy density and the power density were calculated using the equations: energy density E=⅛CV 2 and power density P=IV/(2m).
[0047] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the invention are desired to be protected.
|
A method for synthesizing a graphene-polyaniline hybrid composite, including oxidatively exfoliating natural graphite flakes to yield a graphene body, functionalizing the surface of a graphene substrate with aniline groups wherein the surface of the graphene body is functionalized with aniline groups via a diazonium reaction, and polymerizing the aniline groups, wherein covalently-grafted polyaniline-graphene nanocomposites are formed by in-situ polymerization of aniline in the presence of aniline-functionalized graphene oxide, an oxidant, and an acid dopant.
| 7
|
FIELD OF THE INVENTION
The present invention relates to warning lights for emergency motor vehicles used by police, fire departments and the like to warn the public of dangerous conditions and, more specifically, to warning lights of the foregoing type that oscillate a light beam.
BACKGROUND OF THE INVENTION
Studies indicate that the primary area of danger for an emergency vehicle moving along a roadway is an intersection with another roadway. In order to address this danger, warning devices have been developed intended to alert vehicles moving along the intersecting roadway of the emergency vehicle as it approaches and enters the intersection. Typically, these warning devices include a light whose intensity light varies in a manner that draws attention to the light and the associated emergency vehicle even though the environment of the vehicle and the warning device is filled with other stimuli that compete for the attentions of nearby observers.
Several different approaches are well known for realizing the variable intensity required of such warning lights. For example, it is well known to use flashing lights such as strobe lights for warning devices. It is also known to use rotating or oscillating light beams that appear to an observer as the beams sweep past the observer.
Although rotating light beams are characterized by the type of high intensity useful at intersections, much of the light energy is directed away from the intersection inasmuch that the light beam rotates a full 360°. Conventional stationary warning lights are unable to direct high energy flashes over a sufficiently large area required at an intersection. Oscillating light beams, however, are capable of directing a relatively constant, high energy signal over an area determined by the sweep angle of the beam. In conventional devices of this type, the sweep angle is limited and typically is less than to approximately 120°. An example of such an oscillating light can be found in U.S. patent application Ser. No. 07/592,670, to Stanuch et al., filed Oct. 4, 1990. Although larger effective sweep angles can be created if two or more oscillating lights are ganged together, a larger sweep angle for a single oscillating beam is desirable.
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a warning light assembly that provides an oscillating light beam that can be swept through an angle that approaches and may exceed 180°. In this connection, it is a related object of the present invention to provide a warning light assembly that achieves the foregoing object while maintaining a simple construction that is inexpensive to manufacture and is highly reliable.
It is also an object of the present invention to provide a warning light assembly that oscillates a light beam through approximately 180° or more while maintaining a relatively compact size.
Yet another object of the present invention is to provide a warning light assembly that can be easily modified to provide an oscillating light beam that sweeps out any desired angle. In this connection, it is a related object of the invention to provide the foregoing versatility while maintaining a simple, inexpensive mechanical construction for the warning light assembly.
In accordance with the foregoing objects, an oscillating warning light for an emergency vehicle is provided that comprises three gears rotatably mounted to spindles of a base assembly for driving an oscillating light beam assembly, where the first gear rotates in one direction and the second and third gears are in synchronized oscillation driven by a reciprocating motion imparted to them by the first gear. The first and second gears are coupled by a crank that converts the rotary motion of the first gear to the reciprocating motion that drives the oscillation of the second and third gears. The third gear is associated with the light beam assembly for moving a light beam through an angle β while the second gear reciprocates through an angle Θ, where the angle β is greater than the angle Θ and the ratio of the two angles is inversely proportional to the radius of the second and third gears.
More specifically, a D.C. motor provides a drive for a worm and worm gear assembly that rotates in one direction and provides a means for reducing the speed of the drive. A first spur gear having a diameter D 1 is coupled to the worm gear by a crank that converts the rotary motion of the worm gear to a reciprocating movement for driving the oscillation of the first spur gear. A second spur gear having a diameter D 2 is driven by the first spur gear, and the second gear is rotatably mounted to be coaxial with a rotatable light beam assembly. Preferably, the second spur gear and the light beam assembly form a single assembly mounted to a spindle on the base of the warning light. The second spur gear and light beam assembly oscillate through an angle β, whereas the first spur gear oscillates through an angle Θ, which is less than the angle β and less than 180°. Because the ratio of the angles through which the two spur gears oscillate is inversely proportional to their diameters D 1 and D 2 , the angle β can be made virtually any value, but must be greater than the angle Θ assuming that D 1 is greater than D 2 , by selecting the appropriate relative values for the diameters.
Other objects and advantages of the invention will become apparent upon reference to the following detailed description when taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a warning light assembly in accordance with one embodiment of the invention;
FIG. 2 is an exploded view of the warning light assembly of FIG. 1, clearly illustrating the construction of the assembly;
FIG. 3 is an isolated planar view of a three-gear drive train for the warning light assembly of FIGS. 1 and 2, which according to the invention oscillates a light beam through virtually any angle, depending on the relative sizes of the three gears comprising the drive train; and
FIG. 4 is an exemplary graph illustrating the distribution of flash energy for an oscillating light beam generated by the warning light assembly of FIGS. 1-3, where the light beam oscillates over an angle of 180° at a substantially constant angular velocity.
While the invention will be described in connection with an illustrated and preferred embodiment, there is no intent to limit it to the illustrated embodiment. On the contrary, the intent is to cover all alternatives, modifications and equivalents falling within he spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the drawings, a warning light 11 comprises a base assembly 13 mated to a transparent dome 15. Under the dome 15 and supported on the base 13 is a mechanism 17 for generating and oscillating a light beam. The mechanism includes a D.C. motor 19 driving a speed-reduction transmission, which comprises a worm 21, a worm gear 23 and a spur gear 25. Typically, the D.C. motor 19 rotates at approximately 4,200 RPM when operating most efficiently, which is a free-running mode. To reduce the RPM of the transmission to less than 200 RPM (e.g., a range of 50 to 80 RPM) required for the proper flash rate and oscillating speed of the light beam, the size of the worm gear 23 and the pitch of the worm 21 is selected accordingly. In FIG. 1, an adaptor 27 to a cigarette plug taps the electrical system of an emergency vehicle (not shown) for providing a constant D.C. voltage to the motor 19. A drive shaft 18 of the motor 19 rotates continuously in one direction when the D.C. voltage is applied to terminals 29 and 31 of the motor. The worm 21 is fitted over and keyed to the drive shaft of the motor 19 and engages the worm gear 23, causing the worm gear to rotate continuously in one direction (e.g., counterclockwise as indicated by the arrow in FIG. 2) at a substantially reduced speed relative to the RPM of the worm and the drive shaft.
A crank 33 couples the worm gear 23 to the spur gear 25 and converts the rotary motion of the worm gear to an oscillating motion of the spur gear. The crank 33 has two journal ends 35 and 37 received by respective bearings 39 and 41 formed in the bodies of the spur gear 25 and the worm gear 23. The rotary motion of the worm gear 23 imparts a reciprocating movement to the crank 33 that translates to an oscillating movement of the spur gear 25.
As generally indicated in FIG. 2, the crank 33 moves through a reciprocating stroke that defines an arc angle Θ. By adjusting the relative diameters of the worm gear 23 and the spur gear 25, the stroke of the crank 33 can be varied, thereby changing the angle Θ through which the spur gear oscillates. The stroke of the crank 33 can be increased and thus the angle Θ can be increased by either increasing the diameter of the worm gear 23 or decreasing the diameter of the spur gear 25. There is a limit, however, to the stroke of the crank 33. As the stroke of the crank 33 approaches the diameter D 1 of the spur gear 25, the angle Θ approaches 180°. As will be appreciated by those skilled in the art of oscillating warning lights, for values of the angle Θ greater than approximately 110°, the force imparted by the crank 33 to the spur gear 25 becomes substantially radial in its direction, leaving an increasingly smaller torque for rotating the spur gear. Thus, in a conventional transmission for an oscillating warning light such as that illustrated in U.S. patent application Ser. No. 07/592,670 to Stanuch et al., the angle swept by an oscillating light is limited to approximately 110° in order to ensure that sufficient torque is exerted at the endpoints of the oscillation for reliable oscillation of the light beam.
In accordance with the invention, the warning light 11 oscillates through an angle β that can be virtually any angle but must be greater than the angle Θ assuming that D 1 is greater than D 2 . A parabolic reflector 43 is mounted to a second spur gear 45, which is driven by the first spur gear 25. The second spur gear 45 and the reflector 43 comprise a reflector and gear assembly mounted for rotation on a spindle 47 that includes a bore 49 for accommodating a socket 51 for a light source 53, which illuminates the surface of the reflector and creates the light beam. The second spur gear 45 is received by a bearing surface 47a of the spindle 47 for free rotation about a vertical axis. By selecting the appropriate ratio of the diameters D 1 of the first spur gear 25 and D 2 of the second spur gear 45, the angle β can be virtually any angle, wherein said angles must be greater than the angle Θ assuming that D 1 is greater than D 2 .
In order to maintain a low profile of the warning light 11, the transmission is mounted in the base assembly to rotate the first and second spur gears 25 and 45 in a common horizontal plane. In order to maintain compactness of the transmission and drive train, the first spur gear 25 is driven by the D.C. motor 19 by way of the worm and worm gear assembly, thus allowing the motor to be mounted in the base assembly 13 so as to minimize its vertical profile.
In order to support the transmission, a platform 51 is secured to a three-prong mount 53a-c by threaded screws 55a, 55b and 55c. The spindle 47 is made of metal, extends from the platform 51 and is fastened to it by conventional means (not shown). Spindles 57 and 59 are also made of metal, extend from the platform 51 and are fastened to it by conventional means. The spindles 57 and 59 have bearing surfaces 57a and 59a, respectively, for supporting the worm gear 23 and the first spur gear 25 for free rotation about vertical axes. The vertical axes of rotation of the worm gear 23 and the first and second spur gears 25 and 45 are mutually parallel.
The worm 21 driven by the motor 19 rotates about an axis perpendicular to the axes of rotation for the spur gears 25 and 45 and the worm gear 23. The worm 21 and worm gear 23 cooperate to rotate 90° the axis of the rotary drive force of the D.C. motor 19 from a vertical plane to a horizontal plane. Once in a horizontal plane, the rotary force is then transformed to a reciprocating movement by the crank 33, which in turn is transformed to a oscillating motion by the first spur gear 25. The second spur gear 45 magnifies the oscillation of the first spur gear 25 by an amount proportional to the relative sizes of the first and second spur gears.
In keeping with the invention, a coupling is provided to join the second spur gear 45 to a light beam assembly comprising a hub 61 received by the spindle 47 and a bracket 63 to which the reflector 43 is riveted. In the illustrated embodiment, the second spur gear is integral with the hub 61 and bracket 63 so as to be supported by the spindle 47 in a common horizontal plane of rotation with the first spur gear 25 and the worm gear 23. The hub 61 is open at its top to complement the bore 49 of the spindle 47, which receives the socket 51 for mating with the lamp 53 (e.g., a halogen lamp). For grounding and retaining the lamp 53, a clip 65 is received by a base portion 53a of the lamp and a grooved lip 47b of the spindle 47. Because of heat generated by the lamp 53, the material comprising the light beam assembly must be capable of withstanding high temperatures. An appropriate material for the assembly is a glass-filled nylon of conventional type (e.g., Nylon 66, 30% glass, by DuPont), which forms the assembly and the second spur gear as one piece using conventional injection molding processes. The first spur gear 25, the worm 21 and worm gear 23 are preferably made of a conventional acetal plastic such as Delrin™ by DuPont.
In order to retain the gears 23 and 25 in place, clip fasteners 67 and 69 are received by annular grooves in the spindles 59 and 57 proximate the free ends of the spindles as illustrated. The platform 51 is made of conventional sheet metal, whereas the spindles 47, 57 and 59 are machined from metal stock. The clip 65 is also metal so as to ground the base 53a of the lamp 53 to the spindle 47, which in turn grounds to the platform 51. The negative terminal 29 of the motor 19 is secured to the platform 51 by mounting screw 55c as best shown in FIG. 2. In order to secure the motor 19, the platform 51 includes a bracket 51a having holes aligned with threaded screw holes in the casing of the motor for receiving screws as illustrated in FIG. 2, which mount the motor to the platform. Finally, an annular band fastener 71 secures the transparent dome 15 to a base 73 of the base assembly 13 when the annular lips or edges of the dome and the base are mated.
In the illustrated embodiment, the ratio of the angles Θ and β is inversely proportional to the ratio of the diameters D 1 and D 2 of the spur gears 25 and 45 that generate the angles. When β is greater than Θ, D 1 is greater than D 2 . In the illustrated embodiment, the relationship is as follows: ##EQU1## As can be readily appreciated from the foregoing relationship, the angle β for the sweep of the beam can be fixed at any desired angle by selecting the appropriate relative sizes of the two spur gears 25 and 45. Furthermore, by adjusting the relative sizes of the worm gear 23 and the first spur gear 25, both the length of the stroke of the crank 33 (see FIG. 3) and the value of the angle Θ can be adjusted, which in turn results in adjustment to the value of the angle β. Also, the ratio of the angles β and Θ is inversely proportional to the ratio of the total number of teeth on the spur gears 25 and 45. For the illustrated embodiment, the relationship is expressed as follows: ##EQU2## Where T 1 is the number of teeth on the first spur gear 25 and T 2 is the number of teeth on the second spur gear 45.
In a conventional prior art oscillating warning light using mechanical transmissions, the angular velocity of the reflector is substantially sinusoidal. That is, the velocity peaks at the mid region of the sweep of the reflector and then slows to a stop at an endpoint of the oscillation. Although the transmission of the present invention also is characterized by a slowdown immediately prior to the endpoints, the increased range of the sweep executed by the invention results in the sweep being substantially linear for large angles. In fact, by appropriately selecting the angle β, the velocity of the light beam generated by the reflector 43 can be made substantially linear over a full 180°. This feature allows the warning light assembly 11 to operate within narrow range of flash energies for the full 180°.
Referring to the exemplary graph of FIG. 4, by selecting the appropriate ratio of the diameters D 1 and D 2 of the spur gears 25 and 45 and the length of the stroke of the crank 33, the warning light assembly 11 generates a substantially constant flash energy over a full 180°. For use in intersections, a minimum flash energy may be required over the full 180° in order to ensure the warning light can successfully compete against other stimuli for an observer's attention. A maximum limit to the flash energy may also be required. Accordingly, by selecting an angle β of approximately 210°, a substantially constant flash energy of 6,000-7,000 candela-seconds is achieved for an entire 180° as indicated by the exemplary graph of FIG. 4. As the speed of the reflector 43 slows at the endpoints, the value of the candela-seconds peak at high values, but these values are outside the 180° sweep angle.
In the exemplary graph of FIG. 4, a 55 watt halogen lamp is assumed with the flash rate being 120 flashes per minute. The values of the flash energy in the graph are derived from experimental data collected by a conventional photometer located approximately 25 feet from a prototype of the warning light 11 with the dome 15 removed. The photometer was vertically positioned to read the highest candela level. The value of the flash energy was determined from the photometer at small angular increments across the sweep of the light beam.
In summary, a warning light assembly 11 is provided that oscillates through an angle β that approaches and may exceed 180°. By selecting the appropriate sizes of the worm gear 23 and the first and second spur gears 25 and 45, the angle of the oscillating light beam can be tailored to any specification. Furthermore, this versatility is achieved by a simple transmission that is inexpensive and highly reliable. Moreover, the transmission is compact and maintains a low profile that allows the base assembly to also maintain a low profile.
|
A warning light assembly is provided that includes a simple drive train for accomplishing an 180° or more oscillation of a light beam. By advantageously utilizing a speed-reduction mechanism, a transmission for converting rotary motion to oscillating motion and a coupling for multiplying the angle of oscillation, the drive provides an inexpensive and rugged enabling design the warning light assembly to oscillate a light beam through angles heretofore unattainable.
| 8
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of controlling opening and closing of a door in a drum-type washing machine, to put it concretely, that opening and closing of the door in the drum-type washing machine is controlled depending on a water level of a tub when the drum-type washing machine comes to a stop in operation.
[0003] 2. Description of the Related Art
[0004] A washing machine is to decontaminate dirt on clothes or bedding through washing, rinsing and dehydrating.
[0005] A drum-type washing machine has a door in front to put laundry in it. A cabinet in the drum-type washing machine has a door-lock-switch which prevents the door from opening while the drum-type washing machine is on.
[0006] The door-lock-switch is affected by a controller of the drum-type washing machine. When the drum-type washing machine is operating, the controller makes the door unopened. When the drum-type washing machine finishes operating, the controller makes it possible to open the door.
[0007] However, when the drum-type washing machine stops by a pause, a mistake by a user, a switch-off, the drum-type washing machine up to the present releases the door-lock-switch and the door can be opened even though water is contained in a tub.
[0008] Consequently, the conventional drum-type washing machine causes inconvenience that water of the tub flows out of the drum-type washing machine as the user opens the door.
SUMMARY OF THE INVENTION
[0009] The present invention is designed to cope with the above-mentioned problem, its main purpose places in providing a method of controlling opening and closing a door in a drum-type washing machine, which prevents water from running out of the machine which unexpectedly becomes stopped while its operation. It is feasible that a water level of a tub is considered before deciding whether to allow the door to open or not.
[0010] The method of controlling opening and closing of the door in the drum-type washing machine comprises the steps of: operating the drum-type washing machine; locking the door not to open; sensing the water level of the tub when the drum-type washing machine stops operating; and releasing a door-lock so that the door becomes ready to open if the water level of the tub is sensed lower than predetermined height.
[0011] When the door-lock is released, a door-opening-lamp is turned on while a door-closing-lamp is turned off.
[0012] If the water level of the tub is sensed higher than predetermined height, the door-lock is maintained and it is returned to the step of sensing the water level of the tub.
[0013] The method of controlling opening and closing of the door in the drum-type washing machine further comprises that a child-lock is turned on before the drum-type washing machine stops. The child-lock is on by a user or automatically after the drum-type washing machine is operating.
[0014] The method of controlling opening and closing of the door in the drum-type washing machine further comprises that the door-lock is released following by turning off the child-lock if the drum-type washing machine stops operating and the water level in the drum-type washing machine is lower than predetermined height. The child-lock becomes off by the user or automatically.
[0015] Therefore, the method of controlling opening and closing of the door in the drum-type washing machine prevents water from flowing out of the door when the drum-type washing machine which has been operating stops or pauses. The reason is that the door holds its condition as can-be-opened or should-be-locked, reading the water level of the tub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
[0017] FIG. 1 is an illustration of a drum-type washing machine adapted for the present invention.
[0018] FIG. 2 is a flow chart of a method of controlling opening and closing of a door in the drum-type washing machine in accordance with the 1st embodiment of the present invention.
[0019] FIG. 3 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 2nd embodiment of the present invention.
[0020] FIG. 4 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 3rd embodiment of the present invention.
[0021] FIG. 5 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 4th embodiment of the present invention.
[0022] FIG. 6 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 5th embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components.
[0024] Now, preferred embodiment of the present invention will be hereinafter described in detail with reference to the accompanying drawings.
[0025] FIG. 1 is an illustration of a drum-type washing machine adapted for the present invention.
[0026] As seen in FIG. 1 , the drum-type washing machine includes: a door 1 ; a cabinet assembly 2 that shapes a body of the drum-type washing machine; a tub (not shown) in the cabinet assembly 2 that contains water; a drum 3 that rotates inside of the tub; and a motor (not shown) connected to the drum 3 that makes the drum 3 rotate.
[0027] A detergent box 4 with cleaning or softening materials and a control panel unit 5 with a controller of the drum-type washing machine are installed in the cabinet assembly 2 .
[0028] A cabinet cover 6 which is the front of the cabinet assembly 2 has a hole 7 for holding the door 1 . One side of the door 1 is connected to the cabinet cover 6 with a hinge and the other side of the door 1 hangs a hook 8 .
[0029] The hook 8 fixes the door 1 by meeting a latch assembly 9 in the cabinet cover 6 .
[0030] The latch assembly 9 is regulated by the controller in the control panel unit 5 . The controller impresses or interrupts an electric current to a door-lock-switch (not shown) and commands its function. The latch assembly 9 accordingly runs and controls opening and closing of the door.
[0031] A child-lock-button 10 is on the control panel unit 5 . As a user pushes the child-lock-button 10 , a signal is delivered to the controller. After receiving the signal, the controller orders the latch assembly 9 to work and the door 1 is laid in a locking condition.
[0032] A child-lock is required to keep a child from entering the drum 3 after opening the door 1 .
[0033] The control panel unit 5 has a door-opening-lamp 11 and a door-closing-lamp 12 , which inform the user whether the door 1 can be opened or not.
[0034] Referring to FIG. 2 , a method of controlling opening and closing of the door in the drum-type washing machine according to the 1st embodiment comprises the steps of: operating the drum-type washing machine at step S 10 with manipulation by the user after laundry is loaded in the drum 3 ; locking the door 1 at step S 20 by impressing the electric current to the door-lock-switch before or after or simultaneously with step S 10 and by working the latch assembly 9 ; sensing whether the drum-type washing machine stops in operation at step S 30 ; sensing the water level of the tub at step S 40 when the drum-type washing machine stops operating; and releasing the door-lock at step S 50 so that the door 1 becomes ready to open by the latch assembly 9 if the water level of the tub is sensed lower than predetermined height.
[0035] The step S 20 of locking the door impresses the electric current to the door-lock-switch and converts the door into locking. In addition, it turns on the door-closing-lamp 12 .
[0036] The step S 30 of sensing the stop implies both the cases that the user puts a stop to the operation of the drum-type washing machine and the drum-type washing machine unexpectedly stops without manipulation by the user.
[0037] The former is, for example, the user turns off a power to put more laundry into the drum 3 before water is drained. The latter is that the drum-type washing machine becomes stopped due to a cut-off of the power, a mistake by the user or the incapacity of motor.
[0038] The step of S 40 sensing the water level reads the water level contained in the tub and decides whether the door-lock is released.
[0039] The step of S 50 releasing the door-lock interrupts the electric current to the door-lock-switch and makes the latch assembly 9 remove the door-lock when the water level of the tub is lower than predetermined height.
[0040] As the controller turns on the door-opening-lamp 11 and turns off the door-closing-lamp 12 at a time, the user can notice the door 1 is available to open at step S 50 .
[0041] The drum-type washing machine is turned out to be in normal operation at step S 30 , it is returned to step S 10 and continues operating.
[0042] If the water level of the tub is higher than predetermined height at step S 40 , the door is locked as it used to be. It is returned to step S 40 and waits till the water level of the tub gets lowered.
[0043] As soon as the water level of the tub is under predetermined height, the step S 50 is activated and the door-lock is released.
[0044] FIG. 3 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 2nd embodiment of the present invention. The 2nd embodiment is developed from the 1st one by adding a function of the child-lock.
[0045] The method of controlling opening and closing of the door in the drum-type washing machine according to 2nd embodiment comprises the steps of: operating the drum-type washing machine at step S 110 after the child-lock-button 10 is on and the child-lock is set up at step S 101 ; locking the door at step S 120 ; sensing whether the drum-type washing machine stops in operation at step S 130 ; sensing the water level of the tub at step S 140 when the drum-type washing machine stops operating; checking the child-lock to be released by manipulation of the child-lock-button at step S 150 when the water level of the tub is lower than predetermined height; releasing the door-lock to be opened at step S 160 when the child-lock-button is released; and turning off the door-closing-lamp and turning on the door-opening-lamp at step S 161 after the door-lock comes to released.
[0046] As the user puts into operation of the child-lock, the door has been already locked at step S 110 . In addition to that, the door is automatically locked depending on the operation of the drum-type washing machine, a double-lock-system is executed at step S 120 .
[0047] Since the child-lock has priority over any other control, the door maintains the locking condition in any cases if the child-lock is on, regardless of the door-lock-switch-off.
[0048] The latch assembly functions the child-lock by the controller in the embodiment, though the latch assembly and a separate locking device can be installed in the drum-type washing machine in order to implement the child-lock.
[0049] Releasing the child-lock by the user is confirmed at step S 150 . Only if the child-lock-releasing-signal is received through the child-lock-button, the door becomes ready to open at step S 160 . If not, it waits till the signal is received.
[0050] If the water level of the tub is higher than predetermined height at step S 140 , the door 1 is locked as it used to be. It is returned to step S 140 and waits till the water level of the tub is lowered at step S 142 .
[0051] FIG. 4 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 3rd embodiment of the present invention.
[0052] From steps S 101 to S 140 in the 3rd embodiment is the same as the process in the 2nd one. When the water level of the tub is lower than predetermined height at step S 140 , contrary to the 2nd embodiment, the child-lock is automatically turned off at step S 200 and allows the door to open by releasing the door-lock at step S 201 . It is possible even though there is no child-lock-releasing-signal.
[0053] When the door-lock is released at step S 201 , the door-closing-lamp is turned off and the door-opening-lamp is turned on.
[0054] The further explanation is excluded since the rests are identical with the 2 nd embodiment.
[0055] FIG. 5 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 4th embodiment of the present invention.
[0056] The 4th embodiment includes, contrary to the 2nd one, the child-lock is off before the drum-type washing machine is in operation at step S 300 and the child-lock is on after its operation at step S 301 .
[0057] The method of controlling opening and closing the door in the drum-type washing machine according to the 3rd embodiment comprises the steps of: operating the drum-type washing machine at step S 110 while the child-lock-button is off at step S 300 ; locking the door and turning on the door-closing-lamp at step S 120 ; automatically turning on the child-lock at step S 301 ; sensing whether the drum-type washing machine stops in operation at step S 130 ; sensing the water level of the tub at step S 140 when the drum-type washing machine stops operating; checking the child-lock to be released by manipulation of the child-lock-button at step S 150 when the water level of the tub is lower than predetermined height; releasing the door-lock to be opened at step 160 when the child-lock is released; and turning off the door-closing-lamp and turning on the door-opening-lamp at step S 161 after the door-lock comes to released.
[0058] The further explanation is excluded since the rests are identical with the 2nd embodiment.
[0059] FIG. 6 is the flow chart of the method of controlling opening and closing of the door in the drum-type washing machine in accordance with the 5th embodiment of the present invention.
[0060] The 5th embodiment is the same as the 4 th one except that the child-lock is automatically turned off without the child-lock-releasing-signal at step S 302 when the water level of the tub is under predetermined height.
[0061] The further explanation is excluded since the rests are identical with the 4th embodiment.
[0062] The method of controlling opening and closing of the door in the drum-type washing machine has the practical strength:
[0063] When the drum-type washing machine becomes stopped without finishing washing, the water level of the tub is sensed. Then, the door is opened only if the water level of the tub is lower than predetermined height. It can be prevented that water flows out caused by accidentally opening the door.
[0064] The user can clearly understand the condition of the drum-type washing machine since a lamp indicates that the door can be opened or should be locked depending on the water level of the tub.
[0065] When the drum-type washing machine stops in operation with the child-lock-on, the door-lock is released after the child-lock is released, even though the water level of the tub is under predetermined height. It can be prevented that the child opens the door when the drum-type washing machine is not operating.
[0066] It can be more definitely prevented that the door is accidentally opened with water contained in the drum-type washing machine on the ground that opening and closing of the door is decided by the double-lock-system including the child-lock.
[0067] Although the preferred embodiments of the present invention have been disclosed 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.
|
The present invention provides a method of controlling opening and closing of a door in a drum-type washing machine. When the drum-type washing machine suddenly stops in operation, e.g. in case of a mistake by a user or a switch-off, a water level of a tub is sensed, which shows lower than predetermined height, thereafter a door-lock-system is converted that the door can be opened. To this function, the present invention has an effect on protecting against an outflow of water of the tub in case the user wrongly opens the door.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage of International Application No. PCT/EP2015/071369 filed Sep. 17, 2015 and which claims the benefit and priority of German Application No. DE1020142019460.1 filed Sep. 25, 2014. The entire disclosure of each of the above applications is incorporated herein by reference.
FIELD
[0002] The present invention relates to a device for sealing a valve for use in a coolant flow of an internal combustion engine, for example of a motor vehicle, wherein the valve can be sealed with respect to the coolant flow.
BACKGROUND
[0003] This section provides information related to the present disclosure which is not necessarily prior art.
[0004] Valves of this type may be used to control the coolant flow of an internal combustion engine in order to ensure an optimal coolant temperature in the fluid circuit, depending on the loading condition. In the control system, it is important that the fluid-tightness of the individual control circuits be ensured.
[0005] Valves having a cylindrical valve body are frequently used in cooling systems, as, for example, in the unpublished DE 102013215971. The rotationally symmetrical valve body is mounted rotatably about the cylinder axis in a valve housing having inlet and outlet channels. Coolant is directed through openings in the outer region of the cylinder, the flow rate being regulated by rotation of the valve body. The channels cooperating with the openings in the outer region of the valve body are sealed by means of sealing sleeves which slide on the outer circumference of the cylinder. To ensure a sufficient sealing function, especially in a highly loaded position of the cylinder, correspondingly high contact pressure of the sleeve may be necessary.
[0006] In the configuration of the control circuits the sealing function is of major importance. The individual components are isolated from one another in a sealed manner. Sealing rings are used for this purpose. Such sealing rings may be used outlet and inlet of the circuit in a multi-way rotary valve.
[0007] However, an excessive pressure in partial regions of the coolant flow produced by very tight sealing systems is also undesirable.
SUMMARY
[0008] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0009] It is therefore the object of the invention to provide a device for sealing a valve in an improved form as compared to the known solutions.
[0010] This object is achieved by a valve having the features of claim 1 . Developments of the invention are apparent from the dependent claims.
[0011] According to the invention a device for sealing a valve for controlling a coolant of an internal combustion engine of a motor vehicle is, which valve is mounted in a cooling system together with a valve housing, wherein the valve housing contains at the inlet and/or the outlet side a sealing ring which has an annular wall and an annular lip extending away from the annular wall and spaced therefrom.
[0012] As a result of the structure of the seal it is possible both to construct a pressure-assisted sealing system and to achieve a reduction of overpressure by means of the adjustable sealing system. A sealing system which can be used in a pressure-controlled manner is thereby achieved.
[0013] It is advantageous that the annular lip extends away from the annular wall at an acute angle. As a result, pressure can be exerted between the two sealing components, pressing the seal more strongly against the components to be sealed, or reducing overpressure in a different installed situation.
[0014] It is advantageous if the annular lip and the annular wall form a V-shaped or U-shaped structure in cross section.
[0015] Advantageously, the annular lip can be moved away from the annular wall when subjected to pressure in the direction of the contact point with the annular wall.
[0016] It is advantageous if the sealing ring is installed together with a spring, or if the sealing ring has an integrated spring body.
[0017] It is further advantageous that the combination of sealing ring and spring increases the contact pressure of the sealing ring or reduces to contact pressure of the sealing ring.
[0018] The contact face of the sealing ring is advantageously linear.
[0019] It is further advantageous that the contact face of the sealing ring is adapted to a cylindrical or spherical shape.
[0020] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0021] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0022] FIGS. 1 to 3 show embodiments of a pressure-assisted sealing system.
[0023] FIGS. 4 and 5 show embodiments of contact-pressure reducing sealing systems.
DETAILED DESCRIPTION
[0024] Example embodiments will now be described more fully with reference to the accompanying drawings.
[0025] FIG. 1 a shows a section through a portion of a cooling system. The cooling system 10 is shown here only in outline. The cooling system 10 must be sealed with respect to a valve housing 1 . A sealing ring 3 is arranged between the cooling system 10 and the valve housing 1 . The sealing ring 3 has a contact face 11 resting against the valve housing 1 . On the side facing away from the valve housing 1 the sealing ring is configured with an annular wall 4 and with an annular lip 5 extending inwardly therefrom at an acute angle towards the cylinder axis Z. Starting from a contact point 6 , the annular lip 5 offers a V-shaped groove with the annular wall 4 .
[0026] In the exemplary embodiment, the radius of the sealing ring 3 in the region of the contact face 11 is smaller than the radius of the annular wall 4 . The sealing ring 3 is in direct contact with a spring ring 7 , which is arranged in a recess of the cooling system 10 . The sealing ring 3 is preloaded with an axial force by means of the spring ring. In this exemplary arrangement the through-flow follows the arrow F. On the high-pressure side P H a channel 12 opens along the outside of the sealing ring 3 , the high-pressure side of the system applying the pressure P H to the sealing ring as far as the V-shaped divergence of the sealing lip 5 . This causes the annular lip to diverge further and to rest snugly against the contact face of the cooling system. In this context the region with a higher pressure in relation to the low-pressure side P L is referred to as the high-pressure side, which is intended merely to emphasize the pressure difference.
[0027] The radially diverging annular lip 5 is arranged such that, as a result of the differential pressure between P H and R L , the annular lip is pressed more strongly against the adjacent face of the cooling system, and the whole sealing ring 3 is pressed more strongly against the valve housing 1 on account of the projected area.
[0028] As a result of the different internal radii, the sealing ring 3 forms a shoulder with an outer shoulder 14 and an inner shoulder 15 . As shown in the drawing, the higher pressure P H is applied to the outer shoulder 14 . This pressure component acts on the shoulder 14 , pressing the inner shoulder 15 upward in the drawing toward the cooling system 10 . With a suitable pressure, therefore, the inner shoulder 15 also bears against the cooling system and forms a seal in conjunction with the annular lip 5 . This construction permits controlled management of the sealing function by means of the pressure difference between P H and P L . The pressure difference acting on two different locations of the seal influences the sealing system and can be managed very effectively.
[0029] In this exemplary embodiment the contact face has a cylindrical configuration. As a result of the assistance by the pressure differential, the spring 7 can be designed with lower spring force. FIG. 1 b shows a view of the sealing ring according to the invention.
[0030] The embodiment of FIG. 2 a and FIG. 2 b show an alternative form. The sealing ring 3 is again located between a high-pressure region P H and a low-pressure region P L . The sealing ring is preloaded by means of the spring 7 . The sealing ring again has an annular wall 4 from which an annular lip 5 , starting from the contact point 6 , diverges. In this exemplary embodiment the sealing ring has the same radius in the region of the contact face 11 and in the region of the annular wall 4 . However, the annular lip does not diverge toward the inside but toward the outside.
[0031] As a result of the pressure difference, the annular lip 5 is pressed against the adjacent sealing face 13 and the whole sealing ring is pressed more strongly against the contact face 11 . In this case, too, the pressure difference assists the sealing function of the sealing ring.
[0032] FIG. 3 shows an alternative embodiment. Here, the sealing ring also has a constant internal radius over its full extent. The annular wall 4 again has an annular lip 5 , which in this example diverges from the wall via a U-shaped recess. In this embodiment the annular lip diverges in the axial direction and not in the radial direction.
[0033] In addition, the annular lip is preloaded axially by means of an internal spring 8 . As a result of the axial preload, the annular lip 5 seals with respect to the cooling system 10 , only indicated here, against the sealing face 13 . The increased pressure P H is applied in the U-shaped gap between annular lip and annular wall, pressing the annular lip against the sealing face 13 . The pressure assists the force generated by the internal spring 8 with respect to the cooling system 10 , but also against the contact face 11 on the valve housing 1 .
[0034] In this exemplary embodiment the contact face has a crowned configuration.
[0035] The arrangement according to FIG. 4 a and FIG. 4 b shows a sealing ring 3 which, pressed by a spring 7 , is seated on a valve body 1 with a contact face 11 . The sealing ring has a constant internal radius over its full extent. The annular lip 5 spaced from the annular transformation extends outward against the cooling system 10 . The high pressure P H exerts increased pressure on the sealing ring in the region of the V-shaped divergence. This pressure acts against the spring force of the spring 7 . As a result of the pressure on the high-pressure side, a portion of the spring force is compensated and the sealing ring 3 is pressed less strongly against the valve housing 1 . Through appropriate design of the force of the spring body, therefore, an overpressure from the high-pressure side can be counteracted in the cooling system, since the sealing system dissipates the pressure via leakage as a result of the reduced contact pressure.
[0036] FIG. 5 shows an alternative embodiment in which the pressure difference is also used to regulate a specified leakage. The elevated pressure on the pressure side acts on the annular lip 5 so that the pressure works against the spring force of the internal spring 8 . Here, too, the dimensioning of the spring and of the pressure system can allow a specified leakage to be achieved, whereby overpressure in the system is mitigated.
[0037] The embodiments illustrated are examples which can be supplemented with well-known modifications by the person skilled in the art. The variants encompass all possible forms of the contact faces, as well as the design of the sealing ring.
LIST OF REFERENCE NUMERALS
[0000]
1 Valve housing
3 Sealing ring
4 Annular wall
5 Annular lip
6 Contact point
7 Spring
8 Internal spring
10 Cooling system
11 Contact surface
12 Channel
13 Sealing face
14 Outer shoulder
15 Inner shoulder
|
A device for sealing a valve for controlling a coolant of an internal combustion engine of a motor vehicle is described, which valve is mounted in a cooling system together with a valve housing, wherein the valve housing contains, at the inlet and/or the outlet side, a sealing ring which has an annular wall and a spaced annular lip extending away from the annular wall from a contact point.
| 5
|
[0001] This Application claims the benefit of the filing date of U.S. Provisional Application No. 60/419,361 filed Oct. 18, 2002, which is owned by the assignee of the present Application.
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] Reference is made to commonly assigned co-pending patent applications Ser. No. ______ Docket No. F-632 filed herewith entitled “METHOD FOR FIELD PROGRAMMABLE RADIO FREQUENCY DOCUMENT IDENTIFICATION DEVICES” in the names of Anand V. Chhatpar, Jeffrey D. Pierce, Brian M. Romansky, Thomas J. Foth and Andrei Obrea; Ser. No. ______ Docket No. F-633 filed herewith entitled “METHOD FOR FIELD PROGRAMMING RADIO FREQUENCY IDENTIFICATION DEVICES THAT CONTROL REMOTE CONTROL DEVICES” in the names of Jeffrey D. Pierce, Brian M. Romansky, Thomas J. Foth, and Anand V. Chhatpar; Ser. No. ______ Docket No. F-635 filed herewith entitled “METHOD FOR FIELD PROGRAMMABLE RADIO FREQUENCY IDENTIFICATION TESTING DEVICES FOR TRANSMITTING USER SELECTED DATA” in the names of Thomas J. Foth, Brian M. Romansky, Jeffrey D. Pierce, Andrei Obrea, and Anand V. Chhatpar; Ser. No. ______ Docket No. F-637 filed herewith entitled “METHOD FOR FIELD PROGRAMMABLE RADIO FREQUENCY IDENTIFICATION DEVICES TO PERFORM SWITCHING FUNCTIONS” in the names of Andrei Obrea, Brian M. Romansky, Thomas J. Foth, Jeffrey D. Pierce, and Anand V. Chhatpar; Ser. No. ______ Docket No. F-638 filed herewith entitled “METHOD FOR FIELD PROGRAMMING RADIO FREQUENCY IDENTIFICATION LABELS” in the names of Thomas J. Foth, Brian M. Romansky, Jeffrey D. Pierce, and Anand V. Chhatpar; and Ser. No. ______ F-640 filed herewith entitled “METHOD AND APPARATUS FOR FIELD PROGRAMMING RADIO FREQUENCY IDENTIFICATION DEVICES” in the names of Brian M. Romansky, Thomas J. Foth, Jeffrey D. Pierce, Andrei Obrea and Anand V. Chhatpar.
FIELD OF THE INVENTION
[0003] This invention pertains to electronic circuits and, more particularly, to programmable radio frequency return forms.
BACKGROUND OF THE INVENTION
[0004] From the invention of paper thousands of years ago to the present date, paper has been used as the preferred medium by individuals and societies for the recording, processing and storage of information. With the introduction of computers into society, many of the functions previously performed exclusively with paper are now being accomplished by writing information on paper and entering the written information into a computer. Typically, the information written on paper is entered into computers by optically scanning the paper. The foregoing method of entering information into computers is inconvenient, because the paper must be placed directly on the scanner, and no intervening objects may be placed between the paper and the scanner. Another method utilized by the prior art for writing information on paper and entering the written information into a computer involved placing a piece of paper over an expensive digitizing pad and using a special pen that produced digital data by indicating the coordinates of the digitizing pad. Thus, heretofore, there was no economic, convenient way for wirelessly entering information written on plain paper into a computer.
[0005] Another method utilized by the prior art for entering information into a computer involved the use of radio frequency identification (RFID) tags. The RFID tags were programmed to contain digital information either during the manufacturing of the read only memory portion of the RFID integrated circuit, or in the field using electromagnetic radio frequency signals to store information in the nonvolatile memory portion of the RFID tag. One of the difficulties involved in the utilization of RFID tags was that if an end user wanted to enter information into the RFID tag, the end user had to use a specialized device that communicated with the RFID tag through a radio frequency. Another problem involved in the utilization of RFID tags that were programmed by the manufacturer was that the end user had to share the information that was going to be programmed into the RFID tag with the manufacturer of the tag.
[0006] Many goods are currently being offered for sale from a catalog or over the Internet. The prospective buyer of goods offered for sale from a catalog or the Internet may have an opportunity to view an image of the goods offered for sale on a printed page and/or a display screen. The prospective buyer would not have an opportunity to view and examine the goods before purchasing the goods. Consequently, the buyer may be of the opinion that purchased clothing was manufactured from the wrong fabric, is of the wrong color and was poorly made. Buyers of electronic goods often thought the equipment did not function in the manner they expected. Buyers of books and furniture also were of the opinion that the purchased books and/or furniture did not meet their expectations. Thus, the buyers of goods from catalogs or over the Internet often wanted to return the purchased goods to the seller and receive their money back.
[0007] Typically, the buyer would telephone the seller and inform the seller that the buyer would like to return some or all of the purchased goods. The seller may send the buyer a “merchandise return label”; tell the buyer to pack the goods that they want to return in the package in which the goods were sent; have the buyer complete a form placed inside the returned package that indicted the returned goods and the reason for their return and, affix the aforementioned label to the package. The buyer would have to write the buyer's address on the label, and the seller would have to open the package to read the form.
[0008] Bar codes have been used in a wide variety of applications as a source for information. Typically, bar codes are used at a point-of-sale terminal in merchandising for pricing and inventory control. Bar codes are also used in controlling personnel access systems, mailing systems, and in manufacturing for work-in-process and inventory control systems, etc. The bar codes themselves represent alphanumeric characters by series of adjacent stripes of various widths or lengths, i.e., the Universal Product Code, Planet Code, etc.
[0009] A bar code is a set of binary numbers. It consists of black bars and white spaces. A wide black bar space signifies a one, and a thin black bar or space signifies a zero. The binary numbers stand for decimal numbers or letters. There are several different kinds of bar codes. In each one, a number, letter or other character is formed by a certain number of bars and spaces.
[0010] Bar code reading systems or scanners have been developed to read bar codes. The bar code may be read by having a light beam translated across the bar code and a portion of the light illuminating the bar code is reflected and collected by a scanner. The intensity of the reflected light is proportional to the reflectance of the area illuminated by the light beam. This light is converted into an electric current signal, and then the signal is decoded.
[0011] Conventional bar codes are limited in the amount of information they contain. Even two-dimensional bar codes, such as PDF-417 and Code- 1 , are limited to a few thousand bytes of information for practical uses. The ability to encode greater information density is limited by the resolution of available scanning and printing devices.
[0012] It is also difficult to create or change a bar code without using a printing device.
SUMMARY OF THE INVENTION
[0013] This invention overcomes the disadvantages of the prior art by providing a method that allows one to mark information with a pencil or conductive ink on paper equipped with a RFID type circuit, and provide the marked information to the RFID circuit, or have the written information cause the RFID circuit to perform some function. The marked entered information may be corrected by erasing the written information with a pencil eraser and writing new information on a material with a pencil. The material may be any cellulose type product, i.e., paper, cardboard, chipboard, wood or plastic, fabric, animal hide, etc. Information may also be marked into a RFID circuit or have the marked information cause the RFID circuit to perform some function by utilizing a standard ink jet computer printer to print lines on paper equipped with a RFID type circuit, by having the printed lines perform the function of wires. The aforementioned printed information may be modified by having an individual connect different printed wires by drawing a penciled line between the wires or by punching holes in the printed lines.
[0014] This invention accomplishes the foregoing by utilizing the RFID serial number generation portion of the RFID circuit that is used when the RFID circuit is being read. In the prior art, the bits used to encode one's and zero's into the generation portion of the RFID circuit were typically fixed. This invention utilizes the serial number generation portion of the RFID circuit by exposing on a piece of paper some or all of the bits left open or closed to represent a binary values, i.e., ones or zeros. A user may complete the RFID serial number storage portion of the RFID circuit by filling in the space between the connections with a pencil to alter the binary values. Alternatively, the serial number generation portion of the RFID circuit may be exposed on a piece of paper with all of the connections made, and a user may break a space between the connections with a sharp instrument or hole punch to alter the binary values. Alternatively, the serial number generation portion of the RFID circuit may have some of the bits all ready left open or closed to represent a unique number.
[0015] An additional advantage of this invention is that the seller may be able to read the merchandise return forms that were placed inside many different packages without opening the packages.
[0016] An additional advantage of this invention is that the seller may be able to read the merchandise return forms that were placed inside returned packages without opening the packages.
[0017] An additional advantage of this invention is that a RFID type circuit may be combined with marked information that is read by the RFID circuit, wherein the marked information also forms a bar code.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram of a prior art RFID circuit;
[0019] [0019]FIG. 2A is a drawing of a circuit 24 that replaces memory array 21 of FIG. 1 showing how programming of the bits may be accomplished by making the bits externally available for programming RFID circuit 10 ;
[0020] [0020]FIG. 2B is a drawing of a circuit 300 that is an alternate representation of circuit 24 , that replaces memory array 21 of FIG. 1 showing how programming of the bits may be accomplished by making the bits externally available for programming RFID circuit 10 ;
[0021] [0021]FIG. 3 is a drawing showing sensor circuit 25 of FIG. 2A in greater detail;
[0022] [0022]FIG. 4 is a seller furnished form to be completed by a buyer returning goods to a seller;
[0023] [0023]FIG. 5 is a drawing showing how the completed form of FIG. 4 forms a bar code; and
[0024] [0024]FIG. 6 is a drawing showing how a modified RFID circuit attached to a piece of paper may be touched by a human to indicate a desired selection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring now to the drawings in detail, and more particularly to FIG. 1, the reference character 10 represents a prior art RFID circuit. Circuit 10 may be the model MCRF 200 manufactured by Microchip Technology, Inc. of 2355 West Chandler Blvd, Chandler, Ariz. 85224. RFID reader 11 is connected to coil 12 , and 12 is coupled to coil 13 . Coil 13 is connected to modulation circuit 14 . Modulation circuit 14 is connected to clock generator 15 and rectifier 16 . Modulation control 17 is coupled to modulation circuit 14 , clock generator 15 and counter 18 . Counter 18 is coupled to column decode 20 . Row decode 19 is coupled to memory array 21 , and array 21 is coupled to modulation control 17 . It would be obvious to one skilled in the art that a battery may be used to supply power to circuit 10 .
[0026] Reader 11 has a transmitter mode and a receiver mode. During the transmit mode of reader 11 , reader 11 transmits a radio frequency signal for a burst of time via coil 12 . After the transmission of a signal by reader 11 , reader 11 turns into a receiver. Coil 12 is inductively linked with coil 13 , and coil 13 receives the radio frequency signal from coil 12 and converts the aforementioned signal into inductive energy, i.e., electricity. When coil 13 has sufficient energy, coil 13 will cause clock generator 15 to generate timing pulses which drive counter 18 . Counter 18 drives row decode 19 which causes memory array 21 to read the fixed bit data pattern stored in memory array 21 one bit at a time. As the data bits are being read by array 21 , the data bits are transmitted to modulation control circuit 17 . Control circuit 17 sends the data bits to reader 11 via modulation circuit 14 and coils 13 and 12 .
[0027] [0027]FIG. 2A is a drawing of a circuit 24 that replaces memory array 21 of FIG. 1 showing how programming of the bits may be accomplished by making the bits externally available for programming RFID circuit 10 . A plurality of sensor circuits 25 is contained in circuit 24 . Sensor circuits 25 are labeled SC 1 SC 2 SC 3 . . . SC n . Line 29 is connected to SC 1 and graphite contact 52 and line 30 is connected to SC 2 and graphite contact 53 . Line 31 is connected to SC 3 and graphite contact 54 and line 32 are connected to SC n and graphite contact 55 . There is a sensor circuit 25 for each graphite contact. The description of FIG. 4 will describe how information may be entered into circuit 24 via graphite contacts 52 - 55 . SC 1 has an input 33 , which enables the data output 34 . Input 33 is connected to one of the n lines 37 , and data output 34 is connected to data line 36 and pull up resistor 35 . Data line 36 is connected to modulation control 17 (FIG. 1).
[0028] When counter 18 selects the value 1 , column decode 20 will enable line 33 , which will cause the same logic level that is on graphite contact 52 to be placed on data output 34 . When line 33 is not selected, the value on graphite contact 52 does not have any influence on the data output line 34 . Enable outputs 33 for SC 1 . . . SC n are bundled together in lines 37 so that only one line 37 is turned on at a time. Lines 37 are connected to column decode 20 . Column decode 20 is connected to counter 18 , and counter 18 is connected to row decode 19 . Counter 18 generates a sequence of numbers from 1 through n to enable a different line 37 in sequential order. Thus, data line 36 will receive the data outputs 34 from SC 1 . . . SC n at different times.
[0029] [0029]FIG. 2B is a drawing of a circuit 300 that is an alternate representation of circuit 24 , that replaces memory array 21 of FIG. 1 showing how programming of the bits may be accomplished by making the bits externally available for programming RFID circuit 10 . Circuit 300 includes AND gates 301 , 302 , 303 and 304 and OR gate 305 .
[0030] One of the inputs of AND gate 301 is connected to column decode 20 and the other input to AND gate 301 is connected to one of the ends of resistor 322 , one of the ends of diode 306 and one of the ends of diode 314 . The other end of resistor 322 is connected to ground. The other end of diode 306 is connected to one of the terminals of toggle switch 310 , and the other end of toggle switch 310 is connected to row decode 19 . The other end of diode 314 is connected to one of the terminals of toggle switch 318 , and the other end of toggle switch 318 is connected to row decode 19 .
[0031] One of the inputs of AND gate 302 is connected to column decode 20 , and the other input to AND gate 302 is connected to one of the ends of resistor 323 , one of the ends of diode 307 and one of the ends of diode 315 . The other end of resistor 323 is connected to ground. The other end of diode 307 is connected to one of the terminals of toggle switch 311 , and the other end of toggle switch 311 is connected to row decode 19 . The other end of diode 315 is connected to one of the terminals of toggle switch 319 , and the other end of toggle switch 319 is connected to row decode 19 .
[0032] One of the inputs of AND gate 303 is connected to column decode 20 , and the other input to AND gate 303 is connected to one of the ends of resistor 324 , one of the ends of diode 308 and one of the ends of diode 316 . The other end of resistor 324 is connected to ground. The other end of diode 308 is connected to one of the terminals of toggle switch 312 , and the other end of toggle switch 312 is connected to row decode 19 . The other end of diode 316 is connected to one of the terminals of toggle switch 320 , and the other end of toggle switch 320 is connected to row decode 19 .
[0033] One of the inputs of AND gate 304 is connected to column decode 20 , and the other input to AND gate 304 is connected to one of the ends of resistor 325 , one of the ends of diode 309 and one of the ends of diode 317 . The other end of resistor 325 is connected to ground. The other end of diode 309 is connected to one of the terminals of toggle switch 313 , and the other end of toggle switch 312 is connected to row decode 19 . The other end of diode 317 is connected to one of the terminals of toggle switch 321 , and the other end of toggle switch 321 is connected to row decode 19 .
[0034] Column decode 20 and row decode 19 function by taking the selected output at logic one, i.e., a high level and keeping all the other outputs at logic zero, i.e., a low level. The output of AND gates 301 - 304 are connected to the input of OR gate 305 , and the output of OR gate 305 is data that is connected to the input of modulation circuit 17 . If switches 310 , 311 , 312 and 313 , respectively, remain open, AND gates 301 - 304 , respectively, will have a “zero” output. If switches 310 , 311 , 312 and 313 , respectively, are closed, AND gates 301 - 304 , respectively, will have a “one” output. The output of AND gates 301 - 304 , respectively, will be read when switches 318 - 321 , respectively, are closed.
[0035] [0035]FIG. 3 is a drawing showing sensor circuit 25 of FIG. 2A in greater detail. The negative input of comparator 41 is connected to line 29 , and the positive input of comparator 41 is connected to line 38 . Comparator 41 may be a LM339N comparator. One end of line 38 is connected to a 2-3 volt reference voltage, and the other end of line 38 is connected to one of the ends of resistor 39 . The other end of resistor 39 is connected to the positive input of comparator 41 and one of the ends of resistor 40 . The other end of resistor 40 is connected to the input of NAND gate 42 , the output of comparator 41 and one of the ends of resistor 43 . The other end of resistor 43 is connected to a source voltage to act as a pull up resistor. The other input to NAND gate 42 is enable output 33 . The output of gate 42 is data output 34 . Resistor 39 may be 47,000 ohms, and resistor 40 may be 470,000 ohms. Resistor 43 may be 1,000 ohms. Comparator 41 has a positive feedback to provide a small amount of hysteresis
[0036] Sensor circuit 25 is a differential circuit that accommodates variations in the conductivity of the conductive material. The conductive material may be used as a voltage divider to produce V ref on line 38 under the same conditions experienced by paper in on line 29 . Thereby, nullifying the effects of varying resistance in the conductive material. It will be obvious to one skilled in the art that sensor circuit 25 may replace switches 310 - 313 and 318 - 321 of FIG. 2B.
[0037] [0037]FIG. 4 is a seller-furnished form to be completed by a buyer returning goods to a seller. RFID circuit 10 is attached to paper 50 by means of a conductive adhesive such as an anisotropic adhesive (not shown). The adhesive connects copper contacts (not shown) exiting RFID circuit 10 with graphite contacts 52 - 55 which terminate in lines 56 - 58 . A returned goods identification number 51 is placed on paper 50 to identify the buyer of the purchased goods. This number matches the identification number stored in RFID circuit 10 . Graphite contacts 52 , 53 , 54 and 55 and lines 56 , 57 , 58 , 59 and 60 are printed on standard bond paper, standard photocopier paper, standard computer paper, etc., by a standard computer printer like the model Desk Jet 880C printer manufactured by Hewlett Packard using a Hewlett Packard 45 black ink cartridge. The Hewlett Packard laser jet 1100 printer and its associated toner cartridge may also be used to print graphite contacts 52 - 55 and lines 56 - 60 . It would be obvious to one skilled in the art that any conductive contacts may be used for the graphite contacts. It would also be obvious to one skilled in the art that unique forms may be printed for each instance of a sale and only the contacts representing information about the goods being returned to the seller need to be printed.
[0038] If the buyer decides to return a shirt to the seller, the buyer uses a graphite pencil, i.e., number 2, HB, etc., or a Paper Mate® black ballpoint pen to fill in rectangle 61 . If the buyer decides to return pants to the seller, the buyer fills in rectangle 62 with a graphite pencil, and if the buyer decides to return shoes to the seller, the buyer fills in rectangle 63 with a graphite pencil. If the buyer changes his/her mind regarding the goods to be returned or makes a mistake in filling in one of the rectangles, the buyer could erase the penciled marking in the rectangle with a pencil eraser so that a RFID reader would only read what the buyer indicated on the finished form. The buyer would insert the finished form into a package (not shown) containing the returned goods, and the seller would be able to read the completed form when he/she receives the package with a RFID read without opening the package.
[0039] [0039]FIG. 5 is a drawing showing how the completed form of FIG. 4 forms a bar code. If someone decided to use a graphite pencil, i.e., number 2, HB, etc., or a Paper Mate® black ballpoint pen to fill in rectangles 61 , 63 , 426 , 427 , 431 and 435 indicating they are returning a shirt that has the incorrect color, pants that have the incorrect size and shoes that are damaged. Rectangle 61 would represent a binary one of a bar code, and a closed circuit will exist between contact 52 , line 56 , line 436 , and contact 411 . Rectangle 63 would represent a binary one of a bar code, and a closed circuit will exist between contact 54 , line 58 , line 436 , and contact 411 . Rectangle 426 would represent a binary one of a bar code, and a closed circuit will exist between contact 401 , line 414 , line 436 , and contact 411 . Rectangle 427 would represent a binary one of a bar code, and a closed circuit will exist between contact 406 , line 419 , line 436 , and contact 411 .
[0040] It would be-obvious to one skilled in the art if rectangles 62 , 424 , 425 , 428 , 429 , 430 , 432 , 433 , and 434 and were filed in with a graphite pencil, rectangles 62 , 424 , 425 , 428 , 429 , 430 , 432 , 433 , and 434 would represent binary ones; and, if rectangles 61 , 63 , 426 , 427 , 431 and 435 were not filed in with a graphite pencil, rectangles 61 , 63 , 426 , 427 , 431 and 435 would represent binary zeros. The lines and contacts connecting rectangles 62 , 424 , 425 , 428 , 429 , 430 , 432 , 433 , and 434 would be closed circuits, and the contacts connecting rectangles 61 , 63 , 426 , 427 , 431 and 435 would be open circuits. By forming a bar code representation, paper 50 may be read with either a RFID reader or a conventional bar code scanner.
[0041] [0041]FIG. 6 is a drawing showing how a modified RFID circuit attached to a piece of paper may be touched by a human to indicate a desired selection. RFID circuit 10 is attached to paper 138 by means of an adhesive (not shown). Graphite contacts 139 , 140 , 141 and 142 and lines 143 , 144 , 145 , 146 and 147 are printed on paper 138 by a standard computer printer like the model Desk Jet 880 C printer manufactured by Hewlett Packard using a Hewlett Packard 45 black ink cartridge. If a human user wanted to select the information represented by line 144 , the user would place their finger between points A and B on line 144 . A RFID reader (not shown) will be able to read the above selection. The foregoing would allow a human who has opened a package of returned goods to indicate the proprieties of the returned goods, i.e., one of the goods is missing, the wrong goods have been returned, all goods are present, broken goods have been returned, etc.
[0042] The above specification describes a new and improved label and RFID type circuit that uses printed lines to perform the function of wires so that information may be modified in the RFID type circuit by having an individual connect different printed wires by drawing a penciled line between the printed lines or by punching holes in the printed lines to supply information regarding the returned goods. It is realized that the above description may indicate to those skilled in the art additional ways in which the principles of this invention may be used without departing from the spirit. Therefore, it is intended that this invention be limited only by the scope of the appended claims.
|
A method that allows one to mark information with a pencil on a label equipped with a RFID type circuit, and have the marked information provided to the RFID circuit, or have the written information cause the RFID circuit to supply information regarding the returned goods. The marked entered information may be corrected by erasing the written information with a pencil eraser and writing new information on the paper with a pencil. Information may also be marked into a RFID circuit or have the marked information cause the RFID circuit to perform some function by utilizing a standard ink jet computer printer to print lines on paper equipped with a RFID type circuit, by having the printed lines perform the function of wires. The aforementioned printed information may be modified by having an individual connect different printed wires by drawing a penciled line between the wires or by punching holes in the printed lines.
| 6
|
TECHNICAL FIELD
The invention relates to the field of civil engineering machines and more particularly to machines of the loader type. Its object is more precisely a device making it possible to measure the inclination of a mobile working implement of the machine. A particular application of the present invention makes it possible to automatically correct the inclination of the bucket during the various loading operations.
PRIOR ART
Usually, a civil engineering machine that makes it possible to pick up goods, such as materials, placed on the ground in order to dump them into a trailer body or into a truck or vice versa is called a “loader”. A loader therefore in a known manner comprises a chassis and particular working equipment. This working equipment usually includes an arm that is articulated relative to the chassis. This arm may be raised under the action of a cylinder usually called an “arm cylinder”.
One of the ends of the arm receives a working implement, such as a bucket, which is itself articulated relative to the arm. To move the working implement relative to the arm, the working equipment also comprises an assembly of link rods which form, together with a portion of the working implement and a portion of the arm, a deformable quadrilateral. Usually, one of these link rods is articulated relative to the working implement, while the other is articulated relative to the arm, these two link rods being articulated with one another via their ends. The working equipment also comprises an implement cylinder that is controlled to deform the deformable quadrilateral, which makes it possible to incline the working implement relative to the arm.
The driver may control, via a most frequently hydraulic manipulator, the arm cylinder and the implement cylinder separately. Therefore, by acting on the arm cylinder, he lifts the arm while raising the level of the working implement.
By acting on the implement cylinder, he modifies the inclination of the bucket relative to the arm, and therefore relative to the chassis. Therefore, after the working implement, such as a bucket, has been loaded with goods or filled with materials, it is pivoted rearward so that its opening is oriented upward. Conversely, when the bucket has reached the desired height, it is pivoted forward, so as to be emptied into the receiving trailer body.
When one of the arm or implement cylinders is operated, since the working implement is placed at the end of the arm, when the length of the latter varies, the inclination of the arm and/or of the working implement varies relative to the ground. It is often desirable, or even indispensable, to know the value of the angle of inclination of the working implement. This is the case, for example, when the implement is a bucket loaded with materials that may risk inclining too much and consequently dumping its load unexpectedly, which may cause problems of safety, of material breakage and/or waste of time.
Preventing the working implement from losing its goods is one of the reasons that justify the need to be able to measure the angle of inclination of the working implement relative to the ground. This measurement makes it possible specifically to modify the inclination of the working implement relative to the arm by manipulating the deformation of the deformable quadrilateral. During the movement of raising the arm, the implement cylinder may therefore be actuated to keep the opening of the working implement in a constant inclination, in order to prevent the latter from dumping rearward unexpectedly.
Document US-A-2004/0060711 describes a device capable of transmitting the measurement of the inclination of the working implement to an actuator capable of acting appropriately on the cylinder of the working implement by means of a hydraulic system in order to compensate for the inclination of the working implement under the effect of the variation of inclination of the arm. This device comprises a cam mechanism moved by a connecting bar also connected to the deformable quadrilateral. In this arrangement, the position of the cam is a direct function of the inclination of the working implement.
However, this device is not very adaptable to the various working implements that are likely to be mounted on the arm as required. Specifically, the cam, through its particular profile, often according to an involute to a circle, is specific to a determined geometry of the working implement. If the user wishes to change the working implement, he must also install the cam that is appropriate to the geometry of the new implement or, more simply, adjust the length of the connecting bar that is made to be adjustable. Otherwise the compensation of inclination is incorrect and the aforementioned problems may occur.
Document EP-A-0 597 657 also teaches of a machine whose working implement and arm are each fitted with an angular sensor in order to determine their respective inclination then to control the cylinders according to the signals transmitted by the angular sensors, so as to prevent the goods carried by the working implement from being tipped.
However, in such a device failures of the angular sensors may occur, particularly of the sensor situated close to the implement, because they are positioned at a distance from the chassis. Specifically, they are therefore exposed to vibrations, to impacts and to elements causing deterioration or disruption of measurement such as rain, dust or mud, which may over time damage these angular sensors despite their sealed manufacture. Consequently, these sensors may no longer operate at all or may operate erratically and, in consequence, transmit incorrect information.
In the same manner, the electric wires that connect these angular sensors to a computing unit or to an actuator to transmit the measurement signals are exposed to the same disruptive elements and therefore risk the same consequences.
In addition, the change of working implement there again poses an adaptation problem. Specifically, it is necessary to carry out a calibration operation on the computing unit to take account of the signals sent by the sensor according to the shape and dimensions of the new implement. Specifically, the behavior of the kinematic linkage changes on this occasion.
A first problem that the invention proposes to solve is that of making it possible to measure the inclination of the working implement reliably. Another problem that the invention seeks to solve is that of allowing an automatic correction of the inclination of the working implement based on the inclination measurement taken.
DESCRIPTION OF THE INVENTION
The invention therefore relates to a civil engineering machine of the “loader” type. Such a machine comprises a chassis and working equipment. The working equipment comprises:
at least one arm that can move relative to the chassis, an arm cylinder, of which one end is connected to the arm and the other to the chassis, and capable of rotating the arm relative to the chassis, a working implement articulated relative to the arm, a main kinematic linkage forming, with a portion of the working implement and a portion of the arm, a main deformable mechanism, an implement cylinder capable of being controlled to cause the deformation of the main deformable mechanism in order to ensure the inclination of the working implement relative to the arm, a hydraulic control circuit allowing the implement cylinder to be supplied by means of a directional flow valve.
According to the invention, the working equipment also comprises:
a secondary kinematic linkage forming, with a portion of the arm situated in the zone of articulation of the arm on the chassis, a deformable telltale mechanism whose deformation is a direct function of the inclination of the working implement relative to the chassis, an angular sensor capable of measuring an angle representative of the deformation of the telltale mechanism, a command and control device connected to said angular sensor and capable of controlling the supply of the implement cylinder and/or of the arm cylinder.
In other words, the machine that is the subject of the invention comprises a telltale mechanism that corresponds to a “copy” of the main working mechanism and which faithfully and mechanically imitates the movements of it, so that an angular sensor measures an inclination-image. This inclination-image is representative of the inclination of the working implement. Since the telltale mechanism is shifted closer to the chassis, it is less exposed to the elements causing deterioration or disruption of the inclination measurement. The inclination of the bucket is therefore controlled in a closed loop which provides advantages in terms of precision.
According to an advantageous embodiment of the invention, the main kinematic linkage ( 20 , 21 ) is formed by an assembly of link rods defining a main deformable quadrilateral, and the secondary kinematic linkage is formed by an assembly of small link rods ( 40 , 41 , 42 , 43 ) defining a deformable telltale quadrilateral ( 35 ), whose deformation is a direct function of the inclination ( 100 ) of the working implement ( 15 ) relative to the chassis ( 5 ).
Advantageously, the dimensions of the telltale mechanism may correspond to a homothetic reduction of the dimensions of the main deformable mechanism. Therefore, the telltale mechanism produces a faithful image of the main deformable mechanism.
Advantageously, the telltale mechanism may be deformable under the mechanical action of a movement transmission member. In other words, this member mechanically sends information of the angle of inclination of the working implement relative to the chassis. This connecting bar causes the telltale mechanism to rotate. Such a member therefore makes it possible to faithfully transmit the movement of the deformable quadrilateral to the telltale mechanism and, consequently, to transmit the angle of inclination to be measured.
According to a practical embodiment of the invention, the movement transmission member may comprise a rigid bar articulated at one end on one of the link rods forming the main mechanism and at the other end in the zone of attachment of the arm to the chassis.
In a particularly advantageous manner, the machine may also comprise:
a hydraulic compensation device making it possible to generate an additional control pressure in order to move the implement cylinder according to the signal transmitted by the angular sensor, a circuit selector capable of transmitting to the directional flow valve the higher of the control pressure delivered by the manipulator and the additional control pressure,
so that the inclination of the working implement is kept generally constant irrespective of the controls applied by the driver on the manipulator. Therefore, the unexpected dumping of the goods is prevented, whether it is on the cabin side for materials contained in a bucket or on the side external to the machine for goods installed on a pallet, which is likely to slip forward along forks that are overinclined.
The hydraulic device is therefore capable of automatically keeping the working implement in a substantially horizontal inclination, so as to keep the goods in the working implement.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner of embodying the invention and the advantages that result therefrom will clearly emerge from the description of the embodiment that follows supported by the appended figures in which:
FIG. 1 is a general side view of a machine of the loader/backhoe type,
FIG. 2 is a side view of the working equipment of the loader of FIG. 1 shown in two different positions of the arm,
FIG. 3 is a kinematic diagram of the working equipment of a machine according to the invention,
FIG. 4 represents a diagram similar to that of FIG. 3 , to which is added the hydraulic circuit of a machine according to the invention, and
FIG. 5 is a perspective view illustrating a telltale quadrilateral according to one embodiment of the invention.
MANNER OF EMBODYING THE INVENTION
As already explained, the invention relates to a civil engineering machine having a “loader” function, and for example a “backhoe-loader” as illustrated in FIG. 1 . In its front portion, this machine 1 comprises working equipment 2 allowing it to perform the function of a loader. This working equipment 2 consists mainly of two arms 3 situated on either side of the machine. At its rear end 4 , these arms 3 are articulated on the chassis 5 .
These arms 3 have a slightly curved shape so that their front ends 6 are substantially level with the ground in the lowest position of the arms 3 . These arms 3 may be moved under the action of arm cylinders 7 also situated on either side of the chassis 5 . These cylinders 7 are articulated at one end 8 on the chassis, and at their opposite ends 9 on the main arms 3 , substantially at the mid-level 10 of the latter.
The actuators for moving the movable members are in this instance linear hydraulic cylinders, but they could equally be rotary, pneumatic cylinders or else electric motors, all equally capable of rotating the arms of the machine. In addition, the linear cylinders employed may be connected to the parts to be moved at their ends, or at any point of their structure. Similarly, nevertheless without departing from the context of the invention, the machine may also comprise only one arm instead of two.
At their front ends 6 , the main arms 3 receive a working implement that is advantageously interchangeable if it is mounted on an implement-carrier. In this instance, the working implement represented in the figures is a bucket 15 . Nevertheless, it could be another working implement, such as a fork for transporting pallets. In the rest of the description, the working implement 15 and its carrier will be assimilated because the interchangeability of the implement does not form a determinate feature of the present invention.
This bucket 15 is articulated relative to the arms 3 , so that it can be inclined at different angles. In this manner, the opening 16 of the bucket may be inclined either toward the front when materials 17 are to be loaded into it, or toward the rear when the bucket 15 is full and it is moved.
In the embodiment illustrated corresponding therefore to one side of the working equipment 2 , two link rods 20 , 21 form, with the terminal portion (on the working implement side) of one or the other arm 3 and a portion of the bucket 15 , a main deformable quadrilateral which defines four apexes 60 , 61 , 62 , 63 . More precisely, the working equipment 2 comprises a first rear link rod 20 which is articulated on the arm 3 at the apex 64 of the quadrilateral situated at one end of the link rod 20 .
The equipment also comprises a front link rod 21 which is articulated at each end on the one hand on the bucket 15 , and on the other hand on the implement cylinder 27 and the link rod 20 , at the apex 60 and the apex 61 of the deformable working quadrilateral. The two link rods, front 21 and rear 20 , are therefore articulated with one another at their top ends 25 . The articulations are in this instance achieved by means of pivot links known to those skilled in the art. Therefore, when the inclination of the bucket 15 varies relative to the arm 3 , the deformable quadrilateral including the link rods 20 , 21 deforms.
This deformation of the deformable quadrilateral is caused by the action of an implement cylinder 27 . This implement cylinder 27 has a rod 28 that is articulated on the bucket 15 , substantially between the articulation point situated at the apex 62 of the front link rod 21 and the articulation point 13 of the bucket relative to the arm 3 . The end situated on the side of the chamber 29 of the implement cylinder 27 is, for its part, connected to the common articulation point 25 of the two link rods, front 21 and rear 20 . Therefore, when a force is applied by the implement cylinder 27 , the latter causes the common articulation point 25 of the link rods to move closer to or further from the bucket 15 , and therefore deforms the deformable quadrilateral and consequently, varies the inclination of the bucket 15 relative to the arm 3 .
The main mechanism is therefore in this instance a main deformable quadrilateral, just as the telltale mechanism 35 is a telltale quadrilateral. Similarly, the main kinematic linkage consists of an assembly of link rods, just like the secondary kinematic linkage.
In addition, to allow a measurement of the inclination 100 of the working implement, the machine 1 comprises a connecting bar 30 that extends essentially along the arm 3 and parallel to it, substantially from the zone where the rear link rod 20 is articulated to the articulation point 4 of said arm 3 relative to the chassis 5 . The front end 31 of this connecting bar 30 is articulated on the rear connecting rod 20 , at an articulation point 32 .
The other end 33 of the connecting bar 30 is itself articulated substantially at the articulation point 4 of the arm 3 relative to the chassis 5 . More precisely, this end 33 of the connecting bar is articulated jointly with a telltale quadrilateral 35 as schematically illustrated in FIG. 3 .
The connecting bar 30 therefore defines a closed contour articulated at four points by means of pivot links whose axes are perpendicular to the plane containing the arm 3 and the connecting bar 30 . Since the arm may be curved ( FIGS. 1 and 2 ), this contour is not necessarily a quadrilateral like those appearing in FIGS. 3 and 4 .
This telltale quadrilateral 35 is formed by an assembly of small link rods 40 , 41 , 42 , 43 , a portion of the working implement 15 and a portion of the arm 3 situated in the zone of articulation of the arm 4 on the chassis 5 . Like the working quadrilateral, pivot links articulate these small link rods with one another so as to render the telltale quadrilateral 35 deformable. The articulations are in this instance also made by means of pivot links known to those skilled in the art. Like the working quadrilateral, the telltale quadrilateral 35 may comprise one or more curved small link rods 40 , 41 , 42 , 43 , as appears in FIGS. 4 and 5 .
In addition, the dimensions of the small link rods 40 , 41 , 42 , 43 are chosen so that the telltale quadrilateral 35 forms a homothetic reduction, hence a faithful image, of the working quadrilateral. The apexes of origin of the deformable working quadrilateral each have an apex-image in the telltale quadrilateral 35 .
In addition, because of the homothetic construction, the lengths of the small link rods 40 and 41 correspond respectively to the lengths of the link rods 20 and 21 , each multiplied by a reduction factor K, that is to say lying between 0 and 1. The lengths of the small link rods 42 and 43 correspond respectively to the multiples, by this same factor K, of the lengths 22 and 23 of the portions separating respectively the apexes 61 and 62 on the one hand, and 62 and 63 on the other hand. For convenience of representation, the figures are not to scale. Therefore, the telltale quadrilateral 35 is represented respectively bigger than in the majority of real cases.
On the other hand, a homothetic transformation retains the angles. Therefore, the angles at the apex-images of the telltale quadrilateral 35 are equal to the angles at the apexes of origin of the deformable working quadrilateral. In practice, this is true if the functional clearances necessary to the mobility of the parts forming the machine are excluded.
Furthermore, the telltale quadrilateral 35 is capable of deforming under the mechanical action of a movement transmission member. This member consists of a rigid bar 30 articulated at one end on one of the link rods 20 forming the working quadrilateral and at the other end in the zone 4 of attachment of the arm 3 to the chassis 5 .
Therefore, when the quadrilateral deforms, this bar 30 may mechanically transmit the information of the angle of inclination 100 of the working implement relative to the chassis 5 . This bar 30 causes the deformation of the telltale quadrilateral 35 by means of a small link rod 40 of the telltale quadrilateral that is articulated on the connection 401 . The bar 30 therefore makes it possible to reliably transmit the movement of the working quadrilateral to the telltale quadrilateral 35 . Since the dimensions of the telltale quadrilateral 35 are chosen so as to correspond to a homothetic reduction of the dimensions of the deformable working quadrilateral, the deformation of the telltale quadrilateral 35 and, consequently, the angle of inclination 101 to be measured between one of the small link rods, for example the link rod 42 , and the chassis 5 are therefore a direct function of the inclination 100 of the working implement 15 relative to the chassis 5 .
Clearly, the rigid bar 30 playing the role of a movement transmission member may be replaced by any other equivalent system, such as for example by one or more flexible and inextensible cables suitably disposed, nevertheless without departing from the subject of the invention.
Under the action of the rigid bar 30 , the telltale quadrilateral 35 is therefore capable of deforming when the working quadrilateral deforms. That is why this second quadrilateral 35 is called the “telltale” quadrilateral.
In addition, an angular sensor 44 is installed on the telltale quadrilateral 35 in order to measure the inclination 101 of the small link rod 42 , when the latter moves, jointly with the deformable working quadrilateral, under the action of the rigid bar 30 . In practice, the angular sensor 44 may be a goniometer or any other measurement instrument making it possible to determine, directly or indirectly, the angle of inclination 101 of one of the small link rods 40 , 41 , 42 , 43 of the telltale quadrilateral 35 . Because of the construction explained above, the angular sensor 44 therefore makes it possible to determine the inclination 100 of the working implement relative to the chassis 5 .
It is understood that such a device has the advantage of being adaptable to various working implements 15 likely to be mounted on the arm 3 , whether it be a bucket of different geometry or a fork or any other implement.
In addition, such a device can operate in a reliable and durable manner because the angular sensor 44 is not situated at a distance from the chassis, but, on the contrary, is close to the latter. It is therefore little exposed to elements causing deterioration or disruptions of measurement such as vibrations, impacts, rain, dust or mud; just like any electric wires for transmitting the measurements that it makes. This device therefore provides a reliable and easily exploitable measurement of the inclination of the bucket 15 relative to the chassis. In addition, through its construction and arrangement, the device is robust and may therefore provide measurements in a reliable manner without risk of failure.
Furthermore, the changing of the working implement poses no problem of adaptation to various working implements because the telltale quadrilateral will always sustain a deformation that is directly representative of the inclination of the working implement.
The angular sensor 44 is incorporated into the hydraulic control circuit of the cylinders 7 , 27 so as to form a closed loop with the actuators that the cylinders 7 , 27 form.
Therefore, the machine 1 also comprises a hydraulic manipulator 58 which the driver of the machine 1 operates. The hydraulic manipulator 58 delivers a control pressure to a hydraulic directional flow valve 46 connected to each of the chambers 29 , 281 of the implement cylinder 27 so as to control the arm cylinder 7 and/or the implement cylinder 27 and, consequently, to modify the respective inclinations of the arms 3 and/or the implement 15 to complete the work to be done.
According to a practical embodiment of the invention, as illustrated in FIG. 4 , the machine 1 also comprises an electrohydraulic compensation device 45 making it possible to generate an additional control pressure capable of moving the implement cylinder 27 .
This electrohydraulic compensation device 45 in this instance comprises two solenoid valves 452 , connected upstream to the main source of pressure that is the pump 53 and an electronic computer 451 . Each solenoid valve 452 controls one of the two circuits for supplying the chambers 29 , 281 of the implement cylinder 27 , that is to say the dumping circuit or crowding circuit to incline the bucket 15 respectively toward the front or toward the rear. The electronic computer 451 drives these two solenoid valves 452 through electric signals that are a function of the signals sent by the angular sensor 44 to the electronic computer 451 , signals that are representative of the inclination 101 of a small link rod 40 , 41 , 42 or 43 of the telltale quadrilateral, as explained above.
Therefore, when the arms 3 incline under the action of their cylinders 7 , the telltale quadrilateral 35 deforms causing a change in the measurement of the angle of inclination 101 of the bucket 15 , hence a change of instruction at the solenoid valves 452 , then a change of supply of the hydraulic directional flow valve 46 and finally of the implement cylinder 27 . Consequently, the implement cylinder 27 is inclined so as to compensate for the inclination of the arms 3 thereby keeping the inclination 100 of the bucket 15 constant.
To manage the conflict of priorities arising from the juxtaposition of a manual control and an automatic compensation control, pressure sensors 601 , 571 are installed on the dump and lift ducts in order to measure the pressures thereof originating from the manual controls. As a function of these measurements, the electronic system disables the automatic correction function, in order to give priority to the user, who may therefore modify the position of the bucket 15 as he wishes.
When the user does not act on the manipulator 58 , the control pressures fall below a threshold, so that the pressure sensors 601 , 571 deliver a null signal. At this precise moment, an angle position instruction is stored in an electronic memory, if necessary incorporated into the electronic computer 451 so as to preserve the inclination of the bucket 15 during subsequent raising and lowering movements of the arm 3 . The correction is made only during the raising or lowering of the arms 3 .
In addition, the control members of the dump and lift circuits, namely the manipulator 58 and the solenoid valves 452 , are connected to a circuit selector 54 whose downstream output is connected to the power directional flow valve 46 in order to transmit to it the higher of the control pressure delivered by the manipulator 58 and the additional control pressure delivered by one of the solenoid valves 452 . Therefore, priority is given to the most “important” instruction, so that the user is capable of controlling the bucket 15 while being sure of obtaining compensation in the case of excessive inclination 100 . Consequently, the inclination 100 of the bucket 15 is kept generally constant when no control is applied by the driver to the manipulator 58 , while the inclination of the arm 3 varies.
More precisely, the control manipulator 58 has a pressure supply 59 from the main pump 53 , and two outlet channels 57 , 60 each corresponding to a direction of inclination of the working implement, in this instance of the bucket 15 . The first outlet 60 corresponds to the command to raise the bucket 15 , while the second outlet 57 corresponds to the command to dump the bucket 15 .
Therefore, the circuit selector 54 transmits to the directional flow valve 46 the pressure that is the greatest between the pressure for controlling the manipulator 58 and the pressure delivered by the electrohydraulic device 45 . It is this pressure that then acts on the directional flow valve 46 that causes the movement of the implement cylinder 27 .
In practice, when the pressure delivered by the manipulator 58 is greater than that originating from the electrohydraulic device 45 , it is the pressure value originating from the manipulator 58 that acts on the directional flow valve 46 . Conversely, when the inclination 100 of the working implement induces a movement of the rigid bar 35 such that the pressure delivered by the electrohydraulic device 45 is greater than that originating from the manipulator 58 , this correction pressure originating from the electrohydraulic device 45 acts on the directional flow valve 46 .
In other words, and according to a variant of the invention, the system automatically compensates for the inclination 100 of the bucket 15 in order to prevent the latter from dumping rearward, if it remains in the initial inclination, corresponding to that of the bottom portion, that is to say close to the ground.
As a variant, the dimensions of the small link rods of the telltale quadrilateral may not produce a homothetic reduction of the working quadrilateral. In this case, a correction by the computer may be envisaged if the curve of variation of the angle of the small link rod as a function of the inclination of the working implement is known.
The result of the foregoing is that the machine according to the invention has the essential advantage of allowing a reliable measurement of the inclination of the working implement. This measurement allows this inclination to be controlled in a closed loop. This control may take place automatically to allow an automatic correction of the inclination of the working implement when it is raised. Consequently, the present invention makes it possible to increase the safety of the driver, because the risk of materials falling toward the rear is eliminated.
|
A loading machine has working equipment which includes at least one arm, an actuator for displacing the arm, a working tool hingable with respect to the arm, a main kinematic chain forming together with the working tool part and the arm part a main deformable mechanism and a controllable tool actuator for deforming the main deformable mechanism to cause the tool to tilt. The machine also has a secondary kinematic chain forming together with the part of the arm, which is located in the area of articulation thereof on the frame, a deformable reference mechanism whose deformation directly corresponds to the inclination angle of the working tool, an angle sensor for measuring an angle displaying the deformation of the reference mechanism with respect to the frame, and a control device which is connected to the sensor and controls the feeding of the working tool actuator and/or the arm actuator.
| 4
|
BACKGROUND OF THE INVENTION
The invention relates to a method and to an apparatus for the insertion of a weft thread into a series shed weaving machine with an insertion nozzle and a weft thread distribution apparatus, with the weft thread being continuously fed in by means of a fluid flow and being inserted into successive sheds, and to an apparatus for carrying out the method using a feed-in nozzle and an insertion nozzle and a weft thread distribution apparatus.
In series shed weaving machines the weft threads are inserted by means of a weft thread distribution apparatus. An apparatus of this kind is described in WO 96/38612. In this apparatus a weft thread is introduced by means of a continuous air flow into a connection passage between the weaving rotor and the ring part and inserted via a shoot-in tube into the shed. A severing apparatus and a clamp are placed after the shoot-in tube. Immediately after the arresting of the weft thread by the clamp, a loop is formed in the connection passage as a result of the continuous supply of yarn and is stretched or tautened after the severing of the weft thread.
As the weft thread insertion or speed of rotation of the weaving machine increases, the loop in the connection passage becomes longer and kinks arise, which can lead to congestion and weft faults. In order to improve the undoing of the loops, air can be blown into the connection passage under high pressure by means of an injection nozzle.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved method and apparatus for the insertion of a weft thread into a series shed weaving machine.
The advantages which can be achieved with the invention are to be seen essentially in that the thread loop is produced outside the weft thread distribution apparatus and is thus controllable or adjustable, in that the insertion capacity can be increased, and in that the insertion is done at a uniform fluid pressure.
The invention will be explained in the following with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment of an apparatus in accordance with the invention for the insertion of a weft thread;
FIG. 2 shows a nozzle arrangement in section;
FIG. 3 shows a second embodiment of an apparatus made in accordance with the invention for the insertion of a weft thread;
FIG. 4 shows a third embodiment of an apparatus made in accordance with the invention for the insertion of a weft thread; and
FIG. 5 shows a fourth embodiment of an apparatus in accordance with the invention for the insertion of a weft thread.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made to FIGS. 1 and 2. Starting from a thread storage, a weft thread 1 is introduced into a weft thread distribution apparatus 3 via a metering apparatus and the weft thread insertion apparatus 2 under discussion here and then inserted past a severing apparatus 5 and a thread clamp 6 into a shed which is formed on a weaving rotor 7. The weft thread insertion apparatus comprises a feed-in nozzle 11, a nozzle arrangement 12 and an insertion nozzle 13 which is arranged in the weft thread distribution apparatus 3. Furthermore, a guide member 14 and an auxiliary nozzle 15 are associated with the insertion apparatus. The nozzle arrangement 12 is connected with a rotary slide valve 16 via lines 17 to the compressed air system of the weaving machine.
As shown in FIG. 2 the nozzle arrangement 12 has a body 21 with a passage hole 22 and two seat surfaces 23 and two nozzle needles 24, 25 which are arranged in such a manner that the openings are oriented towards one another. The nozzle needles are formed as hollow needles so that a through-going forwarding passage for a weft thread is present in the nozzle arrangement. An inlet funnel 26 for the weft thread is formed at the one nozzle needle 24, while the other nozzle needle 25 is directly connected to the insertion nozzle 13 in the weft thread distribution apparatus 3.
In the following a method for the insertion of a weft thread by means of the above described-apparatus is explained.
The weft thread 1 is continuously drawn off from the metering apparatus by means of the feed-in nozzle 11 and introduced into the nozzle needle 24. At this time point compressed air is supplied to the nozzle arrangement through the line 17 as a result of the setting of the rotary slide valve 16 so that an air flow is produced in the through-bore 22 which seizes the weft thread and forwards it to the insertion nozzle 13. The weft thread is then shot into the shed and forwarded through the shed in a known manner by means of the travelling field produced by the relay nozzles. Prior to the beginning of the clamping process the reversal of the air flow in the nozzle arrangement 12 is effected by the rotary slide valve so that a thread drawing force is produced in the direction opposite to the forwarding direction. As a result of the thread drawing forces produced by the insertion nozzle and the travelling field, the weft thread continues to be inserted into the shed. Once the weft thread is clamped, the force component of the travelling field is cancelled so that the thread drawing forces produced by the insertion nozzle in the forwarding direction and the nozzle arrangement in the opposite direction cancel, i.e. the forwarding of the weft thread into the shed is interrupted. As a result of this interruption and of the continuous supply of weft thread from the feed-in nozzle 11 a thread loop is produced between the feed-in nozzle 11 and the nozzle arrangement 12. After the clamping the weft thread is severed and blown into the connection passage 4 with the help of the injector nozzle and the weft thread end is substantially extended and held ready for the insertion into the weft thread distribution apparatus 3. By means of the rotary slide valve 16 the flow direction in the nozzle arrangement 12 is again reversed so that the thread loop is undone and the weft thread is inserted into the next shed.
Reference is made to FIGS. 3 to 5, with the weft thread travelling as in the above-described first embodiment. The weft thread insertion apparatus 31 comprises the feed-in nozzle 11, a deflection member 32, an insertion nozzle 33 and an auxiliary nozzle 34. The deflection member 32 is formed in the shape of a bar and arranged to be pivotal about an axis of rotation 35.
In the embodiment of FIG. 4 a guide member 41 and a thread clamp 42 are provided in contrast to the embodiment of FIG. 3.
In the embodiment of FIG. 5 a drive element 51 for the deflection member 32 and an insertion nozzle 52 is provided as well as a thread clamp 53 which is integrated into the body of the insertion nozzle.
In the following the method for the insertion of a weft thread by means of the apparatus in accordance with FIGS. 3 to 5 will be explained.
The weft thread 1 is continuously drawn off from the metering apparatus by means of the feed-in nozzle 11 and introduced past the deflection member 32 into the insertion nozzle 33. At this point in time compressed air is supplied to the insertion nozzle and the weft thread is shot into the shed. The weft thread is then forwarded through the shed in a known manner by means of the relay nozzles. With the actuation of the thread clamp 6 the weft thread is held and the forwarding of the weft thread into the shed is interrupted. As a result of this interruption and of the continuous supply of weft thread from the feed-in nozzle, a thread loop is produced between the feed-in nozzle 11 and the insertion nozzle 33 through positive deflection by means of the deflection member. After the clamping the weft thread is severed by means of the severing apparatus 5 and the thread ends formed are blown by the air flow into the connection passage 4. The force exerted by the air flow on the weft thread acts, on the one hand, as a restraining force with respect to the formation of a loop and, on the other hand, as a stretching or tautening force for the thread end. Through the release of the weft thread by means of the deflection member, the weft thread is inserted into the next shed by means of the insertion nozzle while the loop is undone at the same time.
In the apparatus in accordance with FIG. 4 the weft thread 1 is clamped and held by means of the thread clamp 42 so that, on the one hand, a thread loop forms between the feed-in nozzle 11 and the thread clamp 42 and, on the other hand, the thread end produced by means of the severing apparatus 5 is held stretched, i.e. taut and extended and ready for introduction into the weft thread distribution apparatus. The formation of a loop can be effected by means of an active or a passive deflection movement.
In the method a weft thread is continuously supplied by means of a fluid flow and inserted into successive sheds. Through reversal of the flow direction or deflection of the weft thread a thread loop is formed outside of the weft thread distribution apparatus, whereby the weft thread remains stretched inside the weft thread distribution apparatus.
A nozzle arrangement of which the flow direction is reversible is provided for carrying out the method.
|
Lengths of weft thread are sequentially inserted in sheds formed by a series shed weaving machine. Weft thread is continuously supplied with a fluid flow. By reversing the flow direction of the fluid flow or deflecting the weft thread, a thread loop is formed outside a weft distribution apparatus of the weaving machine so that the weft thread remains taut inside the weft thread distribution apparatus. A nozzle arrangement in which the fluid flow direction is reversible or a weft thread clamping and deflecting arrangement are used to form the loop and maintain the weft thread taut.
| 3
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.