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This application is a national stage completion of PCT/EP 2003/010276 filed Sep. 16. 2003 which claims priority from German Application Serial No. 102 44 026.3 filed Sep. 21, 2002.
FIELD OF THE INVENTION
In motor vehicles, vibrations can occur during the slippage phase of a clutch in the power train, which are generated in the motor vehicle clutch. As can be gathered from the technical article, “Testing Power Trains as Exemplified by Clutch Grabbing: Whole Power Train Development,” ATZ Automobile Engineering Journal 103 (2001) 44 ff., these vibrations arise when periodic torques are generated in connection with a slipping clutch, which torques lie in the characteristic frequency of the power train dynamically separated by the clutch.
BACKGROUND OF THE INVENTION
These vibrations, also known as clutch grabbing, can be self-excited or automatically excited. Self-excited clutch grabbing is caused by a drop of the clutch facing friction value in relation to the rate of sliding and can be rather considerable as a function of the power train overall damping.
Automatically excited clutch grabbing is in contrast stimulated by external sources in relation to the friction partners, including crankshaft axial vibrations or parallel deviations on the clutch pressure plate, in combination with an angular offset between the clutch pressure plate and the clutch disk that supports the friction lining.
The torsional vibrations that arise in the power train in connection with clutch grabbing are converted by the driven motor vehicle wheels into longitudinal oscillations of the entire motor vehicle and are transmitted via the service elements and via the motor vehicle seats to the motor vehicle occupants. Thus clutch grabbing is perceived by the vehicle passengers as unpleasant vibrations or oscillations that can also be associated with noise stress.
Although a high-level damping in the components of the power train does reduce the oscillation amplitudes with automatically excited clutch grabbing, this is nonetheless often an unrealistic demand due to the general wish for the lowest possible fuel consumption for a motor vehicle, since a permanently high damping in the power train is basically attainable only through a constantly active elevation of friction losses, for example in the transmission, in the bearings and in the seals.
Inserting a clutch friction lining with an increasing friction value curve over the rate of sliding has been proposed, for example, as a countermeasure for reducing clutch grabbing and the disturbing longitudinal oscillations of the motor vehicle that go along with it. The friction linings available at this time, however, are not capable of this.
Another possibility for reducing clutch grabbing consists in further reducing the manufacturing tolerances in the clutch region, however this would be possible only with a very high manufacturing expenditure, and it will produce a rather modest contribution to reducing clutch grabbing (“Grabbing-Causes and Remedies,” Prof. Albert Albers, Dr. Eng., Daniel Herbst, Cert. Eng. in: 6 th LuK Colloquium, 1998).
Metrological recording of a clutch jerking in connection with a starting clutch or a converter bridging clutch by means of suitable sensors and a control and regulating device as well as active measures for ending this clutch jerking are moreover known from EP 845 616 A2. These measures consist of altering the ignition time of an internal combustion engine connected with the clutch via drive engineering in order thus to act upon the input torque into the clutch. Another measure provides for increasing the contact pressure of the clutch pressure plate on the clutch friction lining, whereby a slippage operation of the clutch offering some advantages is no longer possible.
Since the known measures bring on unsatisfactory results with respect to avoiding or reducing clutch grabbing, the object of the invention consists in presenting a method and device with which the disturbing rotational vibrations of the power train or the disturbing longitudinal oscillations can at least be diminished in their amplitude height.
The accomplishment of this objective is disclosed in the characterizing features of the method and device main claims, while advantageous further developments and refinements of the invention can be inferred from the dependent claims.
SUMMARY OF THE INVENTION
With respect to the method of the invention, it is accordingly provided that the disturbing vibrations are recognized and evaluated by a control and regulating device using suitable sensors. If previously established limiting values are exceeded, then the control and regulating device acts upon at least one motor vehicle device such that by its activation, the disturbing vibration in the power train and/or in the entire motor vehicle is completely eliminated or at least damped in its amplitude. For this purpose, a rotating component of the motor vehicle power train is acted upon by the control and regulating device via the at least one motor vehicle device such that the rotating component or components are continuously or periodically braked in their rotational motion or are stimulated to a compensatory vibration.
In this connection, it is provided that the at least one device acts on at least one motor vehicle component such that a longitudinal oscillation of the overall motor vehicle stimulated by the vibrations in the power train is eliminated or at least damped in its amplitude height. To generate a compensatory vibration that will damp the disturbing vibrations in the power train or in the entire motor vehicle, at least in their amplitude, or for a damping braking intervention on rotating components in the power train, this compensatory vibration or the brake intervention has the same or a similar frequency and a vibration phase offset in relation to the vibration that is acting in a disturbing manner. This vibration phase offset leads to a mutual compensation of the vibration amplitudes.
In a refinement of the method of the invention, it can be provided that a starting or gear box of the motor vehicle transmission is actuated by the control and regulation device such that its torque transmission capacity oscillates with the frequency of the disturbing vibration and has the mentioned vibration phase offset in relation to this, due to which the amplitude of the disturbing vibration is reduced to a predetermined value.
In another variant of the control method, it is provided that a service brake acting on the input shaft of a transmission is actuated by the control and regulating device such that, with a rise in the vibration amplitude of the disturbing vibration, the service brake brakes the transmission input shaft to a rotational speed that reduces the amplitude of the disturbing vibration to a predetermined value that does not have a disturbing action. Such a control method is especially appropriate for use in power trains in which the transmission is constructed as an automatic or automatically shiftable claw shift transmission.
In motor vehicles in whose power train an abrasion-free permanent brake (for example, an electromagnetic retarder arranged behind the transmission in terms of drive engineering) is inserted, this permanent brake can be actuated via the control and regulation device such that, with a rise in the vibration amplitude of the disturbing vibration, the permanent brake brakes the rotational speed of the wheel drive shafts of the motor vehicle to the extent that the amplitude of the disturbing vibration is reduced to a predetermined value.
Another variant of the method of the invention provides that the service brakes of the driven motor vehicle wheels are actuated by the control and regulating device such that here too, with a rise in the vibration amplitude of the disturbing vibration, the motor vehicle wheels are slowed down to a rotational speed through which the rotary or longitudinal oscillation disturbing the amplitude is reduced to a predetermined value.
It is also possible to act upon an output actuator of the motor vehicle internal combustion engine via the control and regulating device. For this, the rotational speed of the internal combustion engine is altered in accordance with the method in the event of a perceived rise in the vibration amplitude of the disturbing vibration such that this is oscillated with the frequency of the harmful vibration, however its phase displacement to this is such that the amplitude of the disturbing vibration is reduced to a predetermined and not disturbing value.
Such an operating behavior of the internal combustion engine is especially appropriate if the clutch grabbing described at the beginning occurs while switching the motor vehicle. The control and regulating device here regulates the rotational speed of the internal combustion engine when clutch grabbing occurs, so that during one of these known switching travels, the switching rotational speed (for example, the idling rotational speed) of the internal combustion engine is increased such that the amplitude of the disturbing vibration is reduced to a predetermined value. The switching rotational speed can for this purpose be increased at once or in stages until the vibration compensation is attained.
If there is a double clutch transmission present in the power train of the motor vehicle, the two clutches can be used to influence the disturbing vibrations such that, upon recognizing the clutch grabbing, the second clutch is activated in a controlled manner by the control and regulating device with respect to its torque transfer capacity in addition to the first clutch (which is closed for the gear step set) as frequently and as long, until the amplitude of the disturbing vibration is reduced to a predetermined value. In this way, the periodic opening and closing of the second clutch of the double clutch transmission will preferably take place with the same frequency that the disturbing frequency has, but will nonetheless have a vibration phase offset in relation to this through which the vibration amplitudes will at least be largely compensated.
In another refinement of the control method of the invention, it can be provided that, in a power train with a gear box, its synchronization device is activated in a braking manner in the region of a not just shifted transmission step as frequently and as long as it takes until the amplitude of the disturbing vibration is reduced to a predetermined value.
Finally, it should be mentioned that the control and regulating device can record the rotational speeds of the clutch input side and the clutch output side in implementing its control and regulation objectives described above with the aid of rotational speed sensors, and the longitudinal acceleration of the motor vehicle is ascertainable with the aid of a longitudinal acceleration sensor which can, for example, be arranged in the region of a motor vehicle seat.
With respect to the device for implementing the control and regulation functions described, first of all a control and regulating device is arranged in the motor vehicle, which is preferably designed as a microcomputer. The microcomputer can moreover be a transmission or motor control device, for example. This control and regulation device is connected with the sensors for recording disturbing vibrations in the vehicle via sensor lines. The control lines in contrast lead to devices in the power train with which motor vehicle parts can be set into vibration or braked such that their frequency, vibration amplitude and phase angle in relation to the frequency, vibration amplitude and phase angle of the disturbing vibration leads to a damping of the amplitude of the disturbing vibration when these two vibrations are superimposed.
Rotational speed sensors that, for example, record the rotational speed of the input side or the output side of a clutch, preferably a starting clutch or gearbox or other rotating parts in the power train, belong to the sensors mentioned. Moreover the control and regulating device is preferably connected to a vibration sensor that can sense a disturbing vibration in the power train or in the motor vehicle overall. Preferably longitudinal oscillations of the entire motor vehicle in the region of the motor vehicle seat can be recorded with such a sensor as mentioned in the description of the method.
In a further refinement of the device of the invention, it is provided that the control and regulating device is connected to a control device for activation of the clutch via a control line. Through this construction, the clutch can be stimulated to the desired compensatory vibration behavior preferably independently of a conventional clutch activation device. Or, for example, a clutch pressure plate can be periodically or continuously subjected to contact pressure with a higher contact pressing force on the friction lining of the clutch disk.
Moreover, it can be provided with respect to the device of the invention that the control and regulating device is connected to an actuator for activation of a synchronization device in an automated or automatic gearbox via a control line. Such an actuating device can be a hydraulically or pneumatically activatable piston-cylinder arrangement with which a clutch sleeve arranged in the transmission on a transmission shaft is axially displaceable. This clutch sleeve acts in an inherently known manner on axially displaceable synchronizing rings with the help of which a loose wheel can be engaged on the transmission shaft in the torque transmission path such that it can be braked.
In implementing the method of the invention, it can also be provided that the control and regulating device is connected to the actuating device of a service brake for braking an input shaft of a gearbox, preferably an automated claw clutch transmission, via a corresponding control line. In accordance with the method, this service brake is then periodically or continuously activatable independently of its synchronization objectives in connection with a gear shifting for slowing down the transmission input shaft and therewith for reducing the disturbing vibrations.
In another refinement of the device for implementing the control and regulation method of the invention, it is provided that the control and regulation device is connected to a retarder device, thus with an abrasion free permanent brake for braking the drive shaft of the motor vehicle drive wheels via a control line. In the end, the control and regulation method of the invention can also be conducted with a device in which the control and regulation device is connected to actuators on the service brakes of the driven motor vehicle wheels via control lines. Through a corresponding brake intervention by the retarder or by the service brake on the driven motor vehicle wheels, although the occurrence of unfavorable rotary vibrations on the clutch cannot be avoided, with such a measure the damping of the drive train can be periodically increased or constantly increased for the period the clutch grabbing occurs so that the amplitudes of the disturbing vibrations are not unpleasantly high.
Finally, it can be provided that the control and regulating device is connected to a rotational speed adjustment device, thus for example with the output actuator of the internal combustion engine, via a control line. The desired result can also be attained through the procedural influencing of the motor rotational speed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a schematic representation of a drive train of a motor vehicle as well as a large number of variants of the device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In this drive train an internal combustion engine 1 can be connected as is inherently known with a gear box 8 via drive engineering through a starting clutch 4 . For this the clutch 4 has an input side 5 , which is connected to the crankshaft 2 of the internal combustion engine 1 , as well as an output side that stands in connection with the input shaft 3 of the transmission 8 . The output shaft 16 of this transmission 8 drives a differential transmission 17 via an abrasion-free permanent brake 23 , thus for example an electromagnetically operating retarder, from which two drive shafts 18 for motor vehicle wheels 19 , 20 proceed.
Service brakes 21 , 22 are arranged on the motor vehicle wheels 19 , 20 , which can be constructed as drum or disk brakes. Moreover a control and regulation device 24 is represented, which preferably includes a microcomputer and can be an integral component of a motor or transmission control apparatus.
Finally, this Figure illustrates a motor vehicle seat 37 as a final motor vehicle main component on which a motor vehicle occupant can perceive vibrations in the motor vehicle. The motor vehicle seat 37 is physically fastened on the motor vehicle floor 40 via a spring damping system, which is here indicated by a spring 38 and a damping piston 39 , for transmission of the vibrations generated by the drive train in this simplified representation.
As was explained at the beginning, rotary vibrations arising in the motor vehicle clutch 4 in certain operating phases, as for example during the switching operation of the motor vehicle, extend over all main components of the drive train to the motor vehicle wheels 19 , 20 where these rotary vibrations are converted to longitudinal oscillations and are introduced into the motor vehicle body via the wheel suspension. These longitudinal oscillations are perceived as unpleasant by the driver situated on the motor vehicle seat 37 so that the measures of the invention are required to reduce these vibrations at least to a tolerable level.
For this it is first of all necessary to establish the rotary vibrations in the drive train or the longitudinal oscillations of the body resulting from them via corresponding sensors and to communicate them to the control and regulation device. For this purpose, two alternate types of sensors are represented in this drawing, which can be used individually or jointly. Thus one rotational speed sensor 34 , 36 is respectively arranged on the input side 5 and on an output side 6 of the clutch 4 , with which the clutch rotary vibrations of the clutch 4 that characterize grabbing can be established. This rotational speed information can be forwarded via sensor lines 33 , 35 to the control and regulation device 24 . The rotational speed values that characterize the disturbing rotary vibrations can, however, also be metrologically ascertained on all other rotating parts of the drive train.
Another possibility for sensing the disturbing vibrations in the motor vehicle consists, for example, in arranging a vibration sensor 41 in the region of the motor vehicle seat 37 for recording motor vehicle longitudinal oscillations, which sensor is connected to the control and regulating device 24 mentioned through a separate sensor line 32 .
Once the control and regulation device 24 has determined, on the basis of the sensor information mentioned, that the rotary vibrations ascertained on the clutch 4 , for example, and/or the longitudinal oscillations occurring on the motor vehicle body exceed a predetermined amplitude limiting value stored in the control and regulation device, countermeasures are taken which basically all serve to reduce the amplitude of the disturbing vibration (motor vehicle longitudinal oscillation or rotary vibration in the drive train) to the extent that these are preferably reduced below the perception threshold of a motor vehicle occupant situated on the motor vehicle seat. This is attained in that at least one device on or in the drive train of the motor vehicle acts on at least one component in the motor vehicle drive train such that the latter is continuously or periodically braked in its rotary motion or is stimulated to a vibration so that the vibration amplitude of the disturbing vibration is reduced.
A first variant for conducting this control and regulating method can be technically realized in that there is active influence upon a rotating component of the clutch 4 using an actuating device 7 , here a piston-cylinder arrangement, such that the disturbing rotary motion of the clutch 4 is damped. The actuating device 7 is connected with the output side 6 of the clutch 4 in this exemplary embodiment of the invention. The direction of action of the piston-cylinder arrangement 7 is moreover preferably oriented in or against the direction of rotation of the clutch component 6 , even though an axial action upon the clutch 4 can also be appropriate. The piston-cylinder arrangement 7 receives the activation signal through a driving power 31 of the control and regulation arrangement 24 .
In another refinement of the invention, a service brake 11 can be used to reduce the disturbing vibrations present in the drive train. Such a service brake 11 is, as a rule, provided anyway in automated claw gear transmissions 8 in order with its aid to brake down the rotational speed of the transmission input shaft 3 to the synchronizing rotational speed of the higher gear in up-shifting processes. This service brake 11 can, however, also be independently activated or deactivated of such shifting synchronization objectives by the control and regulation device 24 for this to reduce the disturbing rotary vibrations of the clutch grabbing to an extent that is tolerable to the rider. Thus this service brake 11 can, for example, be closed momentarily if the control and regulating device 24 determines a rising flank of the drive train rotary motion or the motor vehicle longitudinal motion mentioned. The amplitude of the disturbing vibrations is reduced in this way.
The braking effect described can also be obtained in connection with completely synchronized transmissions in that step synchronization means of an unshifted gear are, likewise, activated when the control and regulating device 24 determines a rising slope of the drive train rotary vibration or the motor vehicle longitudinal oscillation. In this way, the amplitude of the disturbing vibrations is damped. A synchronization device 10 is provided in the transmission 8 in the schematic drawing explained here in which a clutch sleeve 13 arranged torsionally resistant, but axially displaceable on the transmission output shaft 16 , interacts with a synchronizing ring 14 whose inclined synchronizing surface is pressed during an axial displacement on the transmission output shaft 16 against a synchronizing incline 12 of a toothed wheel 9 arranged on this shaft 16 . The clutch sleeve 13 is axially moved by an actuating device 15 (piston-cylinder arrangement) on the transmission output shaft 16 , wherein the actuating device 15 receives its actuating commands via a control line 27 from the control and regulating device 24 . Here the toothed wheel 9 is at least temporarily connected torsion resistant with the transmission output shaft 16 which exerts a braking and rotary vibration damping action on the drive train downstream.
Furthermore the FIGURE shows that the abrasion-free service brake (retarder) 23 , which is arranged in accordance with drive engineering behind the transmission 8 , can also be used for damping rotary vibrations by braking a drive train shaft, for example a cardan shaft. With the rapidly reacting retarder 23 , the latter can also be used for generating a compensatory vibration in which the phase angle of the compensatory vibration is displaced in relation to the phase angle of the disturbing rotary vibration in the drive train such that the overlapping vibrations at least partially cancel each other out.
The effect described can also be attained by a corresponding activation of the service brakes 21 , 22 of the driven motor vehicle wheels 19 , 20 which, likewise, takes place according to the aforementioned control rules. It is particularly advantageous with this technical solution that no additional actuators on the service brakes 21 , 22 are needed, but available electro-hydraulic brake actuating devices can be actuated via control lines 29 , 30 by the control and regulation device 24 .
Moreover, the internal combustion engine 1 can also be controlled and regulated with regard to its motor rotational speed by the control and regulating device 24 via a control line 25 , such that a motor rotational speed vibration with identical frequency is built up when the control and regulating device 24 determines a rising curve of the aforementioned drive train rotary vibration and the motor vehicle longitudinal oscillation. The grabbing vibration is then damped by the then different rotational speed differences on the clutch.
The disadvantage with this method is that a sawtooth pattern is contained over the course of time of the motor rotational speed, however it is felt to be significantly less disadvantageous by a motor vehicle occupant than the grabbing vibrations described.
It can also be provided that the control and regulation device 24 disposes of suitable resources for determining a switching operation of the motor vehicle. In such an operating case, the switching rotational speed of the internal combustion engine is raised by the control and regulation device 24 when the clutch grabbing occurs. This can take place step by step by corresponding signals through the control line 25 , for example, to the power actuator of the internal combustion engine 1 . This internal combustion motor-related damping of the grabbing vibration is also advantageous because no additional actuator equipment is necessary for this.
Finally, in the interest of completeness, it should be pointed out that even with a power train with a double clutch transmission 43 , a damping of the clutch grabbing vibrations can be attained in that, using the clutch actuator of the second transmission clutch, the latter can be momentarily, periodically closed at least partially with the already mentioned phase offset in order to reduce the amplitude of the disturbing vibration by the braking action so triggered.
The method of the invention and the device of the invention for conducting the aforementioned method can include individual or even several of the different method and device refinements.
In addition to the sensors represented, other rotational speed sensors can be used in the drive train whose signals yield the necessary information through a corresponding conversion in an electronic unit.
Reference numerals
1
internal combustion engine
2
crankshaft
3
transmission input shaft
4
clutch
5
input side of the clutch
6
output side of the clutch
7
actuating device, piston-cylinder
arrangement
8
transmission
9
toothed wheel
10
synchronization device
11
service brake
12
synchronization incline
13
clutch sleeve
14
synchronizing ring
15
actuating device, piston-cylinder
arrangement
16
transmission output shaft
17
differential transmission
18
drive shafts of the driven motor vehicle
wheels
19
motor vehicle wheel
20
motor vehicle wheel
21
service brake
22
service brake
23
retarder, permanent brake
24
control and regulating
device
25
control line
26
control line
27
control line
28
control line
29
control line
30
control line
31
control line
32
sensor line
33
sensor line
34
rotational speed sensor
35
sensor line
36
rotational speed sensor
37
motor vehicle seat
38
spring
39
damping piston
40
motor vehicle floor
41
vibration sensor
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A method and a device with which disturbing vibrations are diminished at least in the height of their amplitude. A control and regulating device ( 24 ) and suitable sensors ( 34, 36, 41 ) activate a device ( 7, 11, 15, 23, 29, 30 ) when previously established limiting values are exceeded with regard to procedure, with which components of the motor vehicle are influenced such that the disturbing vibrations are damped or compensated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of recording devices, and more particularly, to a device that is attached or incorporated into a book and that records, archives and plays back multiple discrete messages.
2. Description of the Related Art
During the past several years, many new types of electronic products have been developed which are capable of recording and then delivering a non-discrete or single audio message when activated. This technology has been used in conjunction with photo frames, children's books (where pre-recorded messages are generally used) and other products. The use of this technology has allowed one to play pre-recorded discrete messages or a single message or to record generally non-discrete messages associated with a picture or other memorabilia.
For example, U.S. Pat. No. 4,809,246 issued to Jeng discloses a sound illustrated book which identifies the opened page and plays a pre-recorded message related to the particular page. U.S. Pat. No. 5,277,492 issued to Skidmore discloses a photo album which includes a tape player. The tape player allows one to describe the pictures in the photo album rather than give a written description, and to record them in a non-discrete manner; i.e., wherein one recording immediately follows the one before it so that there is no way to listen to a message without listening to or fast-forwarding over all of the messages that came before it.
U.S. Pat. NO. 5,577,918 issued to Crowell discloses a message delivery device which saves a single re-recordable message. The device can also be attached to various products. U.S. Pat. No. 5,520,544 issued to Manico et al. discloses a photo album module that records, stores and plays back audio messages. The device is activated by a plurality of photo detectors mounted in the album cover.
Although the above devices may function adequately for their stated purposes, it is believed that none is a fully satisfactory solution to the need for providing an inexpensive, easy to use message recording device that stores a plurality of messages and may be coupled to a pre-existing books or integrated into a new book. Furthermore, these prior art devices do not fulfill the objective of providing a versatile message recording device that enables and disables the recording function, thus allowing messages to be permanently archived. These prior art devices also do not disclosed a method for recording and archiving a large number of discrete messages, without requiring the construction of an unduly large device not suited for use in conjunction with a book, photo album, or similar object. These devices also do not illustrate an apparatus for efficiently preserving a written record identifying the discrete recorded messages. A need therefore existed for a device that is capable of performing these functions. The present invention answers these needs, and provides other related advantages.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a recording device that couples to a book.
A further object of the present invention is to provide a recording device that couples to a book and that archives a plurality of discrete messages.
It is still a further object of the present invention to provide a recording device that couples to a book and that archives a plurality of discrete messages and which may be readily coupled to an existing book.
It is yet a further object of the present invention to provide a recording device that couples to a book and that archives a plurality of discrete messages and which may be integrated into an existing book.
It is still a further object of the present invention to provide a recording devices that couples to a book, that archives a plurality of discrete messages, and which also allows the user to identify in writing each individual recorded message.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
According with the present invention, a device coupled to a book for recording and archiving multiple unique messages is disclosed. The device has a playback and recording means, a memory means for storing a plurality of discrete recorded messages, a message selection means for triggering one of the plurality of discrete message to play or record, an archival control means for enabling and disabling permanent archiving of one or all of the plurality of discrete messages, and an attachment means for coupling the device to a book.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a recording device of the present invention that may be attached to a book cover.
FIG. 2 is a bottom view of the recording device of FIG. 1, showing double sided adhesive tape mounted on the underside of the device.
FIG. 3 is a perspective, partially cut-away view of a message indicator multiplier, illustrating another embodiment of the recording device of the present invention.
FIG. 4 is a perspective view of the recording device shown in FIG. 1 coupled to a yearbook.
FIG. 5 is a perspective view of the recording device shown in FIG. 1 coupled to a three ring binder.
FIG. 6 is a perspective view of another embodiment of the recording device of the present invention, shown integrated into a cover of a book.
FIG. 7 is a block diagram of the main components of one embodiment of the recording device of the present invention.
FIG. 8 is a block diagram of the main components of a second embodiment of the recording device of the present invention.
FIG. 9 is a top view of the displayed components of one embodiment of the recording device of the present invention.
FIG. 10 is a top view of the displayed components of another embodiment of the recording device of the present invention.
FIG. 11 is a partially cut-away perspective view of the recording device of the present invention, illustrating one structure used for preserving a written record identifying the particular recorded messages.
FIG. 12 is a cross-sectional view of the apparatus of FIG. 11, taken along line 12--12.
FIG. 13 is a perspective view of a another embodiment of the recording device of the present invention, illustrating another structure used for preserving a written record identifying the particular recorded messages.
FIG. 14 is a partially cut-away perspective view of the structure shown in FIG. 13, illustrating the storage of the accordion-style structure.
FIG. 15 is a partially cut-away perspective view of the recording device of the present invention, illustrating an archiving feature.
FIG. 16 is a partially cut-away perspective view of the recording device of the present invention, illustrating another method for attaching the recording device to a book.
FIG. 17 is a top, schematic view of the recording device of the present invention, illustrating the use of the present invention with conductive ink.
FIG. 18 is a cut-away, side view of the recording device of the present invention shown in FIG. 19.
FIG. 19 is a top view of another embodiment of the recording device of the present invention.
FIG. 20 is a perspective view of the recording device of the present invention, illustrating another method for attaching the recording device to a book.
FIG. 21 is a cross-sectional end view of the recording device attached with the device shown in FIG. 20.
FIG. 22 is a side cross-sectional view of the recording device attached with the device shown in FIG. 20, shown along line 22--22 of FIG. 21.
FIG. 23 is a perspective view of the recording device of the present invention, illustrating another method for attaching the recording device to a book.
FIG. 24a is an exploded perspective view of the recording device of the present invention, illustrating a structure used for preserving a written record identifying the particular recorded messages.
FIG. 24b is a perspective view of the recording device of FIG. 24a.
FIG. 25 is a perspective view of another embodiment of the recording device of the present invention, illustrating an LCD-type display.
FIG. 26 is a perspective view of the recording device of the present invention, illustrating another method for attaching the recording device to a binder-type book.
FIG. 26a is a perspective view of the recording device of FIG. 26, shown prior to attachment to a binder-type book.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of describing this invention, the definition of a book includes yearbooks, memory books, scrap books, photo albums, binders, notebooks, folders or other related materials.
Referring now to the drawings, FIG. 1 illustrates a preferred embodiment of a book recorder 10. The book recorder 10 is preferably constructed from a strong plastic material, although other materials may be substituted as desired. The book recorder 10 is preferably of a thin rectangular shape, as shown in FIG. 1.
A record indicator 16 and a plurality of message indicators 18 are preferably aligned vertically on the face of the book recorder 10, as shown in FIG. 1. The book recorder 10 is activated by selecting first the record indicator 16 and then one of the plurality of message indicators 18. Consequently, the record indicator 16 and the plurality of message indicators 18 are preferably recessed in order to prevent accidental activation of the book recorder 10. (The electrical components of the book recorder 10 are shown in FIGS. 7-8, discussed below.).
Still referring to FIG. 1, after the user selects the record indicator 16 and then one of the plurality of message indicators 18, an audible message may then be spoken into a microphone 14 to record a message. Once the message is completed, the record indicator 16 is selected once more in order to end the recording session. Other discrete messages may also be recorded by again selecting the record indicator 16 and then selecting a different message indicator 18. Furthermore, if the user does not wish to keep one of the recorded messages, a new message may be substituted for an already recorded message by selecting the record indicator 16, selecting the corresponding message indicator 18, and then entering a new message into the microphone 14.
A message may be played back at any time subsequent to the message being recorded. A message is played back by selecting the corresponding message indicator 18 that was used to record the desired message. The selected saved message will then be audibly played back through the speaker 12.
Another embodiment of the present invention includes a plurality of message multipliers 28, shown in FIG. 3. The message multipliers 28 multiply the number of messages that each message indicator 18 represents. For example, to record a new message, the record indicator 16 is selected followed by one of the message multipliers 28. Next, one of the message indicators 18 is selected and a message is recorded. The saved message then corresponds to the previously selected combination of message multiplier 28 and message indicator 18. Consequently, to play back the recorded message, the same message multiplier 28 is selected with the same message indicator 18. Thus, the purpose of the message multipliers 28 is to save space on the book recorder 10 and to allow the book recorder 10 to be more compact, yet have the ability to save many messages.
Preferably, a discrete text label 22, shown in FIGS. 1, 10-14, 19, 24a-b, and 26 is attached to the book recorder 10. The text label 22 is preferably integral to the book recorder 10 of the present invention, and may be located on a reduced thickness extension of the device that extends over the back cover of a book or binder when the book recorder 10 is coupled to the back cover of a book or binder--as shown in FIGS. 1 and 4. As shown in FIG. 2, in this embodiment, an adhesive strip 26 may be coupled to the underside of the book recorder 10 directly below the text label 22, to allow ready adhesion of the book recorder 10 to a book cover. Of course, other adhesion methods may be used, including glue, velcro, clip, etc. The purpose of the text label 22 is to allow the user to write down a brief description of what a corresponding message indicator 18 describes. For example, an individual entry in the text label 22 may describe a page in a book to which the corresponding message indicator 18 refers, or the name of the person who recorded the message. The text label 22 may also take the form of a liquid crystal display, wherein information regarding a corresponding message indicator 18 which is inputted into the book recorder 10 with an appropriate inputting means such as a keypad is displayed.
FIGS. 11-12 show another embodiment of the text label 22, here identified by the reference number 22b. The text label 22b essentially comprises a plurality of two-holed individual sheets 23, which may be added to, removed, or replaced using the bar 25, which snaps onto corresponding posts 27 in the manner shown in FIGS. 11 and 12. Preferably, the number of individual sheets 23 at least corresponds to the number of message multipliers 28, and may exceed that number. In such instance, the individual sheets 23 should bear indicia 28a corresponding to one or more message multipliers 28. Referring now to FIGS. 24a-24b, another embodiment of a holder for the text label 22 is shown, here identified by the reference number 22c. Like the embodiment of FIGS. 11-12, the text label 22b essentially comprises a plurality of two-holed individual sheets (not shown), which are placed over posts 27. A bar 27a is configured, in the manner shown in FIG. 24a, to snap into place over the individual sheets (not shown) and the posts 27 so as to secure the individual sheets (not shown) into position.
Referring now to FIGS. 13 and 14, a text label 22d is shown. The text label 22d is a card or paper 23c that is pre-folded accordion style as shown in FIG. 13. The text label 22d may be stored on the book recorder 10 using prongs 29. When deployed, as shown in FIG. 13, the text label 22c may contain multiple pages upon which information can be written or typed. As discussed above with respect to FIGS. 11-12, there preferably should be at least as many pages in the text label 22c as there are message multipliers 28, as well as indicia 28a to correspond to one or more message multipliers 28.
Other methods of attaching or incorporating the book recorder 10 to a book are shown in FIGS. 6, 16-17, 20-23, and 26-26a. Referring first to FIG. 6, the book recorder 10 may be directly attached to an extended back cover 13a of a book 11, by adhesive tape, glue, screws or other adhering method, so that the entire book recorder 10 rests on the inside of the back cover 13a. Referring now to FIG. 16, the book recorder 10 may be inserted into a sleeve 15 located on a back cover 13, which is dimensioned as shown in FIG. 16 to permit full access to the face of the book recorder 10--yet also to allow removal of the book recorder 10 for purposes of using the recorder separately from the book, adding memory, changing the batteries, or repairing or replacing the book recorder 10. Referring now to FIGS. 20-22, the book recorder 10 may be removably coupled to a base 100, which base 100 would in turn be secured to the extended back cover 13a of a book 11. The base 100 has mounted thereon two strongs 110, which connect with corresponding detents 120 located on the base of the book recorder 10 in the manner shown in FIG. 22 to secure the book recorder 10 in position. Referring now to FIGS. 26-26a, the book recorder 10 may be coupled or attached to a sheet 150, which sheet 150 has a plurality of openings 152 to correspond to the number and placement of rings on a ring-type binder 160, so as to permit removable attachment of the sheet 150 and book recorder 10 to the binder 160. (The sheet 150 may also be used to store text information, as described above for example with respect to FIGS. 1, 10-14, 19, and 24a-24b.).
Referring now to FIG. 17, another embodiment of the book recorder 10 is shown. Here, the message indicators 18 are coupled to the book recorder 10 using conductive ink, so that a message may be recorded directly corresponding to an image in the book 11. In this embodiment, the message indicators 18 would be dispersed throughout the book 11.
Referring now to FIG. 23, the book recorder 10 may be inserted into the spine of a book 11. In this embodiment, either the entire book recorder 10 may be inserted into the spine of the book 11, or only those portions of the book recorder 10 that are not required to be seen by a user during use of the book recorder 10 may be inserted into the spine of the book 11, while those required to be viewed by the user--e.g., the message indicators 18, microphone 14, and speaker 12--would be displayed on the back cover of the book in a second book recorder 10 lacking those components, wherein the two book recorders 10 would be coupled with wires or conductive ink.
Referring now to FIG. 19, a memory available function 50 may be included on the book recorder 10. When the memory available function 50 is activated by pressing the button labelled "TIME," the book recorder 10 will audibly state the amount of recording/save time available in the book recorder's memory module 60 or 60a (see FIGS. 7 and 8).
Referring to FIG. 15, a general archival control 32 is shown. The general archival control 32 allows a user to enable and disable all of the message indicators 18. Thus, messages may be permanently saved by selecting the general archival control 32 which causes the recording indicator 16 (see FIG. 1) to become disabled, thus preventing the accidental recording over of a previously recorded message. The archival control means 32 may again be selected to re-enable the recording indicator 16. The general archival control 32 is preferably recessed in the housing of the book recorder 10 as shown in FIG. 15, to minimize the possibility that it will be pressed accidentally. (Alternatively, the general archival control 32 may be placed, for example, within the battery compartment 24 (shown in FIG. 1)).
Referring now to FIG. 19, a discrete archival record enable/disable control 62/62a (see FIGS. 7-8) is shown, for use with a message multiplier 28. To activate the archival record enable/disable control 62 or 62a using the embodiment of FIG. 19, a user would first depress the SECURITY button 52, followed by the appropriate message multiplier 28 and, optionally, a message indicator 18. If the user depresses only the SECURITY button 52 and one message multiplier 28, then all of the messages on that multiplier are archived. For example, if the user depresses the SECURITY button 52 followed by the message multiplier 28 designated by the letter "D", then messages D1-D25 would be archived. A repeat of that operation would de-activate the archival record enable/disable control 62 or 62a. (LED indicators 31 corresponding to each of the message multipliers 28 alert the user when a message multiplier 28 has been depressed.) Alternatively, and still referring to FIG. 19, a user may archive a single message by depressing the SECURITY button 52, followed by a message multiplier 28, followed by a message indicator 18. For example, if the user depresses the SECURITY button 52 followed by the message multiplier 28 designated by the letter "D" and then followed by the message indicator 18 designated by the number "3", then message D3 would be archived. A repeat of that operation would de-activate the archival record enable/disable control 62 or 62a. Preferably, the logic control block 72/72a (see FIGS. 7-8) is programmed to indicate audibly with a voice prompt when a message(s) has been archived with a word such as "LOCKED," and to indicate that a message(s) has been unarchived with a word such as "UNLOCKED."
Referring to FIGS. 7-8, the electronic operation of the book recorder is shown. The discrete message selectors and display 82, 82a, provide input and output for the user. The logic control block 72, 72a acts on selections made by the discrete message selectors and display 82, 82a and controls the display therein to provide feedback to the user. (The logic control block 72a preferably includes a compression and expansion algorithm. The compression and expansion algorithm optimizes the storage of saved messages, thereby allowing more message time to be saved on the book recorder 10.) The archival record enable/disable control(s) 62, 62a provides a setting to the logic control block 72, 72a to disable or enable further recording to a message. The memory module(s) 60, 60a provide storage for messages to the audio playback and recorder module 84, 84a which plays back messages stored in or records messages to the memory modules 60, 60a. Because the book recorder 10 may be used for memorabilia, such as photo albums or yearbooks, the recorded messages need to be saved for a substantial period of time. Therefore, in order to ensure longevity of the messages, the memory modules 60, 60a would preferably be non-volatile so as to preserve all of the previously saved messages, even if an interruption in the power supply from the power source 64 occurred.
The memory expansion 66, 66a provides a way to connect additional storage to allow longer messages or a greater quantity of messages than is available from the built-in memory modules 60, 60a. This would permit the addition of memory 200 (see FIGS. 19, 24a) to increase the amount of available message time. The additional memory 200 could be inserted into the book recorder 10 in the manner shown in FIGS. 19 and 24a. The power source 64 provides power to the system, which can be either battery power or an external input device.
The input to the recorder in the audio playback and recorder module 84, 84a can be provided by a microphone (or other audio input) B6, 86a directly as shown in FIG. 7 such as possible for an analog memory storage, or pre-processed by an A/D processing block 68 as shown in FIG. 8, to provide conversion for digital storage and pre-processing and/or amplification of the audio signal.
The output from the playback in the audio playback and recorder module 84, 84a can be direct to a speaker 88, as shown in FIG. 7, or post-processed by a D/A processing 70, as required for digital memory, as shown in FIG. 8, before entering a speaker 88a.
A communications port 74, 74a provides a means for uploading and downloading messages from the memory modules 60, 60a and any memory connected to the memory expansion 66, 66a. This allows an external unit to transfer messages into the memory or out of memory for other purposes such as use on a personal computer or over the Internet. For example, the messages saved on the book recorder 10 may be uploaded and saved onto a computer (not shown), or a recorded message from a computer (e.g., a school fight song) could be downloaded onto the book recorder 10. This communications port 74, 74a may also control playback or storage of samples via the audio playback and recorder module 84, 84a by remotely directing the logic control block 72, 72a to initiate playback or recording of the message.
While the invention has been described with reference to particularly preferred embodiments, it will be apparent that various modifications can be made without departing from the spirit of the invention. Such modifications are intended to fall within the scope of the appended claims.
|
A recording device that is coupled to a book. The recording device records, saves and plays back a plurality of discrete messages. An archival control disables and enables the device, thus permitting the user to ensure that no new messages will be accidentally recorded over existing saved messages.
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BACKGROUND OF THE INVENTION
[0001] The present application relates to processing of medical instruments prior to reuse, and more particularly to pretreatment of the instruments prior to a sterilization process.
[0002] Medical instruments after use are typically contaminated with blood and other body matter as well as potentially contaminated with infectious microorganisms. Before being reused in a future medical procedure these instruments must be washed and sterilized. The process of washing and sterilization becomes complicated when blood and other matter are allowed to dry onto the instruments. Blood in particular becomes much more difficult to remove once it has dried.
[0003] It has been suggested that after use instruments be placed into a liquid filled container to maintain moisture and prevent foreign matter thereon from drying and becoming more difficult to remove. However, such containers can be quite heavy and difficult to move and the liquid therein can become contaminated and it is not desirable to spill this liquid. One solution that has been proposed is an enzymatic foam which is prayed onto instruments after use and prior to eventual sterilization. The foam weighs less than a liquid and purports to enhance cleaning by initiating some degree of cleaning at the early stage when the foam is placed upon the instrument. Such foams provide little or no antimicrobial activity.
SUMMARY OF THE INVENTION
[0004] The present invention improves upon the concept of enzymatic foams by providing a foam which has superior cleaning ability against dried on blood versus an enzymatic foam and also provides a substantial measure of antimicrobial activity. In some aspects of the invention, the foam also provides enhanced foam life. The antimicrobial activity is a desirable benefit to help reduce infection of personnel who may come in contact with the used instruments prior to their terminal cleaning and sterilization.
[0005] A method, according to the present invention, provides for treating an instrument after contamination of a surface thereof. The method comprises the steps of: covering the surface with a foam comprising hydrogen peroxide; and maintaining the foam on the surface to keep the surface moist.
[0006] Preferably, the foam dissolves blood deposits on the surface, including any blood deposits which are dried.
[0007] Instruments are preferably placed into the container prior to adding foam or may be added after adding foam. Preferably, a lid is placed on the container after all instruments to be placed therein are inside and covered with foam. Typically it is then transported with the instrument and foam therein to a different location where the instrument will be cleaned. Preferably, foam is maintained on the surface until such time as the instrument is to be cleaned.
[0008] Preferably, the foam kills microorganisms on the instrument and has an antimicrobial action sufficient to cause a five log reduction of Pseudomonas aeruginosa in thirty minutes, and more preferably within ten minutes.
[0009] In one aspect of the invention a lumen within the instrument is treated with a solution comprising hydrogen peroxide.
[0010] The foam can be applied from a pressurized foam dispensing container or from a manually pumped foam dispensing container.
[0011] In one aspect of the invention, the step of covering the surface with the foam comprises passing a gas through a foamable solution comprising hydrogen peroxide in the container to cause the solution to foam and cover the surface. The gas can have a higher pressure than atmospheric pressure and be passed into the foamable solution through a semi-permeable barrier which is permeable to the gas and impermeable to the foamable solution. Alternatively, a vacuum can be drawn upon the container to induce air to foam the foamable solution, preferably by passing into the foamable solution through a semi-permeable barrier which is permeable to the gas and impermeable to the foamable solution. Alternatively, a foamable solution comprising hydrogen peroxide in the container can be agitated to cause the solution to foam and cover the surface.
[0012] Preferably, the percentage of hydrogen peroxide in the foam is from 0.1% to 15%, more preferably from 2% to 10%, and most preferably from 3% to 8%. The foam may additionally include peracetic acid.
[0013] Preferably, the foam further comprises a surfactant and a foam booster comprising a modified silicone. It can also include a thickening agent comprising an acrylic polymer. Preferably, the foam is capable of maintaining its volume for more than one hour after it contacts the surface. The method can also include the step of reconstituting collapsed foam by passing gas therethrough causing it to refoam.
[0014] It may be desirable when it comes time to remove the instruments from the container to apply a defoaming agent to the foam and or a neutralizing agent which neutralizes the hydrogen peroxide. This makes it easier to see the instruments in the container, reduces the chance of injury from a sharp instrument and reduces personnel contact with hydrogen peroxide.
[0015] An instrument pretreatment system according to the present invention comprises a foamable solution comprising hydrogen peroxide which is packaged with instructions for use which include instructions to foam the solution onto a contaminated surface of a medical instrument prior to cleaning of the instrument and to maintain the foam in contact with the surface until such time as the instrument is cleaned.
[0016] It can further comprise a hydrogen peroxide solution and instructions to apply the hydrogen peroxide solution into a lumen of an instrument prior to cleaning of the instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a block diagram of a system according to the present invention;
[0018] FIG. 2 is a block diagram of an enhanced system of FIG. 1 ;
[0019] FIG. 3 is a front elevation view of a foam dispenser for use in the system of FIG. 1 ;
[0020] FIG. 4 is a front elevation view of an alternative foam dispenser for use in the system of FIG. 1 ;
[0021] FIG. 5 is a front elevation view in cross-section of a container for use in the system of FIG. 1 ;
[0022] FIG. 6 is a front elevation view in cross-section of an alternative container for use in the system of FIG. 1 ; and
[0023] FIG. 7 is a front elevation view in cross-section of a further alternative container for use in the system of FIG. 1 .
DETAILED DESCRIPTION
[0024] During a medical procedure, one or more medical instruments may be employed. These instruments become contaminated with blood, tissue and potentially contaminating microorganisms. Typically the instruments are set aside after use to await washing and sterilization. This waiting period can be several hours or much longer. During this waiting period blood and other matter which dries upon the instrument becomes much more difficult to remove during the subsequent cleaning procedure. This can be a particular problem when a procedure lasts many hours and uses many different instruments or when due to limited personnel time, it is difficult to process the instruments in a timely fashion.
[0025] Turning to the drawings, and in particular to FIG. 1 , according to the present invention, after use and prior to a complete washing and sterilization procedure the instruments 10 are placed into a container 12 and covered with a foam 14 . The foam comprises hydrogen peroxide. The hydrogen peroxide foam 14 acts to dissolve blood, even dried on blood, and to initiate antimicrobial activity against microorganisms on the instrument. The foam 14 encapsulates the instruments 10 and maintains a moist state thereon to inhibit drying of blood and other matter on the instrument. Keeping the blood and other matter from drying promotes superior washing in a subsequent washing and sterilization process.
[0026] One method of dispensing the hydrogen peroxide foam 14 would be to spray the foam 14 from a foaming aerosol spray can 16 . Such cans employing a propellant are well known to those of skill in the art. Also, the container 12 preferably includes an insert or tray 18 having a plurality of apertures therethrough to allow easy rinsing of the instruments 10 and for efficient diffusion of vapor sterilants into contact with the instruments 10 when the container 12 is used in a sterilization procedure. A lid 20 is also preferably provided.
[0027] Instruments 10 are placed into the container 12 as they are finished being used in a procedure. A quantity of foam 14 is sprayed over the instruments 10 to keep them moist and inhibit drying of blood thereon, to start dissolving the blood thereon and to disinfect the instruments. The foam 14 preferably contains between 1 to 15 percent hydrogen peroxide by weight and more preferably between about 3 to 8 percent. Such concentration may not achieve a level of sterilization sufficient for immediate reuse on a patient, but will substantially reduce the load of microorganisms on the instrument surfaces so as to minimize the chances that personal handling the instruments, especially during cleaning, will get infected from them. The lid 20 is preferably placed on the container 12 prior to transporting the instruments from the location of the procedure, such as an operating room, to the location of the washing. When the instruments 10 are ready for washing, the insert 18 can be lifted out and the foam 14 rinsed off while the instruments 10 are still in the insert 18 . Normal washing and sterilization may then occur. Washing may comprise treatment with enzymatic cleansers, detergents or other cleaning agents, preferably in combination with mechanical scrubbing or agitation, including optionally treatment with water jets, ultrasonic vibration or the like. Following washing the instrument should be sterilized, preferably in the container 12 , such as by chemical vapor or steam autoclaving.
[0028] It is particularly convenient if the container 12 with the insert 18 is adapted for use in the terminal sterilization such as a STERRAD® hydrogen peroxide/gas plasma system or a steam system. Suitable materials, such as liquid crystal polymers, and construction details for such containers, especially containers adaptable to either steam or hydrogen peroxide, are shown in U.S. Pat. Nos. 6,379,631 and 6,692,693 to Wu incorporated herein by reference. Such containers are typically wrapped with CSR wrap or incorporate semi-permeable membrane filters to allow sterilization of instruments therein with vapor sterilants while protecting the against ingress of potentially contaminating microorganisms after sterilization.
[0029] Turning also now to FIG. 2 , in addition to covering an exterior surface of the instrument 10 with the hydrogen peroxide foam 14 , if the instrument 10 has a lumen 22 , a liquid or mist 24 comprising hydrogen peroxide is preferably sprayed into the lumen 22 prior to placing the instrument 10 into the container 12 and covering the instrument 10 with foam 14 . The mist is also preferably dispensed from a pressurized container 26 employing a propellant as is known in the art.
[0030] Turning also now to FIG. 3 , to enhance convenience, a dispenser 28 can be provided with a foaming nozzle 30 and misting nozzle 32 . A foamable hydrogen peroxide solution and a propellant are in the dispenser 28 and when distributed through the misting nozzle 32 the solution comes out as a mist 34 appropriate for squirting into a lumen and when dispensed through the foaming nozzle 30 the solution comes out as a foam 36 appropriate for covering exterior surfaces of an instrument.
[0031] Turning also now to FIG. 4 , rather than employ a propellant, a dispenser 38 having a foamable solution of hydrogen peroxide therein may employ manually operated misting nozzle 40 and foaming nozzle 42 . A particularly useful foaming nozzle 42 is the Airspray F2-L11 available from Airspray NV, Alkamar, The Netherlands.
[0032] Turning also now to FIG. 5 , a container 44 is illustrated having a mesh insert 46 and lid 48 . A lower portion of the container has a well 50 into which a quantity of foamable hydrogen peroxide solution 52 may be placed. A port 54 and valve 56 connect to the well 50 through an air bubbler or hydrophobic membrane 58 . A supply of compressed air or other gas attached to the port 54 percolates through the bubbler 58 to foam the hydrogen peroxide solution 52 and fill the container 44 with the hydrogen peroxide foam. Preferably, the lid 48 contains a viewing window 60 to view the progress of foam filling the container 44 and one or more vents 62 to allow gases in the container 44 to escape and allow the foam to fill the container 44 . The vent 62 may be a simple opening, or be covered with a semi-permeable membrane or employ a one-way valve.
[0033] Turning also to FIG. 6 , an alternative container 64 as structured similarly to the container 44 with an insert 66 well 68 with a hydrophobic membrane 70 and a lid 72 with a window 74 rather than a port for compressed air or gas, a port 76 is provided on an upper location of the container 64 and has a valve 78 and an additional hydrophobic membrane 79 . By attaching the port 76 to a source of vacuum and drawing gases out of the container 64 , air will percolate into the container through the hydrophobic membrane 70 providing a foaming action to hydrogen peroxide solution 52 in the well 68 . In either this container 64 or the previous container 44 , if the foam dissipates, it can be refoamed by employing the vacuum or compressed gas as the case may be.
[0034] Turning also now to FIG. 7 , a container 80 having an insert 82 and lid 84 with a window 86 has a well 88 . An agitator 90 sits within the well 88 and is attached to a motor 92 and power source, such as a battery 94 , which is controlled via a switch 96 . Engaging the agitator 90 foams a hydrogen peroxide solution 52 in the well 88 to fill the container 80 .
EXAMPLES
[0035]
[0000]
Formulation 1
Type of foam
Mousse-Like Thick
Foams
Application
Spray
Ingredients
Wt (g)
Deionized Water
60.0
Carbopol Aqua SF-1
3.4
Polymer
Tween 80
2.0
Glycerol
2.0
NaOH (1.0N)
As needed
H 2 O 2
As needed
Preservative(s)
As needed
[0000]
Formulation 2
Type of foam
Mousse-Like Thick
Foams
Application
Spray
Ingredients
Wt (g)
Deionized Water
120.0
Carbopol Aqua SF-1
6.8
Polymer
Tween 80
4.0
Glycerol
1.0
NaOH (1.0N)
As needed
H 2 O 2
As needed
Preservative(s)
As needed
[0000]
Formulation 3
Type of foam
High Foaming
Application
Aeration/Vacuum/Spray
Ingredients
Wt (g)
Deionized Water
78.0
Fixate G-100 Polymer
6.0
Tween 80
1.0
SilSense Copolyol-1
1.0
Silicone
Glycerin
4.0
H 2 O 2
As needed
Preservative(s)
As needed
[0000]
Formulation 4
Type of foam
High Foaming
Application
Aeration/Vacuum/Spray
Ingredients
Wt (g)
Deionized Water
85.0
SilSense Q-Plus
1.0
Silicone
Tween 80
2.0
Glycerol
3.0
59% H 2 O 2
5.0
Preservative(s)
As needed
[0000]
Formulation 5
Type of foam
High Foaming
Application
Aeration/Vacuum/Spray
Ingredients
Wt (g)
Deionized Water
91.0
Fixate G-100 Polymer
6.0
Tween 80
1.0
SilSense Q-Plus
1.0
Silicone
59% H 2 O 2
5.0
Preservative(s)
As needed
[0000]
Formulation 6 (for ~6% peroxide)
Type of foam
High Foaming
Application
Aeration/Vacuum/Spray
Ingredients
Wt (g)
Deionized Water
150.0
Tween 80
8.0
SilSense Copolyol-1
2.0
Silicone
59% H 2 O 2
18.0
[0000]
Formulation 7 (for ~3% peroxide)
Type of foam
High Foaming
Application
Aeration/Vacuum/Spray
Ingredients
Wt (g)
Deionized Water
150.0
Tween 80
8.0
SilSense Copolyol-1
2.0
Silicone
59% H 2 O 2
9.0
[0000]
Formulation 8 (Defoaming and neutralizing solution)
De-foaming agent (Rug Doctor
1%
water-based silicone emulsion)
Catalase
~1000 units/ml
Water
Remainder
[0000]
Formulation 9 (Foaming Mousse (3% H 2 O 2 ))
Ingredient
Amount (g)
Weight %
Function
Material Type
Deionized Water
120
83.3
Solvent
Aqueous Phase
Carbopol AQUA SF-1
10
6.9
Thickener
Acrylic Polymer
(35%)
Tween 80
4
2.8
Foaming Agent
Surfactant
SilSense Q-Plus
1
0.7
Foam Booster
Modified Silicone
Silicone
Tack Reducer
Liquid
Hydrogen Peroxide
9
6.3
Disinfecting agent
Oxidizer
(59%)
Decontaminating
agent
Sodium Hydroxide
As needed
<1.0
pH Modifier
Basic solution
(0.1N)
Citric Acid (50%)
As needed
<1.0
pH Modifier
Acidic solution
Final pH = 6.1
[0000]
Modified formulation 7 (with pH adjustor)
High-Foaming (3% H 2 O 2 )
Ingredient
Amount (g)
Weight %
Function
Material Type
Deionized Water
150
88.8
Solvent
Aqueous Phase
Tween 80
8
4.7
Foaming Agent
Surfactant
SilSense Copolyol-1
2
1.2
Foam Booster
Modified Silicone
Silicone
Tack Reducer
Liquid
Hydrogen Peroxide (59%)
9
5.3
Disinfecting agent
Oxidizer
Decontaminating
agent
Sodium Hydroxide
As needed
<1.0
pH Modifier
Basic solution
(0.1N)
Citric Acid (50%)
As needed
<1.0
pH Modifier
Acidic solution
Final pH = 6.0
[0000]
Modified formulation 6 (with pH adjustor)
Hi-Foaming (6% H 2 O 2 )
Ingredient
Amount (g)
Weight %
Function
Material Type
Deionized Water
150
84.3
Solvent
Aqueous Phase
Tween 80
8
4.5
Foaming Agent
Surfactant
SilSense Copolyol-1
2
1.1
Foam Booster
Modified Silicone
Silicone
Tack Reducer
Liquid
Hydrogen Peroxide (59%)
18
10.1
Disinfecting agent
Oxidizer
Decontaminating
agent
Sodium Hydroxide
As needed
<1.0
pH Modifier
Basic solution
(0.1N)
Citric Acid (50%)
As needed
<1.0
pH Modifier
Acidic solution
Final pH = 5.6
[0000]
Preferred formulation
More
Most
Preferred
preferred
Preferred
Hydrogen
0.1–15%
2–10%
3–8%
peroxide
Surfactant
0.5–20%
1–10%
2–6%
Foam booster
0.1–10%
0.3–5%
0.5–3%
(Modified
silicone)
Thickening
0.5–20%
1–10%
1.5–5%
agent
(Acrylic
polymer)
pH
4.5–7.5
5–7
5.5–6.5
[0036] Tests
[0037] (A) Test with Fresh Blood
[0038] A drop of fresh blood, approximately four millimeters in diameter was applied to a Petri dish. One was left untreated and the other treated with a peroxide foam of formulation 7 generated with Airspray F2-L11 Finger Pump Foamer. Within ten minutes the untreated blood had dried whereas the treated blood had reacted and dissolved in the peroxide foam.
[0039] (B) Tests with Dried Blood
[0040] A drop of dried blood was treated with room temperature tap water for ten minutes and another drop of dried blood was treated with a 3% hydrogen peroxide foam of formulation 7 generated with Airspray F2-L11 Finger Pump Foamer. The drop of dried blood treated with tap water remained after ten minutes. After ten minutes, the drop of dried blood treated with the hydrogen peroxide foam had dissolved.
[0041] An additional test was conducted comparing a commercially available enzyme foam, Prepzyme XF enzyme foam, available from Ruhof Corporation of Mineola, N.Y. A drop of dried blood was treated with the Prepzyme XF and another drop of dried blood was treated with a 6% hydrogen peroxide foam of formulation 6. After ten minutes the blood treated with the Prepzyme XF remained whereas the blood treated with the hydrogen peroxide foam was dissolved within five minutes.
[0042] (C) Foam Stability Test
[0000] A foam prepared according to formulation 9 was placed into a Petri dish of dimensions 150 mm diameter and 15 mm deep. Prepzyme XF was placed into a similar Petri dish. The foams were allowed to rest for one hour whereupon they were inspected. The foam of formulation 9 maintained substantially all of its volume over the period of one hour. The Prepzyme foam had fallen to the extent that a portion of the lower surface of the Petri dish was no longer covered by foam. After four hours the foam of formulation 9 still covered the bottom surface of the Petri dish.
[0043] (D) Tests Against Microorganisms
[0044] Tests of efficacy in killing microorganisms were conducted comparing both a 3% hydrogen peroxide foam prepared according to formulation 7 and 6% hydrogen peroxide foam prepared according to formulation 6 against the Prepzyme XF enzymatic foam using the following test procedure:
Step 1: Place microorganism suspension onto sterile filter Step 2: Allow the suspension to dry Step 3: Add either peroxide foam or enzyme foam to cover filter Step 4: Allow foam to set on microorganism for pre-determined time Step 5: Rinse filter with 10 mL sterile neutralizing/defoaming solution (formulation 8) Step 6: Rinse filter with three times of 100 mL sterile water Step 7: Place filter on TSA agar and incubate @ 32 C for 48 hours Step 8: Determine the number of survivors (TNTC=Too Numerous to Count)
[0053] Efficacy results with duplicated samples:
[0000]
Staphylococcus
Pseudomonas
Aureus
aeruginosa
Control
TNTC & TNTC
TNTC & TNTC
(Average:
(Average:
1.64 × 10 5 )
2.49 × 10 5 )
[0000]
Exposure
Time
Staphylococcus
Pseudomonas
(Minutes)
Foam
aureus
aeruginosa
5
No foam
TNTC & TNTC
TNTC & TNTC
with
catalase/de-
foaming
agent
(Control)
Enzyme foam
TNTC & TNTC
TNTC & TNTC
(Ruhof
Prepzyme XF)
3% hydrogen
TNTC & TNTC
16 & 37
peroxide
foam
6% hydrogen
~500 & ~500
0 & 0
peroxide
foam
10
Enzyme foam
TNTC & TNTC
TNTC & TNTC
(Ruhof
Prepzyme XF)
3% hydrogen
~1000 & ~1000
0 & 1
peroxide
foam
6% hydrogen
46 & 22
0 & 0
peroxide
foam
[0054] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A method of treating an instrument after contamination of a surface thereof includes the steps of covering the surface with a foam and maintaining the foam on the surface to keep the surface moist prior to cleaning the instrument to prevent foreign matter thereon from becoming dried on and more difficult to remove during cleaning. The foam includes hydrogen peroxide, dissolves blood and provides antimicrobial effect.
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FIELD OF THE INVENTION
This invention relates generally to the field of digital certificates and certificate revocation lists (CRL). More particularly, this invention relates to creation of a delta CRL that spans changes over more than two CRLs.
BACKGROUND OF THE INVENTION
Digital certificates are in wide use on the Internet and in the field of electronic commerce for authentication of all sorts of electronic transactions. In general, such digital certificates are used to certify the identity of an entity in the digital world, particularly as defined by the public key infrastructure (PKI). As digital certificates are issued and used, they often are either revoked or expire after a predetermined amount of time. In other situations, a digital certificate may be revoked or placed on hold pending some event. In order for digital certificates to be useful, it is important that those entities using digital certificates to authenticate the identity of an entity presenting the digital certificate have confidence that the digital certificate is valid. Generally, the validity of a digital certificate can be determined by reference to a Certificate Revocation List (CRL) produced by an authority that generates the certificates (usually a Certificate Authority).
FIG. 1 depicts a simple exemplary computer network 100 that utilizes a digital certificate and a Certificate Revocation List. In system 100 , a user terminal 104 may request via a network (for example the Internet) 108 , a digital certificate from a Certificate Authority 112 . The Certificate Authority 112 generates and issues the certificate, which is returned to the user terminal 104 . The user terminal 104 can then utilize the digital certificate to carry out the transaction with another entity such as remote server 116 . Such transactions may include financial transactions or any other transaction in which the identity of the user terminal 104 should be reliably authenticated.
When user terminal 104 sends the digital certificate to remote server 116 , the remote server 116 can inspect the digital certificate against a list of revoked certificates (the Certificate Revocation List) stored by the remote server 116 . In the event remote server 116 has not obtained a recent CRL, one can be requested from the Certificate Authority 112 . Certificate Authority 112 then either generates a new CRL or sends the most recently generated CRL to the remote server 116 . Remote server 116 can then determine whether nor not the digital certificate sent by user terminal 104 is valid. Thus, remote server 116 can authenticate the user terminal 104 and determine whether or not to authorize particular transaction at hand.
FIG. 2 depicts a message flow diagram 200 for the transaction just described. In this message flow diagram, a certificate request 204 is sent from the user terminal 104 to the Certificate Authority 112 . The Certificate Authority 112 generates a certificate at 208 and returns the certificate at 212 to the user terminal 104 . The user terminal 104 can then submit a transaction using the certificate at 218 to the remote server 116 . Remote server 116 can then request a new CRL at 222 of the Certificate Authority. The Certificate Authority 112 then generates or retrieves a CRL at 226 and sends the CRL to the remote server 116 at 230 . Depending on the nature of the transaction, the remote server 116 may process the CRL at 232 by taking various actions including, for example, sorting, filtering or reformatting the CRL and storing information in its own database. At 234 , the certificate can be authenticated against the CRL data at the remote server 116 . At 238 the transaction can be either approved or rejected in accordance with the authentication at 234 and at 242 the approval or rejection can be confirmed with the user terminal 104 . Those skilled in the art will recognize that many other message flows are possible with the message flow 200 if FIG. 2 being intended as exemplary of a simple use of a digital certificate and a Certificate Revocation List.
With reference to FIG. 3 the Certificate Authority 112 may generate the Certificate Revocation List in accordance with process 300 . CRLs are generated at the Certificate Authority either on a periodic basis, or as a result of some event such as a certificate revocation, or some combination thereof. The process starts at 302 after which a database of certificates is queried for certificates meeting a particular criteria of inactivity. One example is for the query to request all certificates that have been revoked. Other certificates are assumed to still be valid and active.
At 304 the certificate database at the Certificate Authority responds to the query with certificates meeting the specified criteria. Header information is then generated, for example, in accordance with X.509 and RFC 2459 standards (or other applicable CRL standards) at 312 and at 316 the certificate is formatted (for example, as an ASN.1 or other format CRL.) The digital certificate is signed at 320 to assure its authenticity and is then stored at 322 within a computer residing at the Certificate Authority. The process returns at 326 . Whenever a request is made for a new digital certificate, process 300 is carried out or, in some instances, the most recently generated CRL may be retrieved and forwarded to the requester.
As digital certificates find wider use, the number of such certificates issued has increased dramatically. With this increase comes an associated increase in the number of entries in a Certificate Revocation List. Accordingly, the process 300 as just described can become an extremely time consuming process that can result in the CRL being untimely in that many minutes or even hours can pass before an updated CRL can be generated. This is obviously undesirable since the process of authentication using the CRL should preferably be carried out on the most recent information available.
In addition to the certificate revocation list just described, certificate authorities commonly generate a certificate revocation list that is referred to as a delta CRL or ΔCRL. A delta CRL is simply a type of CRL that reflects changes made between two consecutive CRLs. Delta CLRs can be generated, for example, using process 300 wherein the query of 304 is a query that further limits the selection criterion to digital certificates that have been changed since the most recently generated CRL (or between two adjacent CRLs).
The concept of delta CRLs is illustrated in FIG. 4 by a sequence of CRLs numbered 1, 2, 3 and 4 with delta CRLs ( 504 , 506 and 508 ) spanning CRL #1 and CRL #2, CRL #2 and CRL #3, and CRL #3 and CRL #4. With reference to FIG. 2 , when a delta CRL is sent at 230 , one portion of the processing of the delta CRL at 232 is to retain the data from the most recent CRL while appending the appropriate delta CRL to the existing CRL to update the list of revoked certificates.
SUMMARY OF THE INVENTION
The present invention relates generally to digital certificates and CRLs. Objects, advantages and features of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the invention.
In one embodiment of the present invention a method and apparatus for producing an enhanced CRL is provided. In response to a request containing an identifier of the most recently owned CRL stored by the requester, a certificate authority generates a CRL spanning from the most recently owned CRL to the current CRL. This CRL is formatted as a delta CRL and transmitted as a reply to the requester. This has the advantage of not requiring transmission of the full CRL even though more than one generation of CRL has occurred since the most recently owned CRL by the requester.
A method of creating a digital certificate revocation list (CRL) consistent with an embodiment of the present invention includes determining a latest owned CRL stored by a CRL recipient; creating a delta CRL comprising a list of digital certificates with a status of satisfying at least one inactive criterion, wherein said status has changed since the latest owned CRL; and sending the delta CRL to the CRL recipient.
A method of creating a digital certificate revocation list (CRL) consistent with another embodiment of the invention includes receiving a request for a CRL, the request including an indication of a latest owned CRL; creating a delta CRL comprising a list of digital certificates satisfying at least one inactive criterion since the latest owned CRL; and sending the delta CRL as a reply to the request.
A data structure, stored on a computer readable storage medium or transported over an electronic communication medium, for a digital certificate revocation list (CRL) consistent with an embodiment of the invention includes a list of digital certificates representing changes to a CRL that have occurred since generation of at least two additional CRLs. The CRL includes a CRL identifier wherein the CRL is formatted as a delta CRL.
The above summaries are intended to illustrate exemplary embodiments of the invention, which will be best understood in conjunction with the detailed description to follow, and are not intended to limit the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself however, both as to organization and method of operation, together with objects and advantages thereof, may be best understood by reference to the following detailed description of the invention, which describes certain exemplary embodiments of the invention, taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates a simple exemplary system using digital certificates.
FIG. 2 is a signal flow diagram describing one use of a digital certificate and certificate revocation list in the system of FIG. 1 .
FIG. 3 is a flow chart describing generation of a CRL.
FIG. 4 illustrates the generation of delta CRLs.
FIG. 5 illustrates the generation of delta CRLs spanning multiple delta CRLs.
FIG. 6 is a signal flow diagram describing use of a delta CRL spanning multiple delta CRLs.
FIG. 7 is a flow chart describing one method consistent with an embodiment of the present invention for generation of a delta CRL spanning multiple delta CRLs.
FIG. 8 is a flow chart describing another method consistent with an embodiment of the present invention for generation of a delta CRL spanning multiple delta CRLs.
FIG. 9 illustrates a computer system suitable for use in conjunction with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one skilled in the art that the present invention may be practiced without these specific details or with equivalents thereof. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
Some portions of the detailed descriptions which follow are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, computer executed step, logic block, process, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities.
Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing terms such as “processing” or “querying” or “formatting” or “merging” or “determining” or “receiving” or “requesting” or “signing” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Delta CRL Enhancement in Accordance with the Invention
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure is to be considered as an example of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings.
As great numbers of digital certificates are issued and revoked, a particular CRL can become extremely lengthy and therefore require substantial amounts of time to transmit, receive and process. The present invention addresses this problem by permitting the generation of a delta CRL that spans multiple generations of CRLs. This is illustrated in FIG. 5 wherein, at the request of a requester, a delta CRL can be generated to span multiple CRLs. In this example, a delta CRL 502 is generated to span from CRL #1 to CRL #4. Thus, delta CRL 502 contains the certificate revocation list entries of delta CRL 504 , delta CRL 506 and delta CRL 508 .
Delta CRL 502 can be created using any number of techniques including simply appending the data from delta CRL 504 , 506 and 508 together or by querying a database of digital certificate information for all changes in the certificate revocation list occurring between CRL #4 and CRL #1. The overall process is illustrated by the message flow diagram 600 of FIG. 6 . This diagram is similar to message flow diagram 200 of FIG. 2 until the point where the remote server requests a CRL of the certification authority. When this occurs at 604 of message flow 600 , the CRL request includes the number (or other identifier) of the latest CRL owned (stored) by remote server 116 . This CRL is designated CRL #L. When the request is received at the certificate authority, a delta CRL is generated that spans CRL #L to the current CRL at 608 . This delta CRL is then returned to the remote server at 612 and the remote server processes the delta CRL at 616 by appending its entries to the currently owned CRL #L. This can be literally interpreted to create a new CRL or the data from the delta CRL can simply be appended to the data from CRL #L and used for whatever purpose the CRL is being used for at remote server 116 . Once the processing is complete at 516 , the remote server now owns an equivalent of the most recent CRL.
FIG. 7 depicts a process 700 for creation of the delta CRL in accord with the present invention. At 704 the certificate authority or other entity generating the CRL receives a request for a CRL containing the most recent owned CRL (CRL #L). At 708 , entries are merged from all delta CRLs between the current CRL and CRL #L to retrieve the data necessary for creation of the delta CRL. This data is then formatted as a delta CRL at 716 , signed with a digital signature at 720 and sent to the requester as a reply at 728 .
In an alternative embodiment, depicted as process 800 of FIG. 8 , when a request is received for a CRL, the request containing the most recently owned CRL (CRL #L), a certificate database is queried for the changes taking place between the current state and the state of the most recent CRL at 810 . Or, the current CRL (i.e., the most recently generated CRL) itself can be queried to obtain differences between it and CRL #L. This information is then formatted as a delta CRL at 716 , signed with a digital signature at 720 and sent as a reply at 728 .
In this manner, the delta CRL created in accordance with the present invention can be sent as a reply in lieu of sending a complete copy of the most recent CRL which may be much larger in size than the size of several conventional delta CRLs. Thus, transmission timesaving can be achieved as well as processing timesaving.
The processes previously described as carried out on a computer system, for example, a computer system residing at the certificate authority 112 . Such a computer system is depicted in FIG. 9 as 900 . Computer system 900 includes a central processor unit (CPU) 910 with an associated bus 915 used to connect the central processor unit 910 to Random Access Memory 920 and Non-Volatile Memory 930 in a known manner. An output mechanism at 940 may be provided in order to display or print output for the computer administrator. Similarly, input devices such as keyboard and mouse 950 may be provided for the input of information from the computer administrator. Computer 900 also may include disc storage 960 for storing large amounts of information such as the list of certificates issued and the most recent Certificate Revocation List as well as any Certificate Revocation List cache and other information as required. Computer system 900 is coupled to the network (e.g., the Internet) using a network connection 970 such as an Ethernet adapter coupling computer system 900 through a fire wall and/or locally a network to the Internet.
Those skilled in the art will recognize that the present invention has been described in terms of exemplary embodiments based upon use of a programmed processor. However, the invention should not be so limited, since the present invention could be implemented using hardware component equivalents such as special purpose hardware and/or dedicated processors which are equivalents to the invention as described and claimed. Similarly, general purpose computers, microprocessor based computers, micro-controllers, optical computers, analog computers, dedicated processors and/or dedicated hard wired logic may be used to construct alternative equivalent embodiments of the present invention.
Those skilled in the art will appreciate that the program steps used to implement the embodiments described above can be implemented using disc storage as well as other forms of storage including Read Only Memory (ROM) devices, Random Access Memory (RAM) devices; optical storage elements, magnetic storage elements, magneto-optical storage elements, flash memory, core memory and/or other equivalent storage technologies without departing from the present invention. Such alternative storage devices should be considered equivalents.
The present invention is preferably implemented using a programmed processor executing programming instructions that are broadly described above in flow chart form, and that can be stored in any suitable electronic storage medium or that can be transmitted over any electronic communication medium. However, those skilled in the art will appreciate that the processes described above can be implemented in any number of variations and in many suitable programming languages without departing from the present invention. For example, the order of certain operations carried out can often be varied, and additional operations can be added without departing from the invention. Error trapping can be added and/or enhanced and variations can be made in user interface and information presentation without departing from the present invention. Such variations are contemplated and considered equivalent.
While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations as fall within the scope of the appended claims.
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A method and apparatus for producing an enhanced CRL. In response to a request containing an identifier of the most recently owned CRL stored by the requested, a certificate authority generates a CRL spanning from the most recently owned CRL to the current CRL. This CRL is formatted as a delta CRL and transmitted as a reply to the requester. This has the advantage of not requiring transmission of the full CRL even though more than one generation of CRL has occurred since the most recently owned CRL by the requester.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Application claims benefit of the provisional application 61/685,916 filed on Mar. 27, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
The present disclosure relates to bubble generating protein skimmers, which are typically used with aquariums, and other various methods associated with the removal of protein particle waste from aquarium water. Protein skimmers have been around for many years but without any self regulating internal water level controls to adjust for the constant changing water levels in the sump tanks that they operate in. Protein skimmers are used in aquariums and are essential for the health and water clarity of every aquarium. Proteins are toxic and are constantly being generated by fish and all living things in the aquarium. Protein skimmers remove protein particles from the aquarium water by generating and introducing air bubbles in a water filled air/water chamber where the protein particles in the water naturally attach themselves to the air bubbles when they come into contact with them then float upward through the air/water chamber creating a foam column above the internal water level where the foam gradually spills over into the collection chamber.
Sump tank systems are designed so the sump tank water level varies from evaporation while the main aquarium water level remains constant. Evaporated water is replenished by one of two ways by the aquarium owner.
1. Aquarium owner pours water into sump tank as needed manually. This method creates the greatest variation is sump tank water levels as the timing and amount of water added will vary when it is replenished.
2. Aquariums with electronic float controlled water level systems and dedicated water supplies have a consistent water level variation. These water level variations will be different depending on the system.
Protein skimmers having manual adjusting knobs, dials, valves, sliding gates, or stove pipe tubes as a means of adjusting internal water level require constant daily adjustment.
Aquarists, having to figure out how to adjust the internal water level height with the use of valves, knobs, dials, sliding gates, or stove pipe tubes, may not realize the problematic in-sumptank water level changes that alter internal water levels.
Aquarists manually adjusting air and water flow valves may improperly result in reduced water & air flows greater than manufacturer's intention resulting in poor functionality. Once flooding of collection container has occurred by owner's protein skimmer, owners tend to adjust internal water level more to the safe side of adjustments further minimizing the collection of contaminants from the aquarium.
Protein skimmers with no internal water level control system to compensate for sump tank water level changes, algae growth, water pump wear and voltage fluctuations are almost always off of their peak performance internal water level. When another appliance is turned on such as the high powered aquarium lights on the same circuit as the water pump, power level may be reduced to water pump changing the water pressure it produces. Aquariums have high powered lighting that is on during the day and off at night. This will cause power fluctuations to all items on the same circuit.
Other protein skimmers internal water levels are always changing, varying the distance of the internal water level to the top of the riser column “entrance of collection container”. When internal water level is low, the contaminants end up stuck to the sides of the riser column with a low accumulation of considerably dryer contaminants entering into the collection container if at all, resulting in very poor contaminant removal. When the internal water level is too high water flows freely into collection container at the top of the riser column flooding the collection container, forcing previously collected contaminants back into sump tank and into Aquarium.
An additional drawback associated with certain existing protein skimmers is a requirement to disconnect power to water pump in order to empty collection container in order to prevent water flowing down outside of protein skimmer.
An additional drawback associated with certain exiting protein skimmers is an inability to operate in low water levels as low as one inch without drawing in air from sump tank water's surface into water pump damaging or destroying it. Water pumps with a horizontally directional intake port need at least 2″ of water above port to prevent air suction from water's surface depending on HP of water pump.
Aquarists without automatic sump tank water re-fill systems which require a dedicated water supply connected to a water purification filter (R/O filter) with the water flow controlled by an N/C (normally closed) electronic water valve, in which the power to it is controlled by an automatic float switch in the sump tank, cannot keep other protein skimmer designs adjusted properly. These aquarist's without dedicated water re-fill systems pour water into sump tanks by hand at a varying amount of water and frequency of time. These aquarist's have the greatest fluctuations in sump tank water levels and protein skimmer internal water levels. Automatic sump tank water re-fill systems, depending on the range of the float switch's on and off height differential and the volume of the sump tank, can cycle as often as 2 or 3 times a day.
An additional drawback associated with certain existing protein skimmers is an inability of removing larger particles and material too heavy or too large to be removed by the process of foam fractionation.
Loud noise levels of hissing or sucking sounds may be caused by air intake ports where the air is drawn into the protein skimmer that creates the air bubbles.
Water falling back into the sump tank from stove pipes that allows the water to spill out the top of the pipe back into the sump tank may generate additional unwanted sounds.
Foul odors may be caused by the release of air escaping from the collection container which flows at the same rate as being drawn into the protein skimmer that generates the air bubbles.
External water pumps with extravagant plumbing configurations create a risk of breakage during handling, have large footprint requirements, and experience considerable loss of water pressure by friction through elaborate and excessive plumbing. Also increased surface area for algae growth inside plumbing further reduces water flow over time.
Failure of the water pumps may be caused by damage from turning them off & back on again (which is required when emptying collection container) or damage from sump tank water levels ending up too low allowing air to be drawn into pump from sump tanks water surface. Water pump failure is a very common problem according to online Forums.
Micro sized air bubbles escaping back into sump tank and back into aquarium cause clarity problems in the aquarium.
FIELD OF THE INVENTION
The present disclosure relates to bubble-type protein skimmers, which are commonly used with aquariums, and various methods associated with the removal of protein from aquarium water.
BRIEF SUMMARY OF THE INVENTION
Aquarist does not have to worry about adjusting knobs, dials, valves, sliding gates, or stove pipe tubes. The Protein Skimmer is “Plug & Play” with the properly selected siphon tube assembly installed for example 1″-5″ sump tank water level.
Protein Skimmer Prototype has an internal water level control system that automatically adjusts and maintains protein skimmers internal water level to manufacturers predetermined riser column height, for example 2 inches below flood point. Sump tank water level variations, limited Algae growth, limited water pump wear, and voltage fluctuations have very little, to no effect at all on internal water level in protein skimmer thanks to the internal water level control system.
Aquarist can quickly & easily modify protein skimmers predetermined internal water level to customize for the amount of protein generating hosts in the aquarium. Example: Customers with larger aquariums with greater amounts of protein generating hosts may want a lower internal water level due to the amount of foam accumulating above internal water level. This is how the customer can modify the amount of moisture captured with contaminants.
Protein skimmer emits no noticeable odors and eliminates water clarity problems caused by micro air bubbles escaping back into aquarium.
This protein skimmer design eliminates the necessity of disconnecting the power to the water pump when emptying collection container. (This eliminates water pump damage caused by turning off & restarting water pump, dramatically increasing the life of the water pump.) It also prevents contaminants in the protein skimmer's mixing chamber not yet passed into collection container, from draining back into the sump tank thus back into aquarium. This increases protein skimmer's efficiency and it also eliminates the inconvenience to customers of unplugging the power cord and the risk of electrical shock often having wet hands after cleaning collection container when plugging it back in.
It is intended that this application of invention includes all concepts of the present disclosure to be used for other type applications as well. All variations of this current design incorporating the same or similar principles, characteristics, and control systems of the present disclosure are to be included in this application of invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a perspective view of the preferred embodiment of the present invention; FIG. 1 is a perspective view of a protein skimmer which embodies principles of the present disclosure;
FIG. 2 is a perspective sectional view of the preferred embodiment of the lower section of the protein skimmer of the present invention shown on FIG. 1 ;
FIG. 3 is a perspective sectional view of the preferred embodiment of the upper section of the protein skimmer of the present invention shown on FIG. 1 ;
FIG. 4 is a front elevation view of a sump tank aquarium system;
FIG. 5 is a top plan view of the protein skimmer of FIG. 3 ;
FIG. 6 is a cross-sectional view of the upper section of the protein skimmer of FIG. 5 , taken along line 6 - 6 ;
FIG. 7 is a cross-sectional view of the upper section of the protein skimmer of FIG. 5 when the invention is operational, taken along line 6 - 6 ;
FIG. 8 is an exploded assembly view of the protein skimmer of FIG. 1 ;
FIG. 9 is an exploded assembly view of the lower section of protein skimmer of FIG. 2 ;
FIG. 10 is a front elevation view, top view, and perspective view of 23 in FIG. 9 ;
FIG. 11 is a an exploded view of 17 and 20 in FIG. 9 ;
FIG. 12 is a front elevation view of 15 , 16 , & 18 of FIG. 7 ;
FIG. 13 is a front elevation view of 15 , 16 , & 18 of FIG. 6 ;
FIG. 14 is another front elevation view of 15 , 16 , & 18 of FIG. 6 ;
FIG. 15 is an exploded view of FIG. 13 ;
FIG. 16 is front elevation and side view of 16 ;
FIG. 17 is a front elevation view, top view and side elevation view of 18 ;
FIG. 18 is a front elevation view and side elevation view of 15 ;
FIG. 19 is a front elevation view and side elevation view of 30 ;
FIG. 20 is a perspective view of sets 33 , 44 , 55 , & 66 ;
11 Collection chamber lid
12 Collection chamber
13 Air/water chamber
14 base
15 valve actuator
16 suction inlet valve
17 water pump elbow
18 float
19 first tubing
20 second tubing
21 outer siphon tube
22 inner siphon tube
23 rubber grommet
24 intake tube
25 filter pad
26 water pump
28 first rubber O-ring
29 flow restrictor
30 first tubing connector
31 second tubing connector
32 third tubing connector
34 second rubber O-ring
35 water discharge port
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is the present disclosure of the current designed invention of a protein skimmer that could be made of any suitable rigid material preferably a transparent material. FIG. 1 Collection chamber lid ( 11 ), base ( 14 ), FIGS. 6 & 7 funnel shaped top section of air/water chamber ( 13 ), and the funnel shaped section of collection chamber ( 12 ) (connecting the outer and inner tubes), are preferably made and formed with molds by process of vacuum forming of readily available transparent flat stock material. Other parts are preferably made of readily available transparent tube stock, solid stock, flexible and rigid tubing of various diameters. FIG. 1 Filter pad ( 25 ) is of a filter mesh from readily available stock. FIG. 8 float ( 18 ), water pump ( 26 ), rubber grommet ( 23 ), first tubing connector ( 30 ), second tubing connector ( 31 ), third tubing connector ( 32 ), water pump elbow ( 17 ), are readily available retail parts. FIGS. 6 & 7 first rubber O-ring ( 28 ) and second O-ring ( 34 ) are each a readily available retail part. Parts are trimmed with a router with the aid of tooling and joined with adhesives.
FIG. 4 This particular example of designed invention of a protein skimmer is shown in part by air/water chamber ( 13 ) is intended to be partially submerged in the water (H) of an aquarium sump tank (E) application typically located in the aquarium cabinet (F) supporting the aquarium (G).
FIG. 1 The protein skimmer having a water pump ( 26 ) resting on base ( 14 ) inside air/water chamber ( 13 ), that draws water into the protein skimmer from under base ( 14 ), upward through intake tube ( 24 ) in which intake tube ( 24 ) passes through hole cutout in base ( 14 ), then into water pump elbow ( 17 ) upward through water pump ( 26 ) and out of water pump port that protrudes upward through a cutout in filter pad ( 25 ) and into air/water chamber ( 13 ). Filter pad ( 25 ) has been removed for clarity and true location is shown in hidden lines in air/water chamber ( 13 ). Float ( 18 ) and valve actuator ( 15 ) are shown in two different positions located inside the inner tube of collection chamber ( 12 ). Position reference (C) drawn with hidden lines, also shown in FIG. 6 , shows float ( 18 ) and valve actuator ( 15 ) position when the protein skimmer is turned off Float ( 18 ) and valve actuator ( 15 ) drawn in solid lines is representing their position when protein skimmer is turned on and the internal water level (B) is pushing them up. They are being pushed up by the water's surface (B) opening suction inlet valve ( 16 ) allowing air to enter in suction inlet valve ( 16 )'s intake port (D) also shown in FIG. 7 . Air is then allowed to flow through first tubing ( 19 ) and second tubing ( 20 ) and enter into water pump elbow ( 17 ) and water pump ( 26 ).
FIG. 1 Base ( 14 ) elongated cutouts allow sump tank water to enter under base ( 14 ), into intake tube ( 24 ), into water pump elbow ( 17 ), into water pump ( 26 ), into air/water chamber ( 13 ) and exit back out of siphon tube ( 21 ) and ( 22 ) and back out into sump tank through these cutouts.
FIG. 2 is a close-up sectional view of the lower section of the designed invention protein skimmer of FIG. 1 . Water flow is shown by arrows. Parts in FIG. 2 are base ( 14 ), air/water chamber ( 13 ), water pump ( 26 ), rubber grommet ( 23 ), filter pad ( 25 ), second tubing ( 20 ), intake tube ( 24 ), water pump elbow ( 17 ), inner siphon tube ( 22 ), and outer siphon tube ( 21 ). Filter pad ( 25 ) has four round cutouts sized and located to align and accommodate water pump ( 26 ) exhaust port, outer siphon tube ( 21 ), tubing ( 20 ), and the fourth is an open hole to allow water to pass through filter pad ( 25 ) freely in order to maintain pressure equalization above and below filter pad ( 25 ) in air/water chamber ( 13 ) to maintain a consistent flow of water past the filter pad ( 25 ) in the event the filter pad ( 25 ) becomes clogged with contaminants that would restrict water flow. This open hole is located on the opposite side of air/water chamber ( 13 ) from outer siphon tube ( 21 ) cut-outs where the water exits out of protein skimmer. The filter pad ( 25 ) diverts the current back upwards as well as capture contaminants that may otherwise return back into aquarium.
FIG. 3 shows a close-up perspective sectional view of the upper section of the protein skimmer showing collection chamber lid ( 11 ) attached to collection chamber ( 12 ) which is attached to air/water chamber ( 13 ).
FIG. 3 shows protein skimmer during operation with water level (B) pushing up float ( 18 ), valve actuator ( 15 ), and opening suction inlet valve ( 16 ) allowing air to enter suction inlet valve ( 16 )'s intake port (D) and flowing into and through first tubing ( 19 ), and second tubing ( 20 ).
FIG. 5 is a top view of FIG. 3 showing collection chamber lid ( 11 ).
FIG. 6 , 7 Collection chamber ( 12 ) is formed by combining an outer tube and inner tube joined and permanently attached by a funnel shaped part. Near the lowest point of the inner tube of collection chamber ( 12 ) there is a groove that holds first rubber o-ring ( 28 ) in place which seals against the inner opening at the top of the air/water chamber ( 13 ) to prevent leakage between the two parts during operation. Collection chamber ( 12 )'s outer tube wall rests down flush against air/water chamber ( 13 )'s outer tube wall. In collection chamber lid ( 11 ) there is a groove to hold second o-ring ( 34 ) in place which seals and secures it inside collection chamber. Also shown is first tubing ( 19 ) connected to suction inlet valve ( 16 ) and second tubing ( 20 ).
FIG. 6 Float ( 18 ), valve actuator ( 15 ), and suction inlet valve ( 16 ) are shown in protein skimmers turned off position with suction inlet valve ( 16 ) shown in its closed position.
FIG. 7 The suction inlet valve ( 16 ) is open allowing air to enter port (D) shown by directional arrows into first tubing ( 19 ) and second tubing ( 20 ). The internal water level (B) is regulated by the float ( 18 ), valve actuator ( 15 ), and suction inlet valve ( 16 ) by air flow modulation as described in the detailed description of FIG. 1 . Below water line (B) protein particles in the aquarium water attach themselves to the air bubbles passing through the air/water chamber ( 13 ) floating upward to water line (B). These air bubbles accumulate as a foam column (A) and are pushed upward by the new bubbles forming. The foam column (A) grows until it is pushed into the collection chamber lid ( 11 ) outward and slowly overflows into the collection chamber ( 12 ). The bubbles eventually burst while suspended above as shown in FIG. 7 , forming a dark liquid residue in the bottom of the collection chamber. Maintaining this foam column (A) overflow filled with protein particle contaminants being transported out of the aquarium water is essential for the highest rate of protein particle removal and can only be achieved by maintaining a consistent and controlled internal water level within a couple inches from the top of the collection chamber ( 12 ) inner tube.
FIG. 8 shows an exploded view of the designed invention protein skimmer major components and how they fit together. Base ( 14 ), air/water chamber ( 13 ), collection chamber ( 12 ), collection chamber lid ( 11 ), filter pad ( 25 ), water pump ( 26 ), water pump elbow ( 17 ), intake tube ( 24 ), first tubing ( 19 ) and second tubing ( 20 ), second tubing connector ( 31 ) in air/water chamber ( 13 ), first tubing connector ( 30 ) in collection chamber ( 12 ), inner siphon tube ( 22 ) inside of outer siphon tube ( 21 ), rubber grommet ( 23 ), suction inlet valve ( 16 ), valve actuator ( 15 ), and float ( 18 ).
FIG. 9 shows an exploded view of the base ( 14 ), rubber grommet ( 23 ), outer siphon tube ( 21 ) with upper and lower end caps detached for clarity. Lower end cap has a hole cutout sized to accommodate for a water tight fit of inner siphon tube ( 22 ). Outer siphon tube ( 21 ) also shows 2 cutouts on opposite sides of the tube at its lower end to allow water to enter into it. Inner siphon tube ( 22 ) has open ends. Together they are inserted through the rubber grommet ( 23 ) that is inserted into a water discharge port ( 35 ) of the base ( 14 ) that enables a water tight fit of outer siphon tube ( 21 ). FIGS. 1 , 2 , 8 , and 9 , Base ( 14 ) in symmetrical in shape with a total of 6 horizontally elongated cutouts around the perimeter, parallel to bottom of base, of which only three are visible. Therefore the back side view of base ( 14 ) is identical to the front view with the exception of the position of the two round holes cutout into its upper flat surface seen in FIG. 9 . Also in this particular example base ( 14 ) is made from flat stock being vacuum formed with the use of a custom mold creating a hollow underside chamber.
FIG. 10 shows perspective, front and top views of rubber grommet ( 23 ) shown in FIG. 1 , 2 , 8 , 9 .
FIG. 11 Water pump elbow ( 17 ) has a water flow restrictor ( 29 ) inside of it witch increases the velocity of water flow across the air intake end of third tubing connector ( 32 ) increasing the vacuum venturie effect creating a suction that draws air into the water stream.
FIG. 11 shows more detail of water pump elbow ( 17 ), flow restrictor ( 29 ), third tubing connector ( 32 ), and second tubing ( 20 ). Third tubing connector ( 32 ) is inserted into hole drilled into top of water pump elbow ( 17 ) for a secure tight fit. It also shows a right side view of flow restrictor ( 29 ).
FIG. 12 shows valve assembly consisting of float ( 18 ), valve actuator ( 15 ), and suction inlet valve ( 16 ) with suction inlet valve ( 16 ) in the open position.
FIGS. 13 & 14 the float ( 18 ) is hollow and is designed so that it can be adjusted up and down the valve actuator ( 15 ) to customize the internal water level for a specific application. Valve actuator ( 15 ) is made of solid rod material. Suction inlet valve ( 16 ) is made of tubing material.
FIG. 15 shows an exploded view of the valve assembly consisting of float ( 18 ), valve actuator ( 15 ), and suction inlet valve ( 16 ).
FIG. 16 shows a front and right side view of suction inlet valve ( 16 ) which is made of tubing.
FIG. 17 shows a front, top, and right side view of float ( 18 ) which is hollow.
FIG. 18 shows a front and right side view of valve actuator ( 15 ) that's made of solid cylinder material.
FIG. 19 shows a front and right side view of first tubing connector ( 30 ). First tubing connector ( 30 ) is symmetrically round with a hole through it allowing air to flow through it. Second tubing connect ( 31 ) and third tubing connector ( 32 ) may be identical to first tubing connector ( 30 ).
FIG. 20 Siphon tube sets ( 33 ), ( 44 ), ( 55 ) & ( 66 ) are made from a combination of siphon tube ( 21 ) & ( 22 ). FIG. 9 . FIG. 20 Each set has a different flow rate value creating a specific amount of resistance for a particular in sump tank water level (H). FIG. 4 . The longer the length the stronger the siphon suction increasing water flow. The larger the diameter of the tube the less resistance increasing water flow.
FIG. 20 Set ( 44 ) is designed for the lowest in sump tank water level having a smaller inner and outer diameter siphon tube than set ( 55 ) and ( 66 ) with high siphon suction. Next in progression is set ( 33 ) with a lower siphon suction with same diameter siphon tubes. Set ( 66 ) has larger diameter siphon tubes than set ( 33 ) & ( 44 ) increasing water flow with a high siphon suction. Set ( 55 ) has the same diameter siphon tube as set ( 66 ) with a lower siphon suction. Having the correct prescribed set installed maximizes the quantity of micro sized air bubbles creating the best results,
How it Works
FIG. 1 Once the protein skimmer is turned on the water pump ( 26 ) rapidly starts filling the air/water chamber ( 13 ) with water. There isn't any air being introduced into the water stream at this time since suction inlet valve ( 16 ) is closed so the water pump is at its maximum water pressure. As the water level rises in the air/water chamber ( 13 ), water is rising in the outer siphon tube ( 21 ) at the same rate by flowing into its cut-outs shown by arrows located just above the rubber grommet ( 23 ). Once the water level reaches the top of inner siphon tube ( 22 ) water begins to pour down through it and exiting underneath the base ( 14 ). Once the air is purged out of both siphon tubes ( 21 ) and ( 22 ), they act as a siphon, reducing water pressure in air/water chamber ( 13 ) allowing a high flow rate of water through the designed invention protein skimmer. As the water level continues to rise it comes in contact with the float ( 18 ) rising it upward along with valve actuator ( 15 ) which opens the suction inlet valve ( 16 ) allowing air to enter intake port (D) and flowing into first tubing ( 19 ) and second tubing ( 20 ) and down into the water pump elbow ( 17 ) were it enters into the water stream and into water pump ( 26 ). Inside water pump ( 26 ) there are impeller blades which turn the air in the water into micro sized air bubbles as the air passes through them which enter into the air/water chamber ( 13 ). Once the air enters the water stream the air/water chamber ( 13 ) fills with a flood of micro sized air bubbles and the water pump ( 26 ) pressure and water pressure inside the air/water chamber ( 13 ) drop instantly stopping the rise of the internal water level (B), float ( 18 ) and valve actuator ( 15 ). FIG. 7 The water level (B) in the collection chamber's ( 12 ) inner tube immediately stabilizes because the water level (B) governs the amount of air flow back into the protein skimmer's water pump ( 26 ) and the air flow governs the water level by modulating the water pump ( 26 ) water pressure it creates. The air flow is dependent on the water level and the water level is determined by the air flow. This is how the automatic internal water level control system functions.
FIG. 4 Water evaporation in aquarium (G) and sump tank (E) reduce the water level (H) in the sump tank (E) reducing the amount of water pressure the water pump ( 26 ) is submerged in thus reducing the amount of pressure in creates. Evaporation causing a reduction in sump tank (E) water level (H) is a constant gradual change until more water is added to the aquarium (G). The internal water level control system gradually reduces the air flow through the protein skimmer in order to maintain the same internal water level (B) FIG. 7 . When water is added to the aquarium the control system quickly reacts to increase the air flow to the appropriate amount required maintaining set internal water level (B) FIG. 7 .
FIG. 7 During operation the collection chamber ( 12 ) becomes pressurized with the influx of air being forced into it from the water pump ( 26 ) which means the air supply through suction inlet valve ( 16 ) back into the water pump ( 26 ) is under pressure creating an even higher volume of micro air bubbles than would be otherwise created from normal atmospheric pressure. FIG. 7 collection chamber lid ( 11 ) has a very small pressure relief hole (K) allowing a limited amount of air to escape to control the amount of air pressure in the protein skimmer. The vast majority of the same air re-circulates around and around through the protein skimmer eliminating odors and suction sounds. FIG. 7 The foam carrying the protein contaminants (A) are show being pushed up against collection chamber lid ( 11 ) and outward into collection chamber ( 12 ). Collection chamber lid ( 11 ) is sealed with second O-ring ( 34 ) to collection chamber ( 12 ). Collection chamber ( 12 ) is sealed with first O-ring ( 28 ) to air/water chamber ( 13 ) for a water tight connection as it rests upon outer circumference of air/water chamber ( 13 ).
FIG. 7 To empty collection chamber ( 12 ) do not disconnect power, disconnect first tubing ( 19 ) at either connection point. This disables the internal water level control system maximizing the air flow into water pump. The water pressure inside protein skimmer will drop along with the internal water level (B). FIG. 1 With the appropriate siphon tube ( 21 , 22 ) set chosen correctly for sump tank water level (H). FIG. 4 , the internal water level will drop below first O-ring ( 28 ). FIG. 7 where collection chamber ( 12 ) can be lifted off and emptied while the designed invention protein skimmer continues to retain and collect contaminants not yet pushed into collection chamber ( 12 ). FIGS. 1 & 2 With the proper siphon tube ( 21 , 22 ) set plugged into rubber grommet ( 23 ) this designed invention protein skimmer maximizes efficiency through automation.
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The embodiment of a protein skimmer apparatus comprising a float ( 18 ) controlled suction inlet valve ( 16 ), comprised of tubing, such as clear vinyl tubing, preferably horizontally mounted, centrally and predominantly severed or “cut” laterally in an upwardly direction, maintaining an elastically deformable segment acting as a pivoting axis, pivoting upwardly, on one end in communication with first tubing connector ( 30 ), in communication with first tubing ( 19 ), in communication with second tubing connector ( 31 ), in communication with a second tubing ( 20 ), in communication with third tubing connector ( 32 ), in communication with suction inlet opening of water pump elbow ( 17 ). On a second end slip fittedly connected, thereto one end of valve actuator ( 15 ). Float ( 18 ) having vertical holes therein and receiving valve actuator ( 15 ) slip fittedly projected through float ( 18 ). Suction inlet valve ( 16 ) is responsive to movement by float ( 18 ). Water pump ( 26 ) directing water into lower end of air/water chamber ( 13 ), such that water rises within air/water chamber ( 13 ), as to raise float ( 18 ) buoyantly pivoting upwardly, therefore opening suction inlet valve ( 16 ), therefore enabling airflow into water pump ( 26 ), therefore reducing water pressure governed by airflow volume, therefore establishing water level (B) in response to vertical position of float ( 18 ).
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This application is a continuation of application, Ser. No. 917,788 filed June 22, 1978, now abandoned.
BACKGROUND OF THE INVENTION
It is already known to control the movement of articles on a live roller conveyor by a driven belt or its equivalent which is moved into and dropped out of driving engagement with rollers that maintain a fixed position relative to the driven belt. Such an arrangement is disclosed by De Good in U.S. Pat. No. 3,724,642 of Apr. 3, 1973 where a pressure-type lifting means raises the driven belt into roller driving contact, and loss of pressure drops the driven belt out of roller driving contact. The action of the lifting means is controlled by sensor rollers in association with time delay valve means. A similar conveyor drive control arrangement is disclosed in Inwood et al in U.S. Pat. No. 3,768,630 of Oct. 30, 1973. It is also known to arrange article carrying rollers in a conveyor system where the rollers are normally resiliently lifted away from a driven belt having a fixed elevation so that the weight of articles depress the rollers and effect conveyance thereof. Such an arrangement is shown by Pipp in U.S. Pat. No. 3,612,247 of Oct. 12, 1971, and it includes an inflatable member to elevate the depressed rollers in the event an article is blocked and cannot move forward.
Live roller conveyors are known to have group roller braking provisions, such as the tension means of Fleischauer U.S. Pat. No. 3,621,982 of Nov. 23, 1971 which is actuated to apply a friction restraint on a group of rollers of sufficient magnitude to cause slippage in the roller drive means. An alternate braking arrangement is disclosed by Werntz U.S Pat. No. 4,006,815 of Feb. 8, 1977.
BRIEF DESCRIPTION OF THE INVENTION
This invention pertains to improvements in live roller conveyors provided with control means to regulate the movement of articles.
The objects of the present invention are several when applied to an article conveying assembly made up of rollers forming a conveying surface, and a continuously driven member held in contact with the rollers to rotate the rollers. One of the objects is to construct the conveyor in sections which may be connected end to end to form any desired length of conveyor, whether in a straight line or incorporating curved sections, and to be able to add the components of the present invention as and when desired. Another object is to provide a sectionalized conveyor assembly with sensor rollers in the respective sections to regulate the movement of articles in a manner which avoids the pressure of accumulating articles stopped by a lead article by removing the drive to the rollers upstream of the position of the blocked lead article whereby the articles are generally moved in spaced relation suitable for order-picking or processing applications where it is necessary to insert or remove certain articles.
A further object is to provide a sectionalized conveyor assembly with article sensor rollers in the down stream conveyor sections in control of the drive for the rollers in an upstream conveyor section so that some article accumulating pressure may be exerted on a lead article which is blocked, but of a low value so that such a conveyor installation may be utilized in moving a random mix of articles which vary in size and weight.
Yet a further object is to provide a sectionalized conveyor assembly which operates with controlled pressure between groups of articles by incorporating sensor rollers and brake means at substantial spaced intervals such that live roller sections alternate with controllable sections, whereby braking effect and driving effort are a function of article weight and friction with the rollers.
The foregoing objects will be illustrated in greater detail in the following description of the presently preferred arrangement of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention has been shown in certain preferred forms in the accompanying drawings, wherein:
FIG. 1 is a fragmentary plan view of one typical section of a conveyor run for packages or articles, the view showing certain details of the operating structure;
FIG. 2 is a transverse sectional elevation view taken along line 2--2 in FIG. 1;
FIG. 3 is a transverse sectional elevation view on an enlarged scale taken along line 3--3 in FIG. 1;
FIG. 4 is a fragmentary sectional view taken along line 4--4 in FIG. 1;
FIG. 5 is a further fragmentary sectional view of the means to supply air to and release air from the inflatable bladder of the inflatable brake member, the view being typical of the elements and members to be located along line 5--5 in FIG. 1;
FIG. 6 is a fragmentary elevational view taken along line 6--6 in FIG. 1;
FIG. 7 is a fragmentary view of a typical pressure air control system with valves and relays interconnecting the sensor roller with the inflatable member for stopping or releasing the carrier rollers;
FIG. 8 is a fragmentary plan view of a modified section of a conveyor run for packages or articles, the view showing certain modifications in the operating structure over the view of FIG. 1;
FIG. 9 is a transverse sectional elevation on an enlarged scale taken along line 9--9 in FIG. 8;
FIG. 10 is a fragmentary sectional view of the installation of the inflatable member taken along line 10--10 in FIG. 8 to show the location of sensor rollers between ends of the inflatable brake means;
FIG. 11 is a fragmentary elevational view taken along line -11- in FIG. 8; and
FIGS. 12A, 12B, and 12C are schematic plan views, without the details shown in views like FIG. 1 and FIG. 8, of conveyor runs utilizing the principle of the present invention in optional arrangements, wherein FIG. 12A is a view of several conveyor sections each with a plurality of sensor rollers set as in FIG. 8 to generate no pressure between packages, FIG. 12B is the arrangement seen in FIG. 1, and FIG. 12C is a modification of the arrangement seen in FIG. 1 employing an extended length inflatable member and associated sensor roller in alternate conveyor sections.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The conveyor system referred to is seen in a preferred embodiment in FIGS. 1, 2, 3, and 4 which will now be described. The conveyor is composed of any desired number of sections, but for convenience one complete section 10 is shown in partially complete plan view and the adjacent ends of the side rails of two other sections are shown in alignment. It is understood that the longitudinal side rails 11 and 12 of all sections will be supported from the working area upon suitable legs or similar means (not necessary to show). Each rail is a channel set with its web vertically and held in spaced relation by spacer bars 13. The uppermost flanges 14 and 15 and portions of the vertical web of the respective rails 11 and 12 are formed with a series of single open slots 16 spaced from sets of three open slots 17, with the respective slots 16 and 17 in each rail 11 and 12 being oppositely aligned. The arrangement and spacing of the respective slots 16 and 17 allows the installation of the package carrier rollers 18 by dropping them into the selected rail flange slots at a desired spacing. Within each conveyor section 10 there is included a sensor roller 19 which has a special function to be described.
The carrier rollers 18 normally engage a suitable drive member 20 which is supported from below the rollers 18 on snubbing rollers 21 operably mounted on the inside of the web of channel 11. The drive member 20 may be powered in the manner shown and described in the application of Werntz, Ser. No. 801,535 filed May 31, 1977, now U.S. Pat. No. 4,117,923 of Oct. 3, 1978. The return or non-driving pass of the drive member 20 is supported on spaced idler rollers 22. The snubbing rollers 21 support the drive member 20 so it engages the adjacent ends of the carrier rollers 18, and the weight of the packages or articles on the carrier rollers 18 improves the driving engagement thereof on member 20. The length of the drive member 20 can be selected to accommodate any nuumber of conveyor sections 10 that are connected together.
A shallow upwardly opening channel 23 is located adjacent the line of snubbing rollers 21 and is supported from the spacer bars 13 (FIG. 3) by adjustable posts 24 so the vertical position of the channel 23 may be selected to be desirably close to the underside of the series of carrier rollers 18. The channel 18 carries an inflatable member 25 which has a closed end anchored (FIG. 4) in the channel by means 26. The opposite or open end of the member 25 is anchored by means 27. The member 25 as seen in FIG. 5 has its inflatable bladder 25A formed at the open end with a nipple 28 to which is connected an air tube 29. The tube 29 connects to a fitting 30 at a quick exhaust/inlet valve 31 supported on a bracket 32 fastened to the channel 23 by the means 27. The valve 31 has an air inlet fitting 33 forming a place where an air supply tube 34 may be connected (FIG. 7). A muffler element 35 is disposed opposite the fitting 33 to suppress noise as air is exhausted rapidly when deflating the member 25.
Referring to FIGS. 1, 3 and 6, it can be seen that the sensor roller 19 has a body shorter than the carrier rollers, but its shaft 19A is long enough to be dropped into the selected slots 16 in the side rails 11 and 12 so it will be free to lift, or be depressed as a package moves over it. The end of the sensor roller 19 adjacent the member 25 is located where the member 25 is anchored so it will not be raised upon inflating the member 25. The other end of shaft 19A resting in slot 16 in rail 12 passes over a bracket 36 fastened on the web of the rail. The bracket 36 supports a control valve 37 which has its activating element 38 normally held in contact with shaft 19A so as to follow the vertical displacement of the shaft 19A for sensor roller 19. The roller 19 (FIGS. 3 and 6) is normally raised at the end adjacent the rail 12 by a suitable spring 39 anchored at one end by the mounting element 40 for bracket 36. The other end of spring 39 is shaped at 41 to form a seat for the shaft 19A and by which spring the sensor roller 19 is angularly raised since it pivots from the opposite end of shaft 19A supported by rail 11.
Control valve 37 (FIG. 7) has a branched fitting 37A for making contact with the pressure air supply conduit 42 connected to all such valves 37 throughout the length of the conveyor composed of several sections 10. The fitting 37A also has a connection for a conduit 43 which leads to the proper fitting on a control relay device 44 which inclues an adjustable time delay mechanism in control of the passage of pressure air from conduit 43 to conduit 34. The device 37 may be a Clippard Valve, Model MAV-3 obtainable from Clippard Instrument Laboratory Cincinnatti, Ohio. The time delay mechanism is activated by pressure air supplied from control valve 37 through conduit 45 to the relay device 44. The relay device 44 may be a Clippard Delay Valve, No. R-331, three-way valve. The control valve activating element or plunger 38 is normally extended by internal resilient means, but is depressed when a package or article holds the sensor roller 19 down against the spring 39. The depresson of element 38 on valve 37 admits the pressure air to the relay device 44 which then is activated for the predetermined time span and at the end of the time span admits pressure air through conduit 34 and exhaust/inlet valve 31 to the bladder 25A which expands the member 25 under the group of carrier rollers 18 with which it may be associated. Expansion of the member 25 lifts all of the overlying carrier rolls off the drive member 20 and simultaneously brakes the rollers to a stop. Raising the rollers and braking them at about the same time stops advance of all packages or articles and also blocks the conveying path to following articles. Thus, a package or article which sits on sensor roller 19 and holds it depressed for the predetermined time will stop all rollers engaged by the member 25, and that will progressively stop packages or articles on other upstream sensor rollers not shown but constructed in like manner to the one described herein.
The drive member 20 may be a rope made by Sampson Cordage Works and sold under the trade name STABLE BRAID. This rope 20 is two ropes in one, constructed of a braided polyester outer cover and a concentric braided polyester inner core. On the other hand, the inflatable member 25 is a modified member 20 in which the inner core has been removed and a bladder 25A substituted. Thus, the outer braided cover of member 25 acts as a restraining means for the bladder 25A and causes it to inflate substantially uniformly along its length. When installed in the supporting channel 23, the member 25 is given a slight amount of longitudinal tension so the braided cover thereof will tend to compress the bladder 25A when the air is released and thus avoid imposing a drag on the carrier rollers 18.
Turning now to FIGS. 8 to 11, a modified conveyor assembly is shown wherein similar parts and members described by the same reference characters wherever possible. The side rails 11 and 12 of this conveyor assembly 10A are provided with groups of slots 17 on each side of a single slot 16, and this slot arrangement is the same in each rail, as noted for the rails in FIG. 1. Article or package carrying rollers 18 are dropped into selected ones of the rail slot to attain the desired spacing. These rollers 18 are normally in driving contact on the top of the drive rope 20 supported by snubbing rollers 21. A shallow channel 23 supported on rail spacer bars 13 carries a plurality of inflatable brake members 46 similar to member 25. The channel is adjustable so the brake member 45 when relaxed may be brought up close but not enough to develop a drag on the underside of the rollers 18.
The conveyor sections 10A differed from the conveyor sections 10 seen in FIG. 1 by being provided with a plurality of package or article sensing rollers 19B, each of which has its shaft 19C dropped into a selected slot 16 or 17, depending on the desired spacing pattern of carrier rollers 18. The sensor rollers 19B are generally equally spaced, with the most up-stream sensor roller connected to the most down-stream brake member 46 of the adjacent up-stream conveyor section 10A.
The operative connection between the sensor rollers 19B and the associated brake member 46 is the same for each so a description of one connection will suffice for each one. On reference to FIGS. 8 to 11 it can be seen that the end of shaft 19C is dropped into a slot in side rail 12, and is engaged by the seat portion 41 (FIG. 11) of a resilient element or spring 39. The other end of the spring 39 is secured by a mounting means 40 for the bracket 36 on the inside of the web of side rail 12. The bracket 36 carries the control valve 37B in position so its actuator element 38 engages the shaft 19C to follow the rise and fall thereof. Valve 37B in this case is provided at its side with a pressure air exhaust device 37C which may be a Humphrey Super Quick Exhaust Valve, Model SQE, and that device connects with a speed or time control valve device 37D which may be a Humphrey Speed Control Valve, Model SCI. These devices 37C and 37D connect in a series with the line 47 supplying pressure air to the inflatable brake member 46. The valve 37B has an inlet fitting 37A which is inserted in the pressure air supply buss 42, as seen in FIG. 7. The device 37C and 37D are made by Humphrey Products, Kalamazoo, Mich., or an equivalent thereof.
The line 47 leading from the respective devices 37D associated with each sensor roller 19B is connected to the nipple 48 (FIG. 10) of the inflatable bladder 49 which is contained in the braided outer layer 50 of the brake member 26. The nipple 48 is located at the live end of the brake member 46 which is fastened in the shallow channel 23 by means 27. The opposite end of each brake member 46 is fastened in the channel 23 by means 26. When a package or article depresses any one of the sensor rollers 19B that causes the valve 37B to open and supply pressure air to the device 37C which closes its exhaust outlet and delivers the pressure air through the timer device 37D of line 47 for inflating the associated brake member 46 to lift all of the carrier rollers 18 overlying it off the drive means 20 and at the same time stop the rotation of rollers 18. Packages or articles when stopped in this manner form a blockage for following packages or articles, thus progressively depressing up-stream sensor rollers 19B to stop the advance of those packages or articles. When the sensor roller 19B is released to rise, it causes air to be exhausted at device 37C to relax the brake.
The views in FIGS. 12A, 12B and 12C illustrate the versatile nature of the present invention. As an example, in FIG. 12A the conveyor sections 10A of FIG. 8 can be connected up to a stop belt unit 50 at the discharge end. The sensor rollers 19B are shown to be located at about two foot spacing for handling short articles or packages, and each sensor roller is connected by air line 47 to an up-stream brake member 46 (the carrier rollers 18 are not shown for clarity of disclosure). This arrangement results in the articles or packages not pressing against each other as the brake members stop the roller drive by lifting the groups of rollers 18 as noted before. The utility of this arrangement is recognized in installations calling for order picking at warehouses, or where articles need to be removed or inserted in the conveyor line with a minimum of effort. When the stop belt 50 is started the sensor rollers 19B are progressively released upstream, and the articles or packages on the conveyor begin moving in single spaced relation.
The view of FIG. 12B is the type of conveyor control described in FIGS. 1 to 7 which may operate to develop low pressure between packages or articles. The arrangement shown has each conveyor section 10 provided with a brake member 25 about one-half the length of the section 10, and one sensor roller 19. This arrangement is adapted for transporting and accumulating a random mix of articles or packages of different sizes and weights. A requirement is that the sensor roller 19 must be spaced from the up-stream brake means 25 a distance equal to the length of the longest article or package so as not to be capable of being relieved of the load.
The view of FIG. 12C shows an arrangement in which the stop belt 50 is connected to a continuously driven live roller conveyor 10B, and the latter conveyor is connected to a controllable conveyor section 10C which is provided with a sensor roller 19 associated with a long brake member 25B. The intent in this arrangement is to alternate conveyor sections 10B and 10C, although the drive means 20 will be continuous through all of the sections. In operation, the article or package pressure is essentially eliminated by each conveyor section 10C controlling the pressure generated by the continuously driven live roller conveyor sections 10B up-stream thereof. The braking effect and the driving effort are both a function of package or article size and friction so that this arrangement is best adapted for conveying a uniform size and weight of package or article. Adjustment of the positon of the drive means 20 and the elevation of the brake member 25B can result in obtaining essentially no forward advance of the load. When the stop belt 50 is operated, the load will move forward in slugs whose length can be selected by means of the time delay setting in device 44, and only short spaces will be formed. High speed operation will feed a continuous stream to a slower metering belt conveyor.
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A live roller conveyor in which the conveyor path defined by a plurality of rollers is provided with roller drive means normally continually driving all of the rollers for conveying articles, and in which one or more article sensing rollers normally slightly raised above the conveyor path are depressed by articles propelled over the same and when depressed beyond a predetermined time interval serve to operate a combined brake and roller elevating means for arresting the article propelling drive of a group of rollers located upstream from the location of the depressed sensing roller and elevating the arrested group of rollers off of the roller drive means to reduce the drag on the drive means.
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TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to a formation evaluation tool and, in particular to, a downhole tool having a retractor sleeve operably associated with a housing and a mandrel for engaging the mandrel and slidably urging the mandrel relative to the housing in response to changes in the fluid pressure within the downhole tool.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with drilling an oil or gas well, as an example.
During the course of drilling an oil or gas well, one operation which is often performed is to lower a testing string into the well to test the production capabilities of hydrocarbon producing underground formations intersected by the well. Testing is typically accomplished by lowering a string of pipe, generally drill pipe or tubing, into the well with a packer attached to the string at its lower end. Once the test string is lowered to the desired final position, the packer is set to seal off the annulus between the test string and the wellbore or casing, and the underground formation is allowed to produce oil or gas through the test string.
It has been found, however, that more accurate and useful information can be obtained if testing occurs as soon as possible after penetration of the formation. As time passes after drilling, mud invasion and filter cake buildup may occur, both of which may adversely affect testing.
Mud invasion occurs when formation fluids are displaced by drilling mud or mud filtrate. When invasion occurs, it may become impossible to obtain a representative sample of formation fluids or at a minimum, the duration of the sampling period must be increased to first remove the drilling fluid and then obtain a representative sample of formation fluids.
Similarly, as drilling fluid enters the surface of the wellbore in a fluid permeable zone and leaves its suspended solids on the wellbore surface, filter cake buildup occurs. The filter cakes act as a region of reduced permeability adjacent to the wellbore. Thus, once filter cakes have formed, the accuracy of reservoir pressure measurements decrease affecting the calculations for permeability and produceability of the formation.
Some prior art samplers have partially overcome these problems by making it possible to evaluate well formations encountered while drilling without the necessity of making two round trips for the installation and subsequent removal of conventional tools. These systems allow sampling at any time during the drilling operation while both the drill pipe and the hole remain full of fluid. These systems, not only have the advantage of minimizing mud invasion and filter cake buildup, but also, result in substantial savings in rig downtime and reduced rig operating costs.
These savings are accomplished by incorporating a packer as part of the drill string and recovering the formation fluids in a retrievable sample reservoir. A considerable saving of rig time is affected through the elimination of the round trips of the drill pipe and the reduced time period necessary for hole conditioning prior to the sampling operations.
These samplers, however, are limited in the volume of samples which can be obtained due to the physical size of the sampler and the tensile strength of the wire line, slick line or sand line used in removal of the sampler. In addition, prior art samplers have often been unable to sufficiently draw down formation pressure to clean up the zone and quickly obtain a representative sample of the formation fluids. Further, these prior art samplers are limited to a single sample during each trip into the wellbore.
Therefore, a need has arisen for an apparatus and a method for obtaining a plurality of representative fluid samples and taking formation pressure measurements from one or more underground hydrocarbon formations during a single trip into the wellbore using pressure to control the operation of the apparatus. A need has also arisen for a cost effective formation evaluation tool and a cost effective method to evaluate a formation during a drilling operation.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a downhole tool having a housing, a mandrel slidably disposed within the housing and a retractor sleeve operably associated with the housing and the mandrel for engaging the mandrel and slidably urging the mandrel relative to the housing. The mandrel and the retractor sleeve are both slidably operated responsive to changes in the fluid pressure within the downhole tool, which cause the mandrel and the retractor sleeve to move axially relative to the housing.
The retractor sleeve defines at least one external slot which accepts at least one pin radially extending from the housing. The radially extending pin guides the relative rotational motion between the retractor sleeve and the housing as the retractor sleeve slides axially relative to the housing.
A torsion spring having first and second ends is operably associated with the retractor sleeve and the mandrel. The first end of the torsion spring is securably attached to the retractor sleeve. The second end of the torsion spring is slidably rotatable relative to the retractor sleeve. The first end and the second end of the torsion spring have a plurality of rods extending therebetween, allowing relative rotational motion between the first end and the second end of the torsion spring.
Located on the outer surface of the mandrel is at least one external hook. Located on the inner surface of the second end of the torsion spring is at least one internal lug which is securably engagable with the external hook of the mandrel. A coil spring disposed between the housing and the mandrel upwardly biases the retractor sleeve.
In operation, the mandrel is slidably operated responsive to the fluid pressure within the downhole tool. The mandrel has a plurality of positions relative to the housing such that increases in fluid pressure generally shift the mandrel downward relative to the housing. The retractor sleeve is slidably and rotatably operated responsive to the fluid pressure within the downhole tool such that the retractor sleeve, at sufficient fluid pressure levels within the downhole tool, shifts downward relative to the housing and the mandrel, engaging the internal lug of the torsion spring with the external hook of the mandrel. The coil spring upwardly biases the retractor sleeve and the mandrel as the fluid pressure within the downhole tool is decreased, thereby upwardly shifting the mandrel and the retractor sleeve relative to the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas drilling platform operating a formation evaluation tool of the present invention;
FIGS. 2A-2D are half sectional views of a formation evaluation tool of the present invention;
FIGS. 3A-3B are half sectional views of a seal assembly of a formation evaluation tool of the present invention;
FIGS. 4A-4D are quarter sectional views of the operation of a mandrel of a formation evaluation tool of the present invention;
FIG. 5 is a perspective representation of a load spring of the formation evaluation tool of the present invention;
FIG. 6 is a half sectional view of a retractor section of a formation evaluation tool of the present invention;
FIG. 7 is a perspective representation of a retractor sleeve of a formation evaluation tool of the present invention;
FIG. 8 is a perspective representation of a section of a mandrel of a formation evaluation tool of the present invention;
FIG. 9 is a perspective representation of a torsion spring of a formation evaluation tool of the present invention; and
FIGS. 10A-10F are quarter sectional views having flat development representations of the interaction between a retractor sleeve, a housing, and a mandrel of a formation evaluation tool of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring to FIG. 1, a formation evaluation tool for use on an offshore oil or gas drilling platform is schematically illustrated and generally designed 10. A semisubmersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16. A subsea conduit 18 extends from deck 20 of platform 12 to a wellhead installation 22 including blowout preventors 24. Platform 12 has a derrick 26 in a hoisting apparatus 28 for raising and lowering drill string 30 including drill bit 32 and drilling formation evaluation and sampling tool 34.
Tool 34 includes pump assembly 36 and formation evaluation tool 38. Pump assembly 36 may comprise a pump which is operated by cycling the tubing pressure, a pump which is operated by internal flow, a pump operated by rotating the drill string, or a pump operated by repeated raising and lowering of the drill string. Pump assembly 36 may also comprise a pump operated by oscillatory motion of a power section as described in coassigned and copending U.S. patent application Ser. No. 08/657,205, filed on Jun. 3, 1996, entitled "Automatic Downhole Pump Assembly and Method for Use of the Same" which is hereby incorporated by reference.
During a drilling and testing operation, drill bit 32 is rotated on drill string 30 to create wellbore 40. Shortly after drill bit 32 intersects formation 14, drilling stops to allow formation testing before significant mud invasion or filter cake build up occurs. The tubing pressure inside drill string 30 is then regulated to operate pump assembly 36 and formation evaluation tool 38. Pump assembly 36 may be operated to draw down the formation pressure in formation 14 so that formation fluids can be quickly pumped into formation evaluation tool 38. Formation evaluation tool 38 may be operated to obtain a representative sample of formation fluid or gather other formation data with a minimum of drilling downtime. After such sampling of the formation, the tubing pressure may be further regulated to operate formation evaluation tool 38 such that drilling may resume.
Even though FIG. 1 shows formation evaluation tool 38 attached to drill string 30, it should be understood by one skilled in the art that formation evaluation tool 38 is equally well-suited for use during other well service operations. It should also be understood by one skilled in the art that formation evaluation tool 38 of the present invention is not limited to use with semisubmersible drilling platforms as shown in FIG. 1. Formation evaluation tool 38 is equally well-suited for use with conventional offshore drilling rigs or during onshore drilling operations.
Referring to FIGS. 2A-2D, formation evaluation tool 38 is depicted. Formation evaluation tool 38 comprises housing 42 which may be threadably connected with pump assembly 36 proximate the upper end of formation evaluation tool 38 as shown in FIG. 1. Formation evaluation tool 38 includes mandrel 44 which is slidably disposed within housing 42 between shoulder 46 and shoulder 48 of housing 42. Mandrel 44 defines interior volume 50 which may accept probe 52 therein. Profile 54 of mandrel 44 engages spring loaded keys 55 of probe 52 to secure probe 52 in position after probe 52 is inserted into mandrel 44. Annular seals 96 provide a seal between mandrel 44 and probe 52. Probe 52 includes chamber 56, intake valve 58, exhaust valve 60, and pressure recorder chamber 62 for containing a pressure recorder (not pictured). Intake valve 58 may be operably associated with pump assembly 36 or probe 52 may include a pump assembly.
Disposed between housing 42 and mandrel 44 is retractor sleeve 64, torsion spring 66, and coil spring 68. Retractor sleeve 64 slides axially and rotates with respect to housing 42 and mandrel 44. Torsion spring 66 is fixably secured to retractor sleeve 64 proximate the upper end of torsion spring 66 and rotatably disposed within retractor sleeve 64 proximate the lower end of torsion spring 66. Retractor sleeve 64 is upwardly biased by spring 66.
Load spring 70 is disposed between housing 42 and mandrel 44 of formation evaluation tool 38. Load spring 70 supports mandrel 44 and allows mandrel 44 to slide axially relative to housing 42.
Disposed about housing 42 is seal assembly 72. Seal assembly 72 comprises upper seal element 74, floating member 76, lower seal element 78 and floating piston 80. In operation, upper seal element 74 and lower seal element 78 isolate formation 14 from the drilling fluid above upper seal element 74 and below lower seal element 78 so that pump assembly 36 may draw down the pressure in formation 14, thereby minimizing the time needed to obtain a representative sample in a formation fluid sampling operation.
In FIG. 3, a half sectional view of seal assembly 72 is depicted. During a drilling operation, seal element 74 and seal element 78 are deflated so that seal element 74 and seal element 78 do not interfere with drilling mud circulation and are not damaged due to contact with wellbore 40. Seal assembly 72 includes floating piston 80. Floating piston 80 and housing 42 define chamber 82 which is in communication with interior volume 50 via fluid passageway 84 in housing 42. Fluid pressure from inside interior volume 50 enters chamber 82 downwardly urging floating piston 80. Floating piston 80 is downwardly urged due to the difference between the hydraulic force exerted on surface 86, and the hydraulic force exerted on surface 88. Surface 86 extends between inner diameter 90 of floating piston 80 and outer diameter 92 of housing 42. Surface 88 extends between inner diameter 90 of floating piston 80 and outer diameter 94 of housing 42 which is greater than outer diameter 92 of housing 42. Floating piston 80 downwardly urges seal assembly 72 to stretch seal assembly 72 and to further ensure that seal element 74 and seal element 78 do not interfere with the drilling operation. Above and below chamber 82 and between floating piston 80 and housing 84 are annular seals 96, such as O-rings.
Even though FIG. 3 shows seal assembly 72 as sliding axially relative to housing 42, it should be understood by one skilled in the art that seal assembly 72 may slide rotatably about housing 42.
Probe 52 may be inserted into interior volume 50 as shown in FIG. 2. After probe 52 is inserted into mandrel 44, the fluid pressure within interior volume 50 downwardly urges mandrel 44. As mandrel 44 slides downward relative to housing 42, fluid port 98 of mandrel 44 aligns with fluid passageway 100 of housing 42 allowing fluid pressure from interior volume 50 to inflate seal element 74 by traveling between seal assembly 72 and housing 42. Fluid pressure from interior volume 50 also travels through fluid passageway 102 in floating member 76 in order to inflate seal element 78. Once seal element 74 and seal element 78 are inflated and formation 14 is isolated, mandrel 42 is shifted downward to align fluid port 104 with formation fluid passageway 106 of housing 42 and formation fluid passageway 108 of floating member 76. Floating member 76 includes formation fluid port 110 which may include screen 112 to filter out formation particles. When fluid port 104 is aligned with formation fluid passageway 106, fluid port 114 is aligned with fluid passageway 116 which allows the pressure to equalize above seal element 74 and below seal element 78 through interior volume 50 and drill bit 32.
Mandrel 44 may be shifted upward relative to housing 42 aligning fluid port 114 with fluid passageway 106 and fluid passageway 116 and aligning fluid port 98 with fluid passageway 100 to deflate seal element 74 and seal element 78 by equalizing the pressure in wellbore 40 and interior volume 50.
Even though FIG. 2 depicts seal element 74 and seal element 78 as inflatable, it should be understood by one skilled in the art that a variety of seal elements are equally well-suited to the present invention including, but not limited to, compression seal elements.
In FIG. 4, including FIGS. 4A-4D, the interaction between load spring 70 and mandrel 44 is depicted. Mandrel 44 receives pin 118 into slot 120 to prevent relative rotational movement between mandrel 44 and housing 42 as mandrel 44 slides axially relative to housing 42.
Between mandrel 44 and housing 42 is load spring 70. Load spring 70 has profile 122 which includes upper upset 124 and lower upset 126. Mandrel 44 includes upset 128 which interferes with upper upset 124 and lower upset 126 of load spring 70.
As best seen in FIG. 5, load spring 70 comprises a plurality of cantilevered beams 134 which extend between upper end 130 and lower end 132 of load spring 70. Beams 134 are radially deformable responsive to the radial component of the force vector exerted by upset 128 of mandrel 44 on upset 124 and upset 126 of load spring 70 when mandrel 44 is downwardly urged by fluid pressure within interior volume 50.
In FIG. 4A, upset 124 of load spring 70 supports mandrel 44 by interfering with upset 128. After probe 52 is inserted into mandrel 44, the fluid pressure within interior volume 50 may be increased to a level sufficient to downwardly urge mandrel 44 such that upset 128 exerts a radial force on upset 124 radially deforming beams 134 and allowing mandrel 44 to slide downward relative to housing 42 aligning fluid port 98 with fluid passageway 100 to operate seal assembly 72 as described in reference to FIG. 2. When fluid port 98 and fluid passageway 100 are aligned, mandrel 44 is supported by upset 126 of load spring 70 due to interference with upset 128, as best shown in FIG. 4B.
Mandrel 44 may further shift downward relative to housing 42 by increasing the fluid pressure within interior volume 50. Since the interference between upset 126 and upset 128 is greater than the interference between upset 124 and upset 128 a higher fluid pressure is required to sufficiently radially deform cantilevered beams 134 before downward movement of mandrel 44 relative to housing 42 can be accomplished. Once sufficient fluid pressure is provided, mandrel 44 shifts downward until lower end 136 of mandrel 44 contacts shoulder 48 aligning fluid port 104 with fluid passageway 106 as shown in FIG. 4C.
Mandrel 44 may be shifted upward relative to housing 42. As mandrel 44 shifts upward, cantilevered beams 134 of load spring 70 are radially deformed as upset 128 of mandrel 44 contacts upset 126 and upset 124 of load spring 70. After upset 128 of mandrel 44 moves above upset 124 of load spring 70, mandrel 44 is supported by load spring 70.
FIG. 6 depicts the upper end of formation evaluation tool 38. Retractor sleeve 64 is slidably and rotatably disposed between housing 42 and mandrel 44. Extending radially inward from housing 42 are pins 138 which slidably engage slots 140 of retractor sleeve 64 as best seen in FIG. 7. Pins 138 cause retractor sleeve 64 to rotate as retractor sleeve 64 moves axially relative to housing 42.
Disposed between retractor sleeve 64 and mandrel 44 is torsion spring 66. Torsion spring 66 is secured to retractor sleeve 64 proximate upper end 142 of torsion spring 66 via outer threads 144 and inner threads 146 of retractor sleeve 64 as best seen in FIG. 9. Lower end 148 of torsion spring 66 is free to rotate within retractor sleeve 64. Bearing 150 is disposed between lower end 148 of torsion spring 66 and retractor sleeve 64. Extending between upper end 142 and lower end 148 of torsion spring 66 is a plurality of rods 152. Rods 152 allow for relative rotational motion between upper end 142 and lower end 148 of torsion spring 66. Inner surface 154 of lower end 148 includes lugs 156 which are securably engagable with hooks 158 located on outer surface 160 of mandrel 44 as best seen in FIG. 8 and FIG. 9.
Disposed between mandrel 44 and housing 42 is coil spring 68. Coil spring 68 upwardly biases retractor sleeve 64. Coil spring 68 may be preloaded such that a predetermined level of fluid pressure is required to shift retractor sleeve 64 downward relative to housing 42. As coil spring 68 deforms, an increasing amount of fluid pressure is required so that the downward hydraulic force on retractor sleeve 64 can overcome the bias force of coil spring 68.
Referring to FIGS. 10A-10F, the operation of retractor sleeve 64 is depicted. Retractor sleeve 64 is disposed between housing 42 and mandrel 44. Pins 138 are at the lower ends of slots 140. Lugs 156 of torsion spring 66 are adjacent to hooks 158, as best seen in the flat development representations in FIG. 10A.
As the pressure within interior volume 50 is increased, mandrel 44 slides downward relative to housing 42 and retractor sleeve 64. As mandrel 44 slides downward, hooks 158 slide downward relative to lugs 156 of torsion spring 66 as best seen in FIG. 10B.
As the fluid pressure within interior volume 50 is further increased, the hydraulic force exerted on retractor sleeve 64 overcomes the bias force of coil spring 68 such that retractor sleeve 64 slides axially downward relative to housing 42. As retractor sleeve 64 slides downward, pins 138 travel in slots 140 such that retractor sleeve 64 rotates relative to housing 42. As retractor sleeve 64 slides axially downward and rotates, lugs 156 move toward hooks 158 as best seen in FIG. 10C. As retractor sleeve 64 continues to slide downward and rotate relative to housing 42, lugs 156 contact hooks 158.
Once contact is made between lugs 156 and hooks 158, lower end 148 of torsion spring 166 rotates relative to retractor sleeve 64 and upper end 142 of torsion spring 166 in the direction opposite the direction of rotation of retractor sleeve 64 relative to housing 42. The counter rotation between retractor sleeve 64 and lower end 148 of torsion spring 66 continues until lugs 156 are adjacent to hooks 158 and until pins 138 reach the upper portion of slots 140, as best seen in FIG. 10D. The counter rotation of lower end 148 of torsion spring 66 and retractor sleeve 64 creates stored energy within rods 152. This energy causes lugs 156 to engage hooks 158 as retractor sleeve 64 slides further downward relative to housing 42 as best seen in FIG. 10E.
In response to a decrease in the fluid pressure within interior volume 50, the biasing force of spring 68 overcomes the hydraulic force downwardly urging retractor sleeve 64 such that retractor sleeve 64 slides upward relative to housing 42. As retractor sleeve 64 slides upward relative to housing 42, lugs 156 upwardly urge hooks 158 causing mandrel 44 to slide upward relative to housing 42. Retractor sleeve 64 and mandrel 44 slide upward relative to housing 42 until upper end 142 of torsion spring 66 contacts shoulder 170 of housing 42 as best seen in FIG. 10F.
After the fluid pressure within interior volume 50 is removed, the torsion energy stored within rods 152, caused by the rotation of retractor sleeve 64 relative to housing 42 and lower end 148 of torsion spring 66 as pins 138 slide in slots 140 of retractor sleeve 64, exceeds the friction force between lugs 156 and hooks 158 such that lugs 156 disengage hooks 158 returning mandrel 44 to its original position, as best seen in FIG. 10A.
Therefore, the formation evaluation tool and method for use of the same disclosed herein has inherent advantages over the prior art. While certain embodiments of the invention have been illustrated for the purposes of this disclosure, numerous changes in the arrangement and construction of the parts may be made by those skilled in the art, such changes being embodied within the scope and spirit of the present invention as defined by the appended claims.
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A downhole tool for early formation evaluation is disclosed. The tool comprising a housing having a fluid passageway and a mandrel having an interior volume. The mandrel is slidably disposed within the housing and has a plurality of axial positions relative to the housing. The mandrel is slidably operated responsive to the fluid pressure within the interior volume such that the mandrel cycles through said plurality of positions. A retractor sleeve is operably associated with the housing and the mandrel for engaging the mandrel and slidably urging the mandrel relative to the housing. The retractor sleeve is slidably operated responsive to the fluid pressure within the interior volume. A seal assembly is slidably disposed around the housing. The seal assembly includes a floating piston. A chamber is formed between the housing and the floating piston that is in communication with the fluid passageway of the housing such that the fluid pressure within the interior volume enters the chamber and slidably urges the seal assembly, thereby stretching the seal assembly.
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This application claims the benefit of U.S. Provisional Application No. 60/155,230, filed Mar. 3, 1999.
This invention relates to a series of novel diazolepiperazine, diazolepiperidine, and diazoledihydropiperidine derivatives, and to processes for their preparation, to pharmaceutical compositions containing them, and to their use in therapies concerning central nervous system disorders. These compounds are useful for treatment of conditions related to or affected by the 5-hydroxytryptamine-1-A (5-HT1A) receptor subtype in the CNS, including alcohol and drug withdrawl, sexual dysfunction, and Alzheimer's Disease. The utility of these compounds lies in their ability to bind as agonists and antagonists to 5-HT1A receptors. The compounds of the present invention are also useful in the treatment of depression and related CNS disorders (e.g., OCD, anxiety and panic) when combined with the use of serotonin reuptake inhibtors, such as Prozac® (fluoxetine hydrochloride).
BACKGROUND OF THE INVENTION
Depression is a psychiatric condition thought to be associated with decreased serotonin release. Most antidepressant agents potentiate the effects of serotonin by blocking the termination of its activity through re-uptake into nerve terminals.
U.S. Pat. No. 3,655,663 (B.K. Wasson, Apr. 11, 1972) covers 4-(3-secondary amino-2-hydroxypropoxy)-1,2,5-thiadiazoles which exhibit beta-adrenergic blocking properties useful for treatment of angina pectoris. Compounds of the present invention are structurally different from this prior art and are useful for treatment of CNS disorders.
WO 96/38431 (Eli Lilly, May 31, 1996) covers methods of making 1,2,5-thiadiazoles containing azacyclic or azabicyclic ether or thioether substituents for use as muscarinic cholinergic agonists. These compounds are useful as stimulants of the forebrain and hippocampus for treatment of Alzheimer's disease. Compounds of this invention are structurally different from these compounds and are agonists and antagonists of the 5HT1A receptor, not muscarinic agonists.
SUMMARY OF THE INVENTION
Compounds of the present invention are represented by the general formula (1):
wherein:
two atoms of X, Y, or Z are nitrogen and the third atom is sulfur or oxygen;
R is H, halogen, OH, SH, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 1 -C 6 thioalkyl, phenoxy, thiophenoxy, or phenyl, the phenyl ring being optionally substituted by from one to three substituents selected from C 1 -C 6 alkyl; C 1 -C 6 alkoxy; CF 3 ; Cl; Br; F; CN; or CO 2 CH 3 ;
A is C, CH, or N;
R 1 is aryl, heteroaryl, or cycloalkyl groups, the aryl, heteroaryl or cycloalkyl groups being optionally substituted by from 1 to 3 substituents selected from C 1 -C 6 alkyl, C 1 -C 6 alkoxy; CF 3 , Cl, Br, F, CN, or CO 2 CH 3 ;
R 2 is H or C 1 -C 6 alkyl;
R 3 is C 1 -C 6 alkyl, aryl, 5- or 6-membered heteroaryl, C 3 to C 8 cycloalkyl , the cycloalkyl groups being optionally substituted by C 1 -C 6 alkyl, or a 3 to 8-membered heterocyclic ring containing one or more heteroatoms selected from O, S or N, the aryl and 5- or 6-membered heteroaryl groups being optionally substituted by from one to three substituents selected from C 1 -C 6 alkyl, C 1 -C 6 alkoxy, CF 3 , Cl, Br, F, CN, or CO 2 CH 3 ;
or a pharmaceutically acceptable salt thereof.
As used herein, the term alkyl refers to C 1 -C 6 straight or branched chain, and wherein the term cycloalkyl refers to C 3 to C 8 ring, preferably a C 3 to C 6 ring, or an alkyl-substituted ring. The term “aryl” is phenyl or substituted phenyl, biphenyl, 1 or 2-naphthyl and “heteroaryl” refers to 5 or 6 membered ring heterocycles or benzofused heterocycles, specifically including, but not limited to, thiazole, thiophene, 2, 3, or 4-pyridyl, benzothiophene, or indole. The aryl or heteroaryl groups herein can be optionally substituted with one to three substituents selected from the group consisting of C 1 -C 6 alkyl; C 1 -C 6 alkoxy; CF 3 ; Cl; Br; F; CN; CO 2 CH 3 .
Among the preferred compounds of this invention are those of formula (2):
wherein R, R 1 , R 2 , and R 3 , are as defined above, or a pharmaceutically acceptable salt thereof.
Further preferred are those compounds of formula (2) wherein:
R is H, halogen, OH, SH, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 1 -C 6 thioalkyl;
R 1 is aryl, heteroaryl, or cycloalkyl groups, optionally substituted by from 1 to 3 substituents selected from C 1 -C 6 alkyl, C 1 -C 6 alkoxy; CF 3 , Cl, Br, F, CN, or CO 2 CH 3 ;
R 2 is H or C 1 -C 6 alkyl
R 3 is C 1 -C 6 alkyl, optionally substituted aryl, optionally substituted 5- or 6-membered heteroaryl, C 3 to C 8 cycloalkyl optionally substituted by C 1 -C 6 alkyl, or a 3 to 8-membered heterocyclic ring containing one or more heteroatoms selected from O, S or N;
or a pharmaceutically acceptable salt thereof.
The pharmaceutically acceptable salts are the acid addition salts which can be formed from a compound of the above general formula and a pharmaceutically acceptable acid such as phosphoric, sulfuric, hydrochloric, hydrobromic, citric, maleic, fumaric, acetic, lactic or methanesulfonic acid.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention possess high affinity for the serotonin 5-HT 1 A receptor and, consequently, are useful as antidepressant and anxiolytic agents for the treatment in a mammal of a variety of central nervous system (CNS) disorders such as depression, anxiety, sleep disorders, sexual dysfunction, alcohol and/or cocaine addiction, and related problems. The compounds of this invention may also be used in the inducement of cognition enhancement in a mammal, preferably in humans. In addition, the compounds of this invention show marked selectivity for the 5-HT 1 A receptors, as opposed to the α1 receptors.
In view of their receptor binding, these compounds may be characterized as anxiolytic and/or antidepressant agents useful in the treatment of depression and in alleviating anxiety. As such, the compounds may be administered neat o with a pharmaceutical carrier or excipient to a patient in need thereof. The pharmaceutical carrier may be solid or liquid.
It is understood that the therapeutically effective dosage to be used in the treatment of a specific psychosis must be subjectively determined by the attending physician. Variables involved include the specific psychosis or state of anxiety and the size, age and response pattern of the patient. The novel methods of the invention for treating, preventing or alleviating conditions as described above, or for inducing cognition enhancement, comprise administering to mammals in need thereof, including humans, an effective amount of one or more compounds of this invention or a non-toxic, pharmaceutically acceptable addition salt thereof. The compounds may be administered orally, rectally, parenterally, or topically to the skin and mucosa. The usual daily dose is depending on the specific compound, method of treatment and condition treated. An effective dose of 0.01-1000 mg/Kg may be used for oral application, preferably 0.5-500 mg/Kg, and an effective amount of 0.1-100 mg/Kg may be used for parenteral application, preferably 0.5-50 mg/Kg. It will be understood that in combination with other agonists or antagonists of the serotonin-1 receptor (5-HT 1 A), such as those listed above, the effective dose of the present compounds may be reduced relative to the effective amount of the combined active ingredient(s).
The present invention also includes pharmaceutical compositions containing a compound of this invention, or a pharmaceutically acceptable salt thereof, and one or more pharmaceutically acceptable carriers or excipients. Applicable solid carriers or excipients can include one or more substances which may also act as flavoring agents, lubricants, solubilizers, suspending agents, fillers, glidants, compression aids, binders or tablet-disintergrating agents or an encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active ingredient. In tablets, the active ingredient is mixed with a carrier having the necessary compression properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain up to 99% of the active ingredient. Suitable solid carriers include, for example, calcium phosphate, magnesium stearate, talc, sugars, lactose, dextrin, starch, gelatin, cellulose, methyl cellulose, sodium carboxymethyl cellulose, polyvinylpyrrolidine, low melting waxes and ion exchange resins.
Liquid carriers may be used in preparing solutions, suspensions, emulsions, syrups and elixirs. The active ingredient of this invention can be dissolved or suspended in a pharmaceutically acceptable liquid carrier such as water, an organic solvent, a mixture of both or pharmaceutically acceptable oils or fat. The liquid carrier can contain other suitable pharmaceutical additives such as solubilizers, emulsifiers, buffers, preservatives, sweeteners, flavoring agents, suspending agents, thickening agents, colors, viscosity regulators, stabilizers or osmo-regulators. Suitable examples of liquid carriers for oral and parenteral administration include water (particularly containing additives as above e.g. cellulose derivatives, preferably sodium carboxymethyl cellulose solution), alcohols (including monohydric alcohols and polyhydric alcohols e.g. glycols) and their derivatives, and oils (e.g. fractionated coconut oil and arachis oil). For parenteral administration the carrier can also be an oily ester such as ethyl oleate and isopropyl myristate. Sterile liquid carriers are used in sterile liquid form compositions for parenteral administration.
Liquid pharmaceutical compositions which are sterile solutions or suspensions can be utilized by, for example, intramuscular, intraperitoneal or subcutaneous injection. Sterile solutions can also be administered intravenously. Oral administration may be either liquid or solid composition form.
Preferably the pharmaceutical compositions and combination compositions of this invention are in unit dosage form, e.g. as tablets or capsules. In such form, the composition is sub-divided in unit dose containing appropriate quantities of the active ingredient; the unit dosage forms can be packaged compositions, for example packeted powders, vials, ampoules, prefilled syringes or sachets containing liquids. The unit dosage form can be, for example, a capsule or tablet itself, or it can be the appropriate number of any such compositions in package form.
Compounds of the present invention may be prepared by those skilled in the art of organic synthesis employing conventional methods which utilize readily available reagents and starting materials. The methods for preparing compounds of this invention will be further understood from the reaction schemes herein.
Referring to Scheme 1, the requisite dichlorodiazole is allowed to react with tert-butyl carboxy (BOC)-protected piperazine in an organic solvent, such as dimethylformamide (DMF) at elevated temperature under a nitrogen atmosphere to give the corresponding BOC-protected diazolepiperazines I. Treatment of the protected piperazines I with an acid such as hydrochloric acid, in an inert solvent, such as dioxane, under an inert atmosphere gives the deprotected piperazines II. Reaction of the diazolepiperazines II with nitrogen-protected amino acids, such as N-BOC-protected amino acids, in an organic solvent, such as methylene chloride, at room temperature under an inert atmosphere in the presence of an organic base, such as triethylamine (TEA), and a coupling reagent such as cyclohexylcarbodiimide (DCC) and hydroxybenzotriazole (HOBT) forms the amides III. Stirring the amides III with an acid, such as hydrochloric acid, in an organic solvent, such as dioxane, at room temperature under an inert atmosphere gives the amino amides IV. Reduction of the amides with diborane in an organic solvent, such as tetrahydrofuran (THF) gives the corresponding amines V. Acylation of the terminal amine with an acylating agent, such as an acyl halide or coupling of the amine with a carboxylic acid gives products of this invention VI.
Referring to Scheme 2, the requisite chlorodiazolepiperazine II, is allowed to react with a metal, such as sodium, in a polar solvent, such as methanol, at elevated temperatures under an inert atmosphere to give diazolepiperazine derivatives VII. Allowing these piperazines VII to react with an N-BOC-protected amino acid and a coupling reagent, such as DCC in the presence of HOBT and a base, such as TEA, in an organic solvent, such as methylene chloride, gives the amides VIII. Stirring the amides VIII with an acid, such as hydrochloric acid, in an organic solvent, such as dioxane, gives the amino amides IX. Reduction of the amino amides IX with diborane in an organic solvent, such as THF, under an inert atmosphere, at elevated temperature gives the amines X. Acylation of the terminal amine with an acylating agent, such as an acyl halide, or coupling of the amines with a carboxylic acid gives products of this invention XI.
Referring to Scheme 3, the requisite chlorodiazolepiperazine amide III is allowed to react with a metal, such as sodium, in a polar solvent, such as methanol, at elevated temperatures under an inert atmosphere to give diazolepiperazine derivatives VIII. Stirring the amides VIII with an acid, such as hydrochloric acid, in an organic solvent, such as dioxane, gives the amino amides IX. Reduction of the amino amides IX with diborane in an organic solvent, such as THF, under an inert atmosphere, at elevated temperature gives the amines X. Acylation of the terminal amine with an acylating agent, such as an acyl halide, or coupling of the amines with a carboxylic acid gives products of this invention XI.
Referring to Scheme 4, the N-protected 4-acylpiperidine or N-protected -4-acyldihydropiperidine is added to carbethoxyhydrazine in a polar solvent, such as methanol, at a low temperature, such as 0-5° C., and then heated under reflux to give the hydrazones XII. The hydrazones XII are heated from 30-100° C. in the presence of thionyl chloride to give 1,2,3-thiadiazole derivatives XIII. Deprotection of XIII gives the secondary amines XIV. Reaction of XIV with N-protected amino alcohols containing a leaving group, such as tosylate, in a polar solvent, such as dimethylsulfoxide, at elevated temperatures, such as 30-100° C., gives N-protected amine intermediates XV. Removal of the protecting group gives XVI and reaction of XVI with an acylating agent or with a carboxylic acid and a coupling reagent such as DCC gives compounds of this invention XVII.
Referring to Scheme 5, 4-substituted pyridines XVIII which can be prepared by known methods [Per Sauerberg, et al. J. Med. Chem. 1992 35, 2274-2283] are protected on nitrogen by a group which can be removed, such as the N-carbethoxy group, to give XIX. XIX is reduced to XX using a reducing agent, such as NaBH 4 . The protecting group is removed [for the BOC group an acid such as hydrogen chloride can be used] to give XXI which is allowed to react with an N-protected amino acid, such as a BOC-protected amino acid, to give amides XXII. Removal of the protecting group, such as treatment of the BOC group with an acid such as hydrogen chloride, gives XXIII. Reduction of the amides XXIII with a reducing agent such as diborane in an organic solvent such as tetrahydrofuran, gives XXIV. Acylation of XXIV with acylating agents or reaction of XXIV with carboxylic acids and a coupling agent such as DCC gives compounds of this invention XXV
5-HT1A Receptor Binding Assay
High affinity for the serotonin 5-HT 1A receptor was established by testing the claimed compound's ability to displace [3H] 8-OH-DPAT binding in CHO cells stably transfected with the human 5HT1A receptor. Stably transfected CHO cells are grown in DMEM containing 10% heat inactivated FBS and non-essential amino acids. Cells are scraped off the plate, transferred to centrifuge tubes, and washed twice by centrifugation (2000 rpm for 10 min., 4° C.) in buffer (50 mM Tris pH 7.5). The resulting pellets are aliquoted and placed at −80° C. On the day of assay, the cells are thawed on ice and resuspended in buffer. The binding assay is performed in a 96 well microtiter plate in a total volume of 250 mL. Non-specific binding is determined in the presence of 10 mM 5-HT, final ligand concentration is 1.5 nM. Following a 30 minute incubation at room temperature, the reaction is terminated by the addition of ice cold buffer and rapid filtration through a GF/B filter presoaked for 30 minutes in 0.5% PEI. Compounds are initially tested in a single point assay to determine percent inhibition at 1, 0.1, and 0.01 mM, and Ki values are determined for the active compounds.
5-HT1A Receptor Intrinsic Activity Assay
The intrinsic activity of compounds of the present invention was established by testing the claimed compounds ability to reverse the stimulation of cyclic adenosinemonophosphate (cAMP) in CHO cells stably transfected with the human 5-HT1A receptor.
Stably transfected CHO cells were grown in DMEM containing 10% heat inactivated FBS and non-essential amino acids. The cells are plated at a density of ×10 6 cells per well in a 24 well plate and incubated for 2 days in a CO 2 incubator. On the second day, the media is replaced with 0.5 mL treatment buffer (DMEM+25 mM HEPES, 5 mM theophylline, 10 mM pargyline) and incubated for 10 minutes at 37° C. Wells are treated with forskolin (1 mM final concentration) followed immediately by the test compound (0.1 and 1 mM for initial screen) and incubated for an additional 10 minutes at 37° C. The reaction is terminated by removal of the media and addition of 0.5 mL ice cold assay buffer (supplied in the RIA kit). Plates are stored at −20° C. prior to assessment of cAMP formation by RIA. EC 50 values are determined for the active test compounds. Compounds shown to have no agonist activities (Emax=0%) are further analyzed for their ability to reverse agonist induced activity. In separate experiments, 6 concentrations of antagonist are preincubated for 20 minutes prior to the addition of agonist and forskolin. Cells are harvested as described above. The cAMP kit is supplied by Amersham and the RIA is performed as per kit instructions, and calculations of IC 50 performed by GraphPad Prism.
5-HT1A binding
cAMP
Compound
Ki (nM)
Emax
Compound 4
0.84
93.00 (EC 50 = 4.61 nM)
Compound 5
425.20
Compound 6
47% @ 1 _M
Compound 7
4.55
0.00 (IC 50 = 49.26 nM)
Compound 8
1.55
0.00 (IC 50 = 72.74 nM)
Compound 9
9.87
Compound 11
3.04
0.000 (IC 50 = 113.00 nM)
The following non-limiting specific examples are included to illustrate the synthetic procedures used for preparing compounds of the formula 1. In these examples, all chemicals and intermediates are either commercially available or can be prepared by standard procedures found in the literature or are known to those skilled in the art of organic synthesis. Several preferred, non-limiting embodiments are described to illustrate the invention.
EXAMPLE 1
1-(4-Chloro-[1,2,5]thiadiazol-3-yl)piperazine Hydrochloride
Piperazine-1-carboxylic acid tert-butyl ester (10 g, 0.054 m) was dissolved in anhydrous dimethylformamide (DMF, 50 mL) under nitrogen in a single-necked round bottomed flask. The clear solution was placed in a preheated oil bath (50 C-60 C). 4,5-Dichloro-[1,2,5]thiadiazole (5.0 mL, 0.054 m) was added and the reaction mixture was allowed to stir for 24 h. A yellow solution containing a white solid was observed. After cooling to room temperature, the mixture was diluted with an equal volume of anhydrous ethyl ether and stirred for 5 minutes. The solid was removed by filtration and the yellow filtrate was concentrated under aspirator vacuum to remove ether and then evaporated under oil pump vacuum to remove DMF. The yellow residue was dried at oil pump vacuum overnight to give 9.91 g of 4-(4-chloro-[1,2,5]thiadiazol-3-yl)piperazine-1-carboxylic acid tert-butyl ester. Two recrystallizations of crude product from hexane gave white crystals: mp 83-86° C.
Anal. Calcd for C 11 H 17 ClN 4 O 2 S.0.075 mol hexane:
Theory: % C, 44.18;% H, 5.85;% N, 18.00
Found: % C, 44.44;% H, 5.84;%N, 17.80
The tert-butyl ester 1 (400 mg, 1.3 mmol) was treated with 4N HCl (5.0 mL) in dioxane under a nitrogen atmosphere. The ester dissolved and a white precipitate formed gradually. The mixture was allowed to stir overnight at room temperature. The reaction mixture was diltued with heptane and filtered to collect a crystalline solid which was rinsed with heptane and dried to give 285 mg of the title compound as a pale yellow solid, mp: 205° C. (dec).
Anal. Calcd. for C 6 H 9 ClN 4 S.HCl. 0.15 H 2 O
Theory: % C, 29.56;% N, 4.26;% N, 22.98
Found: % C, 29.99;% N, 4.40;% N, 22.34
EXAMPLE 2
4-Piperazin-1-yl-[1,2,5]thiadiazole-3-ol Hydrochloride
The title compound of example 1 (1.25 g, 5.18 mmol), was combined with 2.5 N NaOH (10 mL) and dimethylsulfoxide (DMSO, 1.0 mL) and heated under reflux with stirring for 2.5 h. The heat was shut off and the cloudy mixture was allowed to cool and stir overnight. The pale yellow solution was chilled in an ice bath and acidified to pH 0 with concentrated HCl. The mixture was chilled in an ice bath for several hours and filtered to collect a white crystalline solid which was dried under reduced pressure over Drierite to give 0.469 g of the title compound, mp: 230° C. (dec).
Anal. Calcd. for C 6 H, 0 N 4 S.HCl.0.25 H 2 O
Theory: % C, 31.69;% H, 5.06;% N, 24.65
Found: % C, 31.54;% H, 4.66;% N, 24.21
EXAMPLE 3
1-(4-Methoxy-[1,2,5}thiadiazol-3-yl)piperazine Hydrochloride
The title compound of Example 1 (0.95 g, 3.9 mmol) was suspended in anhydrous methanol (10 mL) under a nitrogen atmosphere. Pellets of sodium metal (0.733 g, 32 g-atoms) were added slowly with stirring. An exotherm to reflux occurred. Heating under reflux was continued for 2 h in preheated oil bath. The reaction mixture was then cooled to room temperature and allowed to stir overnight. The volatiles were removed under reduced pressure and the mustard-colored residue was partitioned between ethyl acetate and water. The aqueous phase was extracted with ethyl acetate (3×). The organic phases were combined, dried (MgSO4) and evaporated to give 0.268 g of a yellow oil. The oil was dissolved in methanol and treated with IM HCl in ether (2.0 mL) to give a tan solid which was recrystallized from 1:2 isopropanol:isopropyl ether to give 89 mg of the title compound as mustard yellow crystals, mp: 190° C. (dec).
Anal. Calcd. for C 7 H 12 N 4 OS. HCl. 0.1 isopropanol
Theory: % C, 36.12;% H, 5.73;% N, 23.08.
Found: % C, 36.21;% H, 5.68;% N, 23.37.
EXAMPLE 4
Cyclohexanecarboxylic acid {(1S)-1-benzyl-2-(4-(4-chloro[1,2,5}thiadiazol-3-yl)piperazin-1-yl]ethyl}amide fumarate
N-BOC-L-phenylalanine (6 g, 22.6 mmol) was dissolved in methylene chloride (240 mL) under a nitrogen atmosphere. To this was added the compound of Example 1 (5.0 g, 20.7 mmol) followed by triethylamine (TEA, 2.1 g), HOBT (3.65 g), and dicyclohexylcarbodiimide (DCC, 4.7 g). The reaction mixture was allowed to stir at room temperature overnight. The reaction mixture was filtered to remove insolubles and the volatiles was removed from the filtrate under reduced pressure. The residue was taken up in methylene chloride, cooled in a freezer, and filtered to remove a white solid. The filtrate was purified by chromatography on silica gel eluting with 0.4%-0.6% MeOH in methylene chloride to give Intermediate I ({1-benzyl-2-[4-(4-chloro[1,2,5]thiadiazol-3-yl)piperazin-1-yl]-2-oxo-ethyl }carbamic acid tert butyl ester) as an amorphous solid, mp: 45-51° C.
Anal. Calcd. for C 20 H 26 ClN 5 O 3 S
Theory: % C, 53.15;% H, 5.80;% N, 15.49
Found: % C, 53.02;% H, 5.64;% N, 15.27
Intermediate 1 (2.0 g) was dissolved in dioxane (5 mL) and treated with 4 M HCl in dioxane under a nitrogen atmosphere overnight. A mass of white solid was observed. The reaction mixture was diluted with dioxane and filtered to collect the solid. After drying under reduced pressure, 1.57 g of (2S)-2-amino-1-[4(4-chloro-[1,2,5]thiadiazol-3-yl)piperazin-1-]-3-phenylpropan-1-one hydrochloride [Intermediate II]: mp 201-205° C., was obtained.
Anal Calcd for C 15 H 18 ClN 5 OS . HCl.0.45 dioxane
Theory: % C, 47.15;% H, 5.32;% N, 16.36
Found: % C, 47.03;% H, 5.35;% N, 15.88
Intermediate 11 (0.92 g, 2.6 mmol) was dissolved in anhydrous THF (30 mL) under a nitrogen atmosphere. 1M BH 3 in THF (8.2 mL, 3 equivalents) was added (foaming) and the reaction mixture was heated under reflux 1 h. After cooling to room temperature, 1N HCl (10 mL) was added cautiously and stirring was continued overnight at room temperature. After extracting with ether, the aqueous phase was chilled in an ice bath and adjusted to pH 14 with solid NaOH. A yellow oil separated which was extracted into ethyl acetate, dried (MgSO 4 ), filtered, and evaporated to give a thick yellow oil which was dried under reduced pressure to give 376 mg of Intermediate III.
Intermediate III (357 mg, 1.06 mmol) was dissolved in anhydrous methylene chloride (20 mL) under a nitrogen atmosphere, followed by triethylamine (0.3 mL, 2 equivalents). Cyclohexylcarbonyl chloride (160 mg, 1 equivalent) was diluted with methylene chloride (10 mL) and added dropwise at 0-5 C. The reaction mixture was allowed to warm to room temperature and was stirred overnight. The reaction mixture was quenched with sat. NaHCO 3 (10 mL) and sat. NaCl (10 mL). The organic phase was separated, washed with water (2×), and dried (MgSO 4 ). The solution was filtered and the volatiles were removed under reduced pressure to give a viscous yellow oil was purified by flash column chromatography on silica gel eluting with up to 30% ethyl acetate in hexane to give 185 mg of the free base of the title compound. The compound was converted to the fumarate salt by treatment with fumaric acid in ethanol to give the title compound: mp, 138-140° C.
Anal Calcd for C22H 30 N 5 ClOS.C 4 H 4 O 4
Theory: %C, 55.36;%H, 6.08;%N, 12.41
Found: %C, 55.08;%H, 5.96;%N, 12.14
EXAMPLE 5
N-{(1S)-Benzyl-2-[4[(4-chloro-[1,2,5]thiadiazol-3-yl)piperazin-1-yl)ethyl)isonicotinamide
Intermediate III (120 mg, 0.35 mmol) was dissolved in methylene chloride (15 mL) under nitrogen. Isonicotinic acid (50 mg, 0.41 mmol) was added followed by triethylamine (0.08 mL), 1-hydroxybenzotriazole hydrate, HOBT, (55 mg ), and dicyclohexylcarbodiimide, DCC, (85 mg). The reaction mixture was stirred at room temperature overnight. After filtration to remove solids, volatiles were removed from the filtrate under reduced pressure. The residue was purified by flash column chromatography on silic gel eluting with methylene chloride to 2% methanol in methylene chloride to give the title compound, 100 mg, as a white solid. The free base was converted to the fumarate salt using fumaric acid in ethanol and isopropyl ether. An amorphous solid was obtained. mp: 99-125° C.
Anal. Calcd. for C 21 H 23 N 6 ClOS.1.5 C 4 H 4 O 4 .0.75 H 2 O
Theory: %C, 51.38;%H, 4.97;%N, 13.05.
Found: %C, 51.63;%H, 4.77;%N, 12.43
EXAMPLE 6
Pyridine-2-carboxylic acid {(1S)-1-benzyl-2,3-[4(4-chloro[1,2,5]thiadiazol-3-yl)piperazin-1-yl]ethyl}amide
Example 6 was prepared using Intermediate III and pyridine-2-carboxylic acid according to the method of Example 5. The fumaric acid salt was a granular solid: mp 60-70° C.
Anal Calcd. For C 2 1H 23 N 6 ClOS.C 4 H 4 O 4 . 1 H 2 O.0.2 diisopropylether
Theory: %C, 52.67;%H, 5.36;%N, 14.07.
Found: %C, 52.89;%H, 5.05;%N, 13.59
EXAMPLE 7
Cyclohexanecarboxylic acid {(2R)-1-benzyl-2-[4-(4-chloro[1,2,5]thiadiazol-3-ylpiperazin-1-1yl]ethyl}methylamide
The compound of Example 1 and BOC-protected N-methyl-D-phenylalanine were allowed to react according to the method of Example 4 to give Intermediate IV, {(IR)-1-benzyl-2-[4-(4-chloro-[1,2,5]thiadiazol-3-yl)piperazin-1-yl]-2-oxo-ethyl}methylcarbamic acid tert-butyl ester: mp 109-111 C.
Intermediate IV was allowed to react with 4N HCl in dioxane according to the method of Example 4 to give Intermediate V, (2R)-1-[4-(4-chloro[1,2,5]thiadiazol-3-yl)piperazin-1-yl)-2-methylamino-3-phenylpropan-1-one: mp 230-232° C. chloride (0.08 mL) in methylene chloride (1 mL) at room temperature. After stirring for 5 minutes, 2.5 N NaOH (5 mL) and brine (12 mL) were added. The organic phase was separated and the aqueous was extracted with brine (2×). The combined organic phases were dried (MgSO 4 ), evaporated and the residue was purified on silica gel eluting with 1% methanol in methylene chloride to give 185 mg of the title compound as an oil. (89%). The free base was converted to the fumaric acid salt: mp 51-59° C.
Anal Calcd for C 23 H 32 N 5 OSCl+1.0 C 4 H 4 O 4 +1.0H 2 O
Theory: % C, 54.88;% H, 6.65;% N, 11.40.
Found: % C, 55.11;% H, 6.34;% N, 11.04.
EXAMPLE 8
Cyclohexanecarboxylic acid {(1R)-1-benzyl-2-[4-(4-methoxy-[1,2,5]thiadiazol-3-yl)-piperazine-1-yl]ethyl}methyl amide
Intermediate IV of Example 7 (2.20 g. 4.9 mmole) was dissolved in warm methanol (50 mL) with stirring. Sodium spheres were added portionwise keeping the reaction mixture at reflux and following the reaction by mass spec. When the reaction was complete, the volatiles were removed under reduced pressure and the residue was partitioned between ethyl acetate and water. The aqueous phase was separated, extracted with ethyl acetate and the organic phases were combined, dried (MgSO 4 ), filtered, and evaporated to give an oily residue. The residue was purified by chromatography on silica gel eluting with 0.5% to 0.75% methanol in methylene chloride to give Intermediate VI as a tacky foam. The foam was dissolved in anhydrous dioxane (20 mL), treated with 4 N HCl in dioxane (10 mL) and stirred at ambient temperature for 5 h. Ethyl ether (15 mL) was added and Intermediate VII was collected by filtration (800 mg, 40%) as a white solid, mp: 237-239 C (dec).
Intermediate VII (726 mg, 1.82 mmol) was reduced with IM BH 3 in THF (7 mL) containing TEA (0.3 mL) as described in Example 7. The crude product was purified by chromatography on silica gel eluting with 3.5% to 6% methanol in methylene chloride to give 398 mg (63%) of Intermediate VIII.
A solution of Intermediate VIII (298 mg, 0.86 mmol) in methylene chloride containing TEA (0.17 mL) was treated with a solution of cyclohexylcarbonyl chloride (0.17 mL) in methylene chloride (2 mL). After stirring for 15 minutes the reaction was quenched by the addition of brine (25 mL). The layers were separated and the aqueous phase was extracted twice with methylene chloride. The organic layers were combined, dried (MgSO 4 ), filtered, and evaporated to give a residue which was purified by chromatography on silica gel eluting with 0.5% methanol in methylene chloride to give the title compound (252 mg, 64%) as an oil. The oil was dissolved in ether, treated with ethereal HCl to give the HCl salt of the title compound as a white solid, mp: 190-193° C.
Anal. Calcd for C 24 H 35 N 5 O 2 S+1.00 HCl+0.4 H s O
Theory: % C, 57.50;% H, 7.40;% N, 13.97.
Found: % C, 57.78;% H, 7.12;% N, 13.49.
EXAMPLE 9
N-{1-Benzyl-2-[4-(4-methoxy-[1,2,5]thiadiazol-3-yl)piperazin-1-yl]ethyl}-N-methylbenzamide
A solution of Intermediate VIII (100 mg, 0.29 mmol) in methylene chloride containing TEA (0.12 mL) was treated with a solution of benzoyl chloride (0.05 mL) in methylene chloride (1 mL). After stirring for 4 hours the reaction was quenched by the addition of brine (10 mL). The layers were separated and the aqueous phase was extracted twice with methylene chloride. The organic layers were combined, dried (MgSO 4 ), filtered, and evaporated to give a residue which was purified by chromatography on silica gel eluting with 0.3-0.5% methanol in methylene chloride to give the title compound (90 mg, 69%) as an oil. The oil was dissolved in ether, treated with ethereal HCl to give the HCl salt of the title compound as a white solid, mp: 211-215° C.
Anal. Calcd. For C 24 H 29 N 5 O 2 S+HCl
Theory: %C, 59.06;%H, 6.2;%N, 14.35
Found: %C, 58.69;%H, 6.18;%N, 14.16
EXAMPLE 10
Morpholine-4-carboxylic acid {1-benzyl-2-[4-(4-methoxy[1,2,5]thiadiazol-3-yl)piperazin-1-yl]ethyl}methylamide
A solution of Intermediate VIII (100 mg, 0.29 mmol) in methylene chloride containing TEA (0.12 mL) was treated with a solution of morpholine carbonyl chloride (0.05 mL) in methylene chloride (1 mL). After stirring for 4 hours the reaction was quenched by the addition of brine (10 mL). The layers were separated and the aqueous phase was extracted twice with methylene chloride. The organic layers were combined, dried (MgSO 4 ), filtered, and evaporated to give a residue which was purified by chromatography on silica gel eluting with 0.3-0.5% methanol in methylene chloride to give the title compound (100 mg, 75%) as a waxy solid. The solid was dissolved in ether, treated with ethereal HCl to give the 2 HCl salt of the title compound as a white amorphous solid, mp: 68-97° C.
Anal. Calcd for C 2 2H 32 N 6 O 3 S+2HCl
Theory: %C, 49.53;%H, 6.42;% N, 15.75
Found: %C, 49.74;%H, 6.66;%N, 15.64
EXAMPLE 11
1-Methylcyclohexanecarboxylic acid {(1R)-2-[4-(4-methoxy-[1,2,5]thiadiazol-3-yl)-piperazin-1-yl]-1-pyridin-3-ylmethyl ethyl}amide
The compound of Example 1 was allowed to react with BOC-D-3-pyridylalanine according to the method of Example 1 to give Intermediate X, {(2R)-2-[4(4-chloro-[1,2,5]thiadiazol-3-yl)piperazin-1-yl]-2-oxopyridin-3-ylmethylethyl]carbamic acid tert butyl ester as an amorphous solid.
Anal. Calcd for C 19 H 25 ClN 6 O 3 S
Theory: %C, 50.38;%H, 5.56;%N, 18.55
Found: %C, 51.25;%H, 5.65;%N, 18.18
The method of Example 4 was used to convert Intermediate X to Compound 11 with the exception that methylcyclohexylcarbonyl chloride was used in place of cyclohexanecarbonyl chloride.
Anal. Calcd for C 23 H 34 N 6 O 2 S+2HCl+0.33 H 2 O
Theory: %C, 51.40;%H, 6.87;%N, 15.64
Found: %C 51.38;%H, 6.90;%N, 15.21.
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The present invention provides compounds of the general formula (1):
wherein:
two atoms of X, Y, or Z are nitrogen and the third atom is sulfur or oxygen;
R is H, halogen, OH, SH, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, C 1 -C 6 thioalkyl, phenoxy, thiophenoxy, phenyl or substituted phenyl;
A is C, CH, or N;
R 1 is aryl, heteroaryl, or cycloalkyl groups, optionally substituted by from 1 to 3 substituents selected from C 1 -C 6 alkyl, C 1 -C 6 alkoxy; CF 3 , Cl, Br, F, CN, or CO 2 CH 3 ;
R 2 is H or alkyl
R 3 is C 1 -C 6 alkyl, optionally substituted aryl, optionally substituted 5- or 6-membered heteroaryl, C 3 to C 8 cycloalkyl optionally substituted by C 1 -C 6 alkyl, or a 3 to 8-membered heterocyclic ring containing one or more heteroatoms selected from O, S or N; or a pharmaceutically acceptable salt thereof, as well as pharmaceutical compositions and methods of treating central nervous system disorders using these compounds.
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CLAIM OF PRIORITY
[0001] This is a non-provisional application claiming priority based on App. No. 60/245,965, filed Nov. 3, 2000 and entitled “Latch Device for Securing Cargo Containers Together And/or to Vehicle Decks,” and also claiming priority based on App. No. 60/292,505, filed May 21, 2001 also entitled “Latch Device for Securing Cargo Containers Together And/or to Vehicle Decks.”
BACKGROUND OF THE INVENTION
[0002] The invention relates to container securement devices, and more particularly, to improvements in cargo container securement devices of the type that provides automatic securement and release of a cargo container. The device is mountable and demountable on a deck or frame of a vehicle so that the device can be adapted to different load conditions including a different mix of containers of different length and the like while having unused devices not interfere with the flush mounting of long containers.
DESCRIPTION OF RELATED ART
[0003] U.S. Pat. No. 3,365,229 teaches a top coupler means for interlocking a pair of opposed container corner brackets to provide for a tandem coupling of said containers, said top coupling means including a pair of first and second severable top coupler elements, each element having a clamp portion for engagement with respective corner bracket and a spacer portion engageable with the spacer portion of the other element attendant to space separation of one corner bracket from the other, said first top coupler element being provided with one coupler element interlock portion and said second top coupler element being provided with another coupler interlock portion for intercoupling with the one interlock portion, and means for pivotally interlocking one element with the other, and bottom coupling means for coupling the bottoms of the containers together, and hoisting means therefore. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0004] U.S. Pat. No. 3,603,267 teaches a supporting and securement structure adapted to use on carrier vehicles, including railway flatcars, for the transportation of varied sizes and numbers of box-type containers in which merchandise is shipped; said structure having guide tracks secured to the carrier vehicle structure and one-piece pedestal type supports with integral support portions retained within the guide tracks for movement therealong to predetermined positions of securement and swingable around said support portions between upright and collapsed positions, the support pedestals being constructed and propelled for relative stability in their upright positions and collapsible into relatively small openings in the guide tracks themselves to close said openings when not in use. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0005] U.S. Pat. No. 3,604,363 teaches spring-biased latches on a transport carrier for automatically engaging and disengaging bottom corner container fittings are bodily movable to maintain the same latching engagement within limits for various clearances between the container fittings and the housings secured to the transport carrier on which the latches are mounted. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0006] U.S. Pat. No. 3,604,364 teaches fittings at the corners of a container that are automatically latched to a railway car when it is lowered thereon and unlatched therefrom when the container is lifted from transport position. Each fitting is received in a housing on the car on which a bellcrank latch is mounted to pivot about a pair of spaced axes under the biasing action of a coil compression spring reacting between the housing and the distal end of one arm of the latch. The distal end of the other arm of the latch has latching engagement with the respective container fitting. The housings are slidable along slots extending lengthwise along opposite sides of the car and can be swung to retracted positions on trunnions extending below the floor or deck of the car. The trunnions are located in spaced relation to the latches to cause them to maintain latching engagement with the container on upward movement of it during transport. The retracted housings are arranged to be bypassed by other housings slidable along the slots. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0007] U.S. Pat. No. 3,628,222 teaches a latching mechanism having two pivotally mounted and interacting members. This mechanism provides for automatic locking when moved to the latched position with provisions for unlocking when unlatching is desired. The latching mechanism is particularly adaptable for use in latching shipping containers to the bed of transporting vehicles. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0008] U.S. Pat. No. 3,630,155 teaches a railroad car container bracket mounted on transverse sideplate means attached periodically to the sides of the railroad car deck. The bracket is pivoted on an axis transverse to the longitudinal centerline of the car and constructed in such a manner as to prevent longitudinal, transverse, and vertical movement of a container. When the brackets are in position supporting the four bottom corners of a container, the bracket will transmit impact forces to the deck of the railway car in a unique manner which shields the bracket pivot pin from damaging shearing forces. The bracket also contains a spring-loaded pivot latch which prevents dislodgment of the container in a vertical direction, especially when the container is empty and subjected to high wind loading which tends to tip an empty container from the deck of the container car. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0009] U.S. Pat. No. 3,774,551 teaches a spring biased latch lever is variably pivoted on the housing of container securing means on a transport carrier to accommodate minimum and maximum clearances between the container securing means and the bottom container fitting mounted thereon. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0010] U.S. Pat. No. 4,236,853 teaches a coating of cadmium applied to a container pedestal latch protuberance which lowers the maximum exit force sufficiently as to be within the 2200 pound maximum in the AAR specification while the minimum exit force of 1600 pounds and the maximum container entry force of 800 pounds were also within the specification. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0011] U.S. Pat. No. 4,277,212 teaches a connector for use in the securement of a first member, such as a cargo container, to a base support includes a base member, a post member extending from the base member in one direction and an attaching means for attaching the connector to the base support extending from the base member in the other direction. Restraining means provides vertical restraint to the container when the post member is positioned to extend into the opening of the web of the corner casting thereof and the container is restrained from movement in at least one horizontal direction. In one form, a restraining surface for the container is located on a cam pivotally mounted by the post member and in a second form, a restraining surface for the container is on the post member itself. The cam of the first form is pivotally mounted so that in response to lifting movement, the cam is rotated about its axis to act upon the web portion to impact a force horizontally whereby the container, in loading, follows a path similar to that in loading. In the second form, a plunger, under a force of compression of a spring, acts on the web portion to provide a similar function. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0012] U.S. Pat. No. 4,372,715 teaches a punch type release lock intended for use primarily in retaining load supports such as pallets in locked position in an aircraft. The lock comprises a detent mechanism which is inserted into a recess preferably at the side of the load support. A preferred form of detent mechanism comprises a pair of relatively movable elements, at least one of which is pivoted. The elements include abutments which are movable apart as the elements are inserted into the recess. When a load is applied to the pivoted detent, as for example, by a parachute extracting system, movement of the element in a direction to withdraw the element to release the load support is prevented by a load cell comprising a fuse plate and punch, in which the punch is prevented from movement by the fuse plate until attainment of a predetermined load on the pivoted detent element. At the pre determined load, the punch penetrates the fuse plate and upon penetration of the fuse plate, the punch is relatively freely movable to effectively permit the load support to move the pivoted detent element to completely release the load support. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0013] U.S. Pat. No. 4,382,734 teaches a container pedestal for supporting and securing a cargo container having a catch opening on a vehicle such as a rail car. The pedestal includes a base defining a platform for supporting the container. A pivotal latch lever is biased by a spring into a latched position wherein a latching nose on the lever registers with a latch recess in the container. The latch nose is contacted for pivoting the latch lever from the latched to a released position when the container is raised or lowered. The latch lever can be manually locked, yet self-entry automatic loading can be carried out in the locked condition. A line contact between the latch lever and the spring provides reliable and consistent latch operation due to a uniform spring lever arm length. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0014] U.S. Pat. No. 4,382,735 teaches a container pedestal for supporting and securing a cargo container having a catch opening on a vehicle such as a rail car. The pedestal includes a base defining a platform for supporting the container. A pivotal latch lever is biased by a spring into a latched position wherein a latching nose on the lever registers with a latch recess in the container. The latch nose is contacted by the container for pivoting the latch lever from the latched to a released position when the container is raised or lowered. The latch lever can be manually locked, yet self-entry automatic loading can be carried out in the locked condition. A line contact between the latch lever and the spring provides reliable and consistent latch operation due to a uniform spring lever arm length. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0015] U.S. Pat. No. 4,430,032 teaches a latch for locking a container to a pedestal on the flat deck of a flat car and particularly containers containing flammable materials. The container is supported on a pedestal at each corner thereof and the pedestals are adjustably mounted in guideways for movement along the deck of the flat car in accordance with the length of the container, to support containers at selected intervals along the car. A spring biased latch is provided to lock the container to the pedestal and a lock is provided for the latch is provided which reacts against the pedestal and includes a biasing spring for the lock to positively hold the latch in a locked position even though the car should be derailed. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0016] U.S. Pat. No. 4,626,155 teaches a device for automatically securing a cargo container to a support such as a deck of a vehicle or a second container with the first container is to be stacked. The device includes a base having a projecting shear block received in the locking opening of the container. A head rotates between an unlocked or loading position in which the head moves through the locking opening and a locked position in which the container is secured. Automatic entry and release are provided by a spring within the biasing the head to the locked position but permitting movement to the unlocked position when torque is applied by engagement of the container with a cam surface on the head. Visible indication of the locked position and positive locking of the head in the locked position may be provided. For stacked containers, two aligned shear blocks and two angularly offset heads are provided and the spring may be released for manual locking of the device to one container followed by automatic locking to the second container. The disclosure in this patent is incorporated by reference in the instant application as if filly set forth herein.
[0017] U.S. Pat. No. 5,090,638 teaches a locking mechanism for tying down a piece of freight on a loading floor in an aircraft has a housing recessed in the loading floor. A latch opening member and a latching member are journalled in the housing to tilt toward each other or away from each other. Follower cams of the latching member ride in respective cam guide tracks of the latch operating member. A tension spring tends to bias the latching member and the latch operating member in opposite directions in a freight latching position or into a recessed beyond dead center position. Stop members are so positioned on the latch operating member and on the latching member that the latter cannot be tilted without activating the latch operating member which can be rolled over by a piece of freight in one direction when projecting from the housing and in the other direction when recessed into the housing. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0018] U.S. Pat. No. 5,106,247 teaches an automatic hold down and locking as well as automatic load configuration change capability device system, which can be used to hold down and lock either one long container or several shorter containers within the same loading space, regardless of the outside width or width of bottom side rail flange on the container. The locking device system has four fixed non-retractable fully automatic locking devices positioned on the load carrier at the four outer standard locking points of each long container, and at least two retractable fully automatic locking devices positioned at the long side of the load carrier between and in line with the outer locking points. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0019] U.S. Pat. No. 5,560,088 teaches a coupling piece includes an abutment and locking member which is shiftable relative to the abutment to allow for an automatic and reliable locking of the containers. The coupling pieces do not jam when the connection is released by means of slightly tilting the upper container. The coupling piece is particularly suitable for automatically locking and releasing tightly stowed containers, especially 20′ containers. In an alternate embodiment, a coupling piece is shaped such that the entire coupling piece is shifted to a locking position when containers are placed on top of one another. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0020] U.S. Pat. No. 5,570,981 teaches a cargo container hold down device that includes a shear block defining a base and a housing therefore that is shaped so that the base forms a planar surfacing thereabout on which the cargo container fitting rests in the applied relation of the container relative to the supporting platform involved; the shear block housing pivotally mounts a latch device comprising a latch member that includes a nose portion having an upper cam surfacing for engagement by a correspondingly located container mounted corner fitting, and an under cam surfacing disposed for engagement by such correspondingly located container mounted corner fitting on removal of such container therefrom, the latch member being biased outwardly of the shear block housing to dispose the nose thereof over the container corner fitting supporting surface of the shear block housing, and including an element for withdrawing such latch member within the shear block housing about one pivot axis when the container is applied to the device, and an element for withdrawing such latch member within the shear block housing about a separate axis that is spaced from and parallels the first indicated pivot axis when the container is removed from such device, so as to achieve a smooth and easier loading of the container, and provide for increased force for cam positioning of the device latch member for container removal purposes. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0021] U.S. Pat. No. 5,797,169 teaches a coupling piece for the detachable connection of corner fittings of adjacent containers, especially of containers stacked one above the other on board ships. In order to reduce the manual effort involved in coupling together containers, semi-automatic coupling pieces are known which only need to be manually attached to one container and pre-locked. A full locking after the containers have been placed one on top of the other is effected automatically. Coupling pieces of this type require however, in many respects, a complex automatic actuating mechanism. In order to simplify the automatic actuating mechanism, a plurality of stop faces are provided, which are offset to one another on the locking bolt and which can be brought alternately into a corresponding position to a stop face on a spring-loaded ram. The contact of a stop face of the locking bolt against the stop face of the spring-loaded ram enables the locking bolt to be fixed simply and reliably in the respectively intended position of its crossbolts. The disclosure in this patent is incorporated by reference in the instant application as if fully set forth herein.
[0022] Canadian Patent No. 589031, issued December, 1959, in Class/Subclass 410/80 is believed to generally relate to the subject matter of this invention.
[0023] A company known as Peck & Hale has offered for sale a model F665 Safe-T-Loc Stacker container lock, believed to be more than one year prior to the filing date of this application.
[0024] It will be seen that the forgoing prior art teaches certain parameters for container locks and use various complex solutions to meet the needs taught. The instant invention departs from the complex mechanisms and mechanisms of limited functionality in its use of the housing with several camming surfaces, a latch with specific geometry to engage the surfaces in the housing, the corner casting of the container and the spring, moving through the required motion and imparting the required loads and resistance to forces, yet further providing a simple, strong and efficient structure with a minimum of parts, notably without a latch pivot. Additionally, the prior art typically uses either complex spring mounting and seating arrangements or spring mounting and/or seating arrangements that are difficult to work with, particularly when changing broken springs or replacing springs with appropriately calibrated springs. The instant invention utilizes simple, yet high performance spring mounting and seating.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] A device for securing cargo containers to a vehicle deck and/or two cargo containers together comprising a housing containing a latch mechanism that extends outwardly from the housing to engage a cargo container corner casting. The other side of the housing has two flanges projecting therefrom in a generally “T” shaped plan form.
[0026] In the case where two cargo containers are to be secured together, the flanges are inserted into the aperture of a cargo containers corner fitting manually and oriented in such a manner as to prevent its removal. The appropriate corner fitting of the other cargo container is brought into contact with the exposed end of the device's latch mechanism that extends outwardly from the housing to engage the cargo container corner casting and secure the two cargo containers together. When appropriate force is exerted to pull the two cargo containers apart, the devices latch mechanism that extends outwardly from the housing will automatically retract into the devices housing allowing the two cargo containers to be separated.
[0027] In the case where a cargo container is to be secured to a deck or frame of a vehicle, the flanges are inserted into the aperture of a deck or frame of a vehicle manually and oriented in such a manner as to prevent its removal. The appropriate corner fitting of the cargo container is brought into contact with the exposed end of the device latch mechanism that extends outwardly from the housing to engage the cargo container corner casting and secure it to the deck or frame of a vehicle. When appropriate force is exerted to pull the cargo container off of the deck, the devices latch mechanism that extends outwardly from the housing will automatically retract into the devices housing allowing the cargo container to be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a largely schematic perspective view of a support surface to which the indicated pairs of container support or hold down devices have been applied, and a cargo container is to be supported thereon, which support surface may be, for instance, the deck of a railroad car.
[0029] FIG. 2 is an exploded perspective view of one of the cargo container lock or securement devices arranged in accordance with the invention.
[0030] FIG. 3 is a diagrammatic perspective view showing the container lock or securement device of FIG. 2 assembled and disposed to receive the conventional lower corner fitting of a cargo container that is being lowered onto same; the securement device of FIG. 3 is shown deliberately separated from, for instance, a railroad car deck, that normally supports same, to expose the underside of same for disclosure purposes.
[0031] FIG. 4 is a side elevational view of the latch device for cargo containers.
[0032] FIG. 5 is a frontal elevational view of the latch device for cargo containers.
[0033] FIG. 6 is a back elevational view of the latch device for cargo containers.
[0034] FIG. 7 is a top plan view of the latch device for cargo containers.
[0035] FIG. 8 is a bottom plan view of the latch device for cargo containers.
[0036] FIG. 9 is a side elevational view of the latch device for cargo containers, same as FIG. 4 .
[0037] FIG. 10 is an alternate frontal elevational view other than FIG. 5 of the latch device for cargo containers showing a frontal cavity which is utilized during assembly of the alternate latch that contains two stub protrusions on the end of the leg of the latch.
[0038] FIG. 11 is an alternate bottom plan view other than FIG. 8 of the latch device for cargo containers showing a bottom cavity which is utilized during assembly of the alternate latch that contains two stub protrusions on the end of the leg of the latch.
[0039] FIG. 12 is an alternate bottom plan view other than FIGS. 8 and 11 of the latch device for cargo containers showing an alternate bottom housing shape which maybe utilized when the said latch device is being applied to a support surface that does not require the housings bottom flanges, such as in the case of welding the housing to a support surface.
[0040] FIG. 13 is a sectional side elevational view of the housing for the latch device.
[0041] FIG. 14 is a sectional side elevational view of the latch for the latch device.
[0042] FIG. 15 is a sectional side elevational view of the housing for the latch device which utilizes an alternate latch that contains two stub protrusions on the end of the leg of the latch.
[0043] FIG. 16 is a side elevational view of the alternate latch for the latch device which contains two stub protrusions on the end of the leg of the latch.
[0044] FIG. 17 is a sectional side elevational view of the housing for the latch device showing the initial insertion technique utilized for assembling the said alternate latch that contains two stub protrusions on the end of the leg.
[0045] FIG. 18 is a sectional side elevational view of the housing for the latch device showing the secondary assembly path utilized for assembling the said alternate latch that contains two stub protrusions on the end of the leg, the two stub protrusions on the end of the leg are being inserted through the frontal cavity shown in FIG. 10 .
[0046] FIG. 19 is a sectional side elevational view of the housing for the latch device showing the final assembly path utilized for assembling the said alternate latch that contains two stub protrusions on the end of the leg, the two stub protrusions on the end of the leg are being inserted through the bottom cavity shown in FIG. 11 .
[0047] FIG. 20 is a bottom plan view of the latch device showing the end of a spring in the housings slot cavity and a view of the appropriate retainer.
[0048] FIG. 21 is a bottom plan view of the latch device showing the end of a spring in the housings slot cavity and the retainer placed on top of the spring appropriately.
[0049] FIG. 22 is a bottom plan view of the latch device showing the end of a spring in the housings slot cavity and the retainer turned and secured to captivate the internal spring and latch appropriately.
[0050] FIG. 23 is a sectional side elevational view showing the positions of the latch devices internal components just prior to the cargo containers corner fitting being removed from the device.
[0051] FIG. 24 is a sectional side elevational view showing the positions of the latch devices internal components during partial removal of the cargo containers corner fitting from the device.
[0052] FIG. 25 is a sectional side elevational view showing the positions of the latch devices internal components retracted into the devices housing just after the cargo containers corner fitting has been removed from the device.
[0053] FIG. 26 is a sectional side elevational view showing the positions of the latch devices internal components just prior to the cargo containers corner fitting engaging with the device.
[0054] FIG. 27 is a sectional side elevational view showing the positions of the latch devices internal components fully retracted into the devices housing just after the cargo containers corner fitting has been engaged onto the device.
[0055] FIG. 28 is a sectional side elevational view showing the positions of the latch devices internal components that include the alternate latch that contains two stub protrusions on the end of the leg, just prior to the cargo containers corner fitting being removed from the device.
[0056] FIG. 29 is a sectional side elevational view showing the positions of the latch devices internal components that include the alternate latch that contains two stub protrusions on the end of the leg, during partial removal of the cargo containers corner fitting from the device.
[0057] FIG. 30 is a sectional side elevational view showing the positions of the latch devices internal components that include the alternate latch that contains two stub protrusions on the end of the leg, retracted into the devices housing just after the cargo containers corner fitting has been removed from the device.
[0058] FIG. 31 is a sectional side elevational view showing the positions of the latch devices internal components that include the alternate latch that contains two stub protrusions on the end of the leg, just prior to the cargo containers corner fitting engaging with the device.
[0059] FIG. 32 is a sectional side elevational view showing the positions of the latch devices internal components that include the alternate latch that contains two stub protrusions on the end of the leg, fully retracted into the devices housing just after the cargo containers corner fitting has been engaged onto the device.
[0060] FIG. 33 is a lateral side elevational view of the latch device appropriately rotated so its bottom flanges are orientated with a cargo container corner casting aperture.
[0061] FIG. 34 is a lateral side elevational view of the latch device appropriately rotated so its bottom flanges are orientated with a cargo container corner casting aperture and raised up into the aperture.
[0062] FIG. 35 is a lateral side elevational view of the latch device appropriately rotated so its bottom flanges are orientated to retain the latch device in a cargo container corner casting aperture.
[0063] FIG. 36 is a lateral side elevational view of the latch device appropriately retained in a cargo containers bottom corner casting aligned and ready to be lowered down onto another cargo containers top corner casting.
[0064] FIG. 37 is a longitudinal side elevational view of the latch device appropriately retained in a cargo containers bottom corner casting aligned and ready to be lowered down onto another cargo containers top corner casting.
[0065] FIG. 38 is a sectional horizontal view of the cargo containers bottom corner casting shown in FIG. 20 . The captivated flanged end of the latch device is clarified.
[0066] FIG. 39 is a lateral side elevational view of the latch device appropriately retained between two cargo containers.
[0067] FIG. 40 is a longitudinal side elevational view of the latch device appropriately retained between two cargo containers.
[0068] FIG. 41 is a lateral side elevational view of the latch device appropriately retained between a cargo container on the top and an appropriate vehicle deck on the bottom.
[0069] FIG. 42 is a longitudinal side elevational view of the latch device appropriately retained between a cargo container on the top and an appropriate vehicle deck on the bottom.
[0070] FIG. 43 is a lateral side elevational view of the latch device appropriately retained between a cargo container on the top and an appropriate vehicle deck on the bottom, said device represents being welded to the vehicle deck.
[0071] FIG. 44 is a longitudinal side elevational view of the latch device appropriately retained between a cargo container on the top and an appropriate vehicle deck on the bottom, said device represents being welded to the vehicle deck.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0072] Referring now to FIG. 1 , there is illustrated in somewhat of a diagrammatic manner a support 22 upon which a cargo container 20 is to be secured by Applicant's improved securement devices 10 that, in this regard, are arranged in accordance with FIGS. 2 through 44 of this application, and in accordance with the principles of the present invention herein disclosed. The support 22 may, for instance, be a deck or floor of a railroad flat car or other rail transport vehicle, or support 22 may be another type of vehicle to which the device 10 is applied in multiples of four for the usual application thereof to cargo container corner fittings 21 or the like.
[0073] The principles of the present invention are applicable to devices for securing various types of containers to various types of supports. In the illustrated embodiment of the invention, the cargo containers 20 are identical and are of the usual parallelepiped configuration that is involved in standard and modular forms of containers of this type as illustrated, each of the four lower corners of each container 20 includes a corner fitting 21 in the nature of a corner casting that may be of the type specified by the standards of the Association of American Railroads. The corner fitting 21 defines an upwardly or downwardly facing horizontal wall 51 (see FIG. 3 ) that defines an opening 24 that is of the familiar quadrilateral configuration. In accordance with the present invention, the securement devices 10 are intended to protrude through the locking opening 24 of the individual container corner fittings to achieve securement and automatic entry and release of the respective containers as hereinafter disclosed.
[0074] The lock or securement device 10 of the present invention is illustrated in detail in FIGS. 2 through 44 , which will be described in detail hereinafter.
[0075] The latch device 10 is comprised of housing 11 , a latch 12 , a retainer 13 and a spring 14 . An exploded perspective view is shown in FIG. 2 . An assembled side lateral view of device 10 is shown in FIG. 4 . The housing has flanges 15 and 16 which extend outwardly from the housing which engage a cargo containers corner casting aperture opening 24 or a vehicle decks comparable aperture opening 23 . The housing 11 has a base 18 which is spaced between two cargo containers corner fittings 21 or a cargo containers corner fittings 21 and a vehicle decks appropriate structure and surface 25 .
[0076] The illustrations within this document shows that the vehicle decks appropriate structure and surface 25 is identical to the same aperture shape, size, and structure thickness of a standard cargo container corner casting. This is desirable so that the latch device 10 maybe utilized for orientating with latch 12 upwards as shown in FIG. 41 or downwards as shown in FIG. 39 . It is to be noted that the scope of the design of latch device 10 is not to be limited to an appropriate structure and surface 25 being identical to a cargo containers corner fittings 21 . Housing 11 and flanges 15 and 16 are allowed to be varied so as to engage an appropriate deck aperture that is defined by the user.
[0077] The illustration in FIG. 12 shows an example of the tailorability of housing 11 where instead of flanges 15 and 16 , the bottom end of housing 11 may be formed into a round cylinder shape 52 which is capable of containing retainer 13 and spring 14 . FIGS. 43 and 44 show a side and frontal view respectively of Device 10 securing a cargo container 20 to the vehicle decks appropriate structure 22 . An appropriate surface 54 is to allow device 10 to be supported with proper provisions 53 for shape 52 of housing 11 . FIGS. 43 and 44 show the example of how housing 11 , if made of appropriate materials maybe fastened to surface 54 by welds 55 .
[0078] There are two typical application uses for Latch Device 10 . One application of latch device 10 is for securing standard cargo containers 20 (partial side sectional views shown) together by latching their corner castings 21 , see FIGS. 39 and 40 . The other typical application of latch device 10 is for securing a standard cargo container 20 onto a vehicle deck or frame 22 such as shown in FIGS. 41, 42 , 43 and 44 .
[0079] One unique feature of the latch device 10 is how the device is assembled and its components housing 11 , latch 12 , retainer 13 and spring 14 are held together in relation to each other. To assemble latch device 10 , refer to FIG. 26 . Leg 29 of latch 12 is first inserted into cavity opening 27 of housing 11 and then positioned into the internal pocket 28 as shown in FIG. 26 . Secondly, spring 14 which is a typical metal compression or die spring is inserted through cavity opening 26 of housing 11 with one end on the spring being positioned onto the protrusion 30 of latch 12 . FIG. 20 is a bottom plan view of latch device 10 showing the end of a spring 12 in the housing cavity opening 26 and a view of the appropriate retainer 13 . Retainer 13 is orientated and placed into housing cavity opening 26 on top of the end of spring 12 as shown in FIG. 21 . An appropriate assembly force is applied to retainer 13 compressing spring 12 so as to push retainer 13 into housing cavity opening 26 past tabs 31 and 32 and four internal nubs 33 . Retainer 13 is then rotated appropriately as shown in FIG. 22 and become aligned with tabs 31 and 32 and the four internal nubs. The assembly force that has been applied to retainer 13 is removed and this results in retainer 13 backing out of the housing cavity 26 and bearing against tabs 31 and 32 which prevents complete removal of retainer 13 . The four internal nubs 33 traps the retainer 13 into the desired position holding the parts together and prevents retainer 13 from rotating and inadvertently aligning itself with housing cavity 26 which would allow the parts to come loose. To disassemble latch device 10 , the order of these steps are reversed.
[0080] Another unique feature of the latch device 10 is that it has an integral attachment feature 19 . This feature allows an appropriate tether, such as a chain or cable, to be attached to housing 11 which in turn secures latch device 10 to a deck 22 or frame of a vehicle. Attachment feature 19 is typically a through hole and is not unique by itself, but the uniqueness is that this feature is integral with this type of devices housing 11 and has not been represented by any known prior art. The reason for this type of integral attachment feature is to deter theft of latch device 10 when it is desired for it to be removed from an appropriate structure and surface 25 from a vehicle deck 22 but yet remain with the vehicle. Latch device 10 is to be capable of being removed from the appropriate structure and surface 25 and stowed in an appropriate area on the vehicle so the latch device 10 will not be in the way for other types of lading when cargo containers are not being transported.
[0081] Another unique and novel feature of latch device 10 is that there is no pin, bolt or fastener retaining latch 12 to housing 11 . All prior art that utilizes a pivoting latch uses some type of latch/pin arrangement. Latch device 10 utilizes a latch 12 that is contoured and functionally matched to fit within the internal contours of housing 11 and be restrained by the resulting geometry. FIGS. 23 through 27 show sectional views of latch device 10 at various operational stages of engaging and disengaging with a corner casting 21 of a standard cargo container 20 . FIGS. 28 through 32 show sectional views of latch device 10 at various operational stages of engaging and disengaging with a corner casting 21 of a standard cargo container 20 , this device 10 utilizes an alternate latch 12 shape that has stub protrusions 45 and 46 on the end of leg 29 (see FIG. 2 ).
[0082] FIG. 23 represents the earliest operational stage of when a corner casting 21 of a standard cargo container 20 is being removed off of the latch device 10 and is starting to make contact with the concave underside 40 of latch 12 . It is to be observed that latch 12 is secured in the internal pocket 28 of housing 11 by its leg 29 . Latch surfaces 34 and 36 contact internal housing pocket 28 at surfaces 37 and 39 respectively. Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 is secured into proper position. As corner casting 21 of a standard cargo container 20 is being removed off of the latch device 10 and is in contact with the concave underside 40 of latch 12 . It is to be observed that latch 12 is pivoting in the internal pocket 28 of housing 11 by its Leg 29 . Latch surface 34 is contacting and pivoting about internal housing pocket 28 at surface 37 . Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 translates and pivots through the desired motion. The actual location and shape of latch surface 34 and internal housing surface 37 is allowed to be tailored as desired to obtain the desired release action of the latch device 10 .
[0083] FIG. 24 represents the operational stage of when a corner casting 21 of a standard cargo container 20 is being removed off of the latch device 10 and is making contact with the concave underside 40 of latch 12 . It is to be observed that latch 12 has pivoted and rotated in the internal pocket 28 of housing 11 by its Leg 29 . FIG. 24 shows that latch surface 35 is now coming into contact and pivoting about internal housing pocket 28 at surface 39 . Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 translates and pivots through the desired motion. The actual location and shape of latch surfaces 34 and 35 and internal housing surfaces 37 and 38 is allowed to be tailored as desired to obtain the desired release action of the latch device 10 .
[0084] It is to be observed that this two or more surface pivot and contact areas of latch 12 during the release action of latch device 10 is similar but unique from prior art Brewster U.S. Pat. No. 5,570,981. Latch 12 of latch device 10 is not guided and restrained by a pin. Line action 43 defines the travel line which the contact surfaces of corner casting 21 of a standard cargo container 20 travels while it is being removed off of or being placed onto the latch device 10 . Typically it is desired that latch surface 34 contacting and pivoting about internal housing pocket 28 at surface 37 is near or to the right of line action 43 which results in minimizing the mechanical force advantage of spring 14 . Minimizing the mechanical force advantage of spring 14 during initial release motion of corner casting 21 aids in obtaining low applied forces and smooth startup motion of latch 12 . After startup motion of latch 12 , it is desired to increase the mechanical force advantage of spring 14 so as to minimize the required size of spring 14 . This is accomplished by creating new pivot areas other than surface 34 of latch 12 farther away and to the left of line action 43 as illustrated in FIG. 24 and previously described.
[0085] FIG. 25 represents the operational stage further along when a corner casting 21 of a standard cargo container 20 is being removed off of the latch device 10 and clears contact with the concave underside 40 of latch 12 . It is to be observed that latch 12 is pivoting in the internal pocket 28 of housing 11 by its leg 29 . FIG. 25 shows latch surface 35 is contacting and pivoting about internal housing pocket 28 at surface 38 . It is allowed for latch surface 42 to be contoured and to contact and pivot about internal housing pocket 28 at surface 38 to obtain the desired release effect of latch device 10 . Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 translates and pivots through the desired motion. The actual location and shape of latch surfaces 34 , 35 and 42 and internal housing surfaces 37 and 38 are allowed to be tailored as desired to obtain the desired release action of the latch device 10 .
[0086] FIG. 26 represents the earliest operational stage of when a corner casting 21 of a standard cargo container 20 is engaging with latch device 10 and is starting to make contact with the convex upper-side 41 of latch 12 . It is to be observed that latch 12 is secured in the internal pocket 28 of housing 11 by its Leg 29 . Latch surfaces 34 and 36 contact internal housing pocket 28 at surfaces 37 and 39 respectively. Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 is secured into proper position. As corner casting 21 of a standard cargo container 20 is engaging the latch device 10 and is in contact with the convex upper-side 41 of latch 12 . It is to be observed that latch 12 is pivoting in the internal pocket 28 of housing 11 by its Leg 29 . Latch surface 36 is contacting and pivoting about internal housing pocket 28 at surface 39 . Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 translates and pivots through the desired motion. The actual location and shape of latch surface 36 and internal housing surface 39 is allowed to be tailored as desired to obtain the desired engagement action of the latch device 10 .
[0087] It is to be observed that this pivot and contact area 36 of latch 12 during the engagement action of latch device 10 is similar but unique from prior art Brewster U.S. Pat. No. 5,570,981. Latch 12 of latch device 10 is not guided and restrained by a pin. Line action 43 defines the travel line which the contact surfaces of corner casting 21 of a standard cargo container 20 travels while it is engaging and being placed onto the latch device 10 . Typically it is desired that latch surface 36 contacting and pivoting about internal housing pocket 28 at surface 39 be as far away and to the left of line action 43 which results in minimizing the mechanical force advantage of spring 14 as illustrated in FIG. 24 . Minimizing the mechanical force advantage of spring 14 during the engagement motion of corner casting 21 aids in obtaining low applied forces and smooth engagement motion of latch 12 .
[0088] FIG. 27 represents the operational stage further along when a corner casting 21 of a standard cargo container 20 is being engaged onto latch device 10 and clears contact with the convex upper-side 41 of latch 12 . It is to be observed that latch 12 is pivoting in the internal pocket 28 of housing 11 by its leg 29 . FIG. 27 shows latch surface 36 is contacting and pivoting about internal housing pocket 28 at surface 39 . Spring 14 being positioned onto the protrusion 30 of latch 12 assures that latch 12 translates and pivots through the desired motion. The actual location and shape of latch surface 36 and internal housing surface 39 is allowed to be tailored as desired to obtain the desired release action of the latch device 10 .
[0089] An optional unique feature of the latch device 10 is that for double cargo container stacking it may be desirable to include the integral retractable plunger feature 44 . FIG. 33 is a side elevational view of latch device 10 appropriately rotated so its bottom flanges 15 and 16 are orientated with a cargo container corner casting aperture 24 . The integral retractable plunger feature 44 points out from base 18 of housing 11 . As latch device 10 is raised into cargo container corner casting aperture 24 as shown in FIG. 34 the plunger feature 44 automatically retracts out of the way into the base 18 of housing 11 . The latch device 10 is then rotated while in the cargo container corner casting aperture 24 as shown in FIG. 35 so flanges 15 and 16 prevent removal of latch device 10 from corner casting 21 of a standard cargo container 20 . When latch device 10 has been rotated into the desired position the plunger feature 44 automatically raises out of base 18 of housing 11 into the open area of the cargo container corner casting aperture 24 . A horizontal sectional view of corner casting 21 of a standard cargo container 20 in FIG. 38 shows a planar view of plunger feature 44 in corner casting aperture 24 . Latch device 10 is prevented from inadvertently coming loose and falling out of corner casting 21 while the standard cargo container 20 is being positioned during loading or unloading operations because the plunger feature 44 has been raised out of base 18 and into the open clear area in corner casting aperture 24 . To remove latch device 10 from corner casting 21 one has to grasp the extending part of housing 11 of latch device 10 and manually rotate the latch device 10 about it's axis in such a manner to realign flanges 15 and 16 with corner casting aperture 24 as shown in FIG. 34 . This rotation action results in plunger feature 44 to bear up against the cargo container corner casting aperture 24 cast surfaces and automatically retract back into base 18 of housing 11 no longer acting as a deterrent to removal of latch device 10 . Latch device 10 may then be lowered down out of corner casting aperture 24 as shown in FIG. 33 .
[0090] Latch device 10 plunger feature 44 performs a similar task as the prior art of the Safe-T-Loc manually operated feature described in the Peck & Hale-F665 Safe-T-Loc Stacker flyer. Plunger feature 44 is unique in that it performs its function automatically and is of an obviously different design.
[0091] Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those skilled in the art.
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A cargo container hold down device that includes a housing defined by a base which forms a planar surfacing thereabout on which cargo container corner fittings results in the applied relation on the container relative to the supporting structure or platform involved. The hold down device includes a flanged end which engages a cargo container corner casting aperture opening or an appropriate aperture and utilizes the structure for retention of the hold down device so the opposite side of the hold down device is allowed to automatically engage and disengage with a cargo container corner fitting as necessary to achieve proper handling and transport of cargo containers.
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BACKGROUND OF THE INVENTION
1. Technical Field
This invention generally relates to fencing systems. More particularly, the invention relates to mounting brackets useful for installing horizontal rails to vertical posts. Specifically, the invention relates to a bracket for mounting a rail to a post in confined spaces and to a cover plate that snaps around the bracket once the rail has been retained within the bracket.
2. Background Information
It has become more common in recent years to use either vinyl or plastic products for constructing fences for yards or deck railings. While vinyl fencing is aesthetically pleasing and easy to maintain, the material poses somewhat of a problem for the contractor who must connect the various components together. It is especially problematic to connect horizontal vinyl rails to vertically extending posts in confined spaces.
There is therefore a need in the art for an improved bracket assembly for attaching horizontal rails to vertical posts.
SUMMARY OF THE INVENTION
The mounting bracket assembly of the present invention comprises a bracket that is secured to a vertical fence post and a cover plate that is snap-fitted over the bracket after the rail has been retained within the bracket. The bracket is preferably substantially U-shaped and is mounted in such a way that it is open at a top end. The rail is dropped into the U-shaped bracket and fasteners are used to secure the rail within the bracket. The cover plate is snap fitted over the bracket after the rail has been retained therein so as to conceal the fasteners. The cover plate provides an aesthetically pleasing finish to the connection between the post and rail.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a front elevational view of a deck railing incorporating the mounting bracket assembly of the present invention;
FIG. 2 is a partial perspective view of a rail secured to a post using a first embodiment of a mounting bracket assembly in accordance with the present invention;
FIG. 3 is an exploded perspective view of the rail and post shown in FIG. 2 ;
FIG. 4 is a rear view of the cover plate being snap-fitted over the bracket;
FIG. 5 is a rear view of the bracket and cover plate through line 5 - 5 of FIG. 2 ;
FIG. 6 is a partial cross-sectional bottom view of the cover plate and bracket;
FIG. 7 is an enlargement of the highlighted area of the cover plate and bracket from FIG. 5 ;
FIG. 8 is a side view through line 8 - 8 of FIG. 5 ;
FIG. 9 is a top view through line 9 - 9 of FIG. 5 ;
FIG. 10 is a cross-sectional front view of a post with two rails connected thereto by way of bracket assemblies in accordance with the present invention;
FIG. 11 is a perspective view of a second embodiment of bracket assembly in accordance with the present invention;
FIG. 12 is a rear view of the bracket assembly shown in FIG. 11 ; and
FIG. 13 is a perspective view of the bracket of the bracket assembly of FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1&2 , there is shown a section of a deck railing 10 including a post 12 , mounted to deck planking 14 , and having a plurality of rails 16 secured thereto. A plurality of balusters 18 extend between the upper and lower rails 16 . Rails 16 are secured to post 12 by way of mounting bracket assemblies in accordance with the present invention and generally indicated at 20 .
Referring to FIGS. 3-9 , there is shown a rail 16 connected to a post 12 by way of the mounting bracket assembly 20 in accordance with the present invention. Bracket assembly 20 comprises a bracket 22 and a cover plate 24 .
In accordance with a specific feature of the present invention, bracket 22 has a back wall 26 , a peripheral outer wall 28 extending outwardly away from the back wall 26 and having an opening 30 formed therein. Opening 30 preferably extends entirely across one end of bracket 22 . Peripheral outer wall 28 is substantially U-shaped with the opening 30 therein extending from side section 28 a across to side section 28 b ( FIG. 3 ). Back wall 26 of bracket 22 is also substantially U-shaped. Back wall 26 and peripheral outer wall 28 of bracket 22 substantially define a U-shaped receptacle 27 into which rail 16 may be received. Bracket 22 is complementary shaped and sized to receive an end of rail 16 therein. The distance between side sections 28 a and 28 b is therefore substantially equal to the width “A” of rail 16 ; and the distance between end section 28 c and edge 29 is substantially equal to the height “B” of rail 16 . It should, however, be understood that the bracket could alternatively be sized and shaped to receive rail 16 therein when it is turned through 90 degrees. In that instance, the distance between side sections 28 a and 28 c would have to be substantially equal to the height “B” of rail 16 and the distance between end section 28 c and edge 29 would have to be substantially equal to the width “A” of rail 16 . No matter which way rail 16 is to be oriented, an end of rail 16 is received within receptacle 27 in bracket 22 . So, as is shown in FIG. 3 , rail may be dropped or slid vertically into receptacle 27 through opening 30 (i.e., in the direction of arrow “C”) or, if space provides, may be slid horizontally into receptacle 27 in the direction of arrow “D”. Bracket 22 has a longitudinal axis “E-E” that runs substantially parallel to post 12 and a horizontal axis “F-F” that runs perpendicular to post 12 .
Back wall 26 of bracket 22 defines a plurality of first apertures 32 therein. A plurality of first fasteners 34 are received through first apertures 32 to secure bracket 22 to a side wall 36 of post 12 . Peripheral outer wall 28 defines a plurality of second apertures 38 therein. Second apertures 38 are provided to receive second fasteners 40 therethrough in order to secure rail 16 in shear within bracket 22 . Side sections 28 a , 28 b of peripheral outer wall 28 preferably are also each provided with a flange 42 which extends from an outer edge 44 of bracket 22 through to a short distance inwardly from back wall 26 thereof. Flanges 42 preferably taper forwardly from back wall 26 through to outer edge 44 ( FIG. 3 ). Outer edge 44 of peripheral outer wall 28 is preferably beveled and the beveling may include a front end 42 a of flanges 42 . End section 28 c ( FIG. 4 ) of peripheral outer wall 28 may also be provided with a pair of spaced apart ridges 46 thereon and a pair of notches 48 are provided at a top end of back wall 26 . The purpose of ridges 46 and notches 48 will be described hereinafter.
Cover plate 24 is complementary shaped to surround bracket 22 and, more specifically, to encompass peripheral outer wall 28 thereof, including spanning the opening 30 between side sections 28 a and 28 b . Consequently, because bracket 22 is substantially U-shaped, cover plate 24 is substantially rectangular in shape. Cover plate 24 comprises a perimeter wall 50 that has a top end 50 a , a bottom end 50 b and sides 50 c and 50 d which together define an interior cavity 52 into which bracket 22 is received. The exterior surface of perimeter wall 50 may be provided with a decorative profile so as to give railing 10 a more decorative appearance. A slot 54 extends from a front edge 56 of cover plate 24 through to a back edge 58 thereof. The cover plate 24 is manufactured in such a way that it can flex and sides 50 c and 50 d can be pulled apart from each other as shown in FIG. 4 . Tabs 60 are provided on each of sides 50 c , 50 d proximate back edge 58 thereof. As may be seen from FIG. 5 , tabs 60 are positioned so that when cover plate 24 is snap-fitted over bracket 22 , tabs 60 slide behind flanges 42 . Tabs 60 will then be positioned between flanges 42 and side wall 36 of post 12 . Cover plate 24 also has a lip portion 62 extending inwardly a short distance perimeter wall 50 . Outer edge 44 of bracket 22 abuts lip portion 62 when cover plate 24 is snap-fitted around bracket 22 . A pair of tapered tabs 64 are also provided on bottom end 50 c alongside slot 54 , with the widest part of tabs 64 being positioned proximate back edge 58 of cover plate 24 . Tabs 64 are positioned to interlock with ridges 46 on bracket 22 . Second tabs 66 are disposed on the interior surface of top end 50 a of being positioned proximate back edge 58 of cover plate 24 . Each second tab 66 further includes a downwardly extending projection 68 disposed proximate back edge 58 .
Bracket assembly 20 is used to connect rail 16 to post 12 in the following manner. The installer selects the position on side wall 36 of post 12 where he wishes to install bracket 22 . Back wall 26 is placed in abutting contact with side wall 36 , preferably with opening 30 being position at the top of bracket 22 . Fasteners 34 , which are preferably stainless steel screws, are used to secure bracket 22 to post 12 .
Rail 16 is then dropped into receptacle 27 defined by bracket 22 peripheral outer wall 28 . The end 70 ( FIG. 10 ) of rail 16 preferably is pushed into abutting contact with rear wall 26 of bracket 22 . Second fasteners 40 , which are preferably stainless steel screws, are then used to secure rail 16 within bracket 22 .
Cover plate 24 is then positioned around bracket 22 . In order to do this, side sections 50 c and 50 d of cover plate 24 are pulled apart ( FIG. 4 ) and then cover plate 24 is moved downwardly over bracket 22 . As the inner surface of the top end 50 a of cover plate 24 engages edge 29 of bracket 22 , projections 68 on cover plate 24 slide into notches 48 on bracket 22 . The installer releases side sections 50 c , 50 d , which then snap inwardly toward each other and around bracket 22 . When this occurs, tabs 60 slide behind flanges 42 . The installer then engages side sections 50 c and 50 d of cover plate 24 proximate bottom end 50 b and gently pushes side sections 50 c , 50 d inwardly toward each other. This causes tabs 64 to slide over ridges 46 , thereby locking cover plate 24 in place. It should be noted that when in this position, cover plate 24 cannot slide outwardly away from post 12 and along rail 16 . This is because projections 68 are engaged in notches 48 and tabs 60 are disposed behind flanges 42 . Furthermore, side sections 50 c and 50 d cannot easily be moved outwardly away from each other because the tabs 64 are interlocked with ridges 46 . Back edge 58 of cover plate 24 lies in abutting contact with side wall 36 of post 12 , and lip 62 is in abutting contact with front edge 56 of bracket 22 . All fasteners, 34 and 40 are hidden from view by cover plate 24 and the connection between rail 16 and post 12 is aesthetically pleasing. As may be seen from FIG. 10 , a second bracket 22 and its associated cover plate 24 may be secured to one of the other side walls of post 12 .
When cover plate 24 is positioned around bracket 22 , cover plate 24 lies substantially at right angles to the horizontal axis “F-F” of bracket 22 and substantially axially aligned with longitudinal axis “E-E” of bracket 22 .
In order to unlock tabs 64 from ridges 46 a thin object, such as the end of a flathead screwdriver can be inserted between a bottom wall of rail 16 and the inner surface of lip 62 and a small downward force is applied. Once tab 64 is disengaged from bracket 22 , then side sections 50 c and 50 d are moved arcuately outwardly away from each other so that tabs 60 slide outwardly from behind flanges 42 . Cover plate 24 is then slid slightly upwardly so that projections 68 slide out of slots notches 48 . Cover plate 24 is then completely disengaged from bracket 22 , each one of bottom sections 50 b needs to be individually lifted over substantially prevents this arcuate motion from occurring without a reasonable amount of force being applied thereto.
Referring to FIGS. 11-13 , there is shown a second embodiment of bracket assembly in accordance with the present invention and generally indicated at 120 . Bracket assembly 120 is adapted to be used in association with a rail 116 . Rail 116 is substantially T-shaped in cross-section and is adapted to be received within a bracket 122 mounted on a post 112 . Bracket 122 includes a substantially T-shaped back wall 126 and a substantially U-shaped peripheral outer wall 128 which terminates in a flange 172 at the base of the crossbar 174 of the “T” shape on the back wall 126 . All other components of bracket assembly 120 are substantially the same as those of bracket assembly 20 . Bracket 122 is secured to post 112 by fasteners 134 . Rail 116 gets dropped into the opening 130 between side sections 128 a and 128 b . The underside 176 a of the flanges 176 on rail 116 abuts flange 172 on bracket 122 . Fasteners (not shown) are then screwed into the side walls 116 a of rail 116 . Cover plate 124 is then snap fitted around bracket 122 by pulling the side sections 150 c and 150 d apart from each other and moving cover plate 124 downwardly until the interior surface of top end 150 a engages upper edge 129 of bracket 122 . Cover plate 124 interlocks and is secured to bracket 122 in the same manner as cover plate 24 and bracket 22 .
It will be understood that while the figures illustrate bracket 22 secured to side wall 36 of post 12 with the opening 30 at the top so that rail 16 may be slid vertically into bracket 22 in the direction of arrow C, bracket 22 may be placed in any other desired orientation, e.g. with opening 30 effectively facing the front or back of the railing, or at an angle to the vertical, or even downwardly. The latter orientation is the least favored only for the reason that the end section 28 c of bracket 22 assists in carrying the load of rail 16 and if opening 30 is disposed facing the deck planking 14 , then the load of rail 16 is effectively carried by the fasteners 40 , instead of a combination of the fasteners 40 and end section 28 c.
Furthermore, while a generally rectangular shaped rail and bracket assembly; and a generally T-shaped rail and bracket assembly have been illustrated and described herein, it will be understood that the complementary bracket and rail assembly can be of any desired shape and configuration without departing from the spirit of the present invention.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
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A bracket assembly for securing a rail to a post. The bracket assembly includes a bracket that is secured to the post and a spring-biased cover plate. The cover plate includes a perimeter wall that includes a slot which extends from its front edge through to its back edge. A portion of the perimeter wall terminates adjacent either side of the slot. These portions of the perimeter are movable relative to each other. The bracket includes a back wall with a peripheral outer wall extending upwardly and outwardly away therefrom. The peripheral wall defines a rail receiving receptacle into which an end of a rail is placed. The rail is preferably secured in position by a plurality of fasteners inserted through the rail and into the housing. Once the end of the rail is retained in the bracket, the terminal portions of the perimeter wall are arcuately separated from each other and the cover plate is snap-fitted over the peripheral outer wall of the bracket.
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FIELD OF THE INVENTION
The present invention relates to fiber optic communication; more particularly, the present invention relates to coupling radiant energy from an external waveguide into a waveguide on an integrated circuit.
BACKGROUND
More frequently, optical input/output (I/O) is being used in computer systems to transmit data between system components. Optical I/O is able to attain higher system bandwidth with lower electromagnetic interference than conventional I/O methods.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention. The drawings, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.
FIG. 1 illustrates one embodiment of a system;
FIG. 2 illustrates one embodiment of (cross section) fiber optic connector;
FIG. 3 illustrates one embodiment of a floating side of a fiber optic connector;
FIG. 4 illustrates an exploded view of one embodiment of a floating side of a fiber optic connector;
FIG. 5 illustrates one embodiment of a fixed side of a fiber optic connector; and
FIG. 6 illustrates an exploded view of one embodiment of a fixed side of a fiber optic connector.
DETAILED DESCRIPTION
According to one embodiment, a fiber optic communication mechanism is disclosed. Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
In the following description, numerous details are set forth. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.
FIG. 1 is a block diagram of one embodiment of a computer system 100 . Computer system 100 is a blade server that includes a chassis 110 and blades 120 . In one embodiment, blades 120 are “hot-swappable” devices that are coupled to a backplane of chassis 110 . Each blade may be an independent server having one or more processors, an associated memory, disk storage and network controllers.
According to one embodiment, optical fibers are coupled to each of the one or more blades 120 at the backplane to facilitate optical I/O. In a further embodiment, a blind mate connector is included to couple an optical component on a blade 120 to the optical fibers at the backplane. FIG. 2 illustrates one embodiment of a blind mate connector 200 .
Referring to FIG. 2 , connector 200 includes a floating component 210 and a fixed component 220 . Component 210 is coupled to optical fibers 215 , while component 220 is coupled to fibers 225 . Components 210 and 220 of connector 200 enable precise optical alignment in circumstances where the initial alignment between two systems is coarse. For example, optical alignment between a blade being plugged into a backplane and fibers on the backplane would likely have a course alignment.
According to one embodiment, floating component 210 is mounted on a blade 120 , while fixed component 220 is mounted on the backplane. In a further embodiment, floating component 210 and a fixed component 220 provide for precise optical mating through successive self-alignments.
FIG. 3 illustrates a cross-section of one embodiment of floating component 210 . Meanwhile, FIG. 4 illustrates an exploded view of one embodiment of a floating component 210 . The parts of component 210 include a precision ferrule 410 , springs 420 and 425 , floating piece 430 and case 435 . Ferrule 410 holds fibers 215 and includes alignment holes 414 for mating with the fixed component 220 . Springs 420 and 425 aid in the alignment process and provide for tight optical mating. Floating piece 430 helps in the coarse alignment and guides ferrule 410 into position for the fine alignment. Case 435 holds the entire floating component 210 assembly together.
FIG. 5 illustrates one embodiment of fixed component 220 , while FIG. 6 illustrates an exploded view of one embodiment fixed component 220 . The parts of component 220 include a precision ferrule 610 that holds fibers 225 . In addition, ferrule 610 includes mating pins 614 that mate with the ferrule 410 of floating component 210 . Further, component 220 includes a case 620 that holds ferrule 610 , as well as help in the coarse alignment of floating piece 430 of component 210 .
During operation of connector 200 , a chamfered edge of floating piece 430 of component 210 comes into contact with a chamfered edge of case 620 of component 220 as the two sides of connector 200 approach one other. As the components continue to move closer towards each other, the chamfer on case 620 moves floating piece 430 closer into alignment.
As floating piece 430 moves into position it will also move ferrule 410 of component 210 into alignment. Once floating piece 430 has bottomed out on case 620 the two ferrule pieces, 410 and 610 , will be close enough in alignment that a chamfer on alignment pins 614 in ferrule 610 will be able to guide the floating ferrule 410 into the final alignment position as connector 200 is plugged into its final position.
Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that any particular embodiment shown and described by way of illustration is in no way intended to be considered limiting. Therefore, references to details of various embodiments are not intended to limit the scope of the claims which in themselves recite only those features regarded as the invention.
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A connector is disclosed. The connector includes a floating component to receive a first set of optical waveguides, and a fixed component to receive a second set of optical waveguides and to facilitate optical alignment between the first set of waveguides and the second set of waveguides through automated alignments with the floating component.
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REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 61076089 filed on 26 Jun. 2008, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a downhole junk removal tool for use in removing junk from a well bore.
[0004] 2. Description of Related Art
[0005] Pump off junk mills are used to remove various downhole obstructions, commonly referred to in the petroleum recovery industry as “junk.” Junk mills are frequently used to clean out various metallic and non-metallic obstructions that are in a downhole. Junk is anything that is not supposed to be in the downhole and can include various objects that are accidentally dropped downhole from the surface such as hand tools, wrenches, or parts that have broken off during drilling such as drill bit teeth, nozzles, etc., or accumulated cement or other sediment left behind from a previous downhole operation. A downhole mill is typically located at an end of a work string so that the cutting head of the mill can be rotated and axially loaded against the material that is to be cut.
[0006] A “mill” is a tool that grinds metal downhole. A mill is normally used to remove junk in the downhole or to grind away all or part of a casing string. In the case of junk, the metal must be broken into smaller pieces to facilitate its removal from the wellbore so that the drilling operation can continue. Virtually all mills utilize tungsten carbide cutting surfaces.
[0007] A typical downhole mill includes rotary cutters with hardened cutting surfaces that cut or grind material such as metal, plastic, etc. In contrast, a downhole drill bit is typically used to cut rock or downhole formation.
[0008] Mills, are run down a borehole to cut man-made obstructions referred to as junk, so that a drilling operation can continue. A further category of junk are larger objects. These may include portions of tools which have been discarded or been broken within the well bore, or large sections of tubes which have been cut away when portions of a casing have been milled or drilled.
[0009] Apparatus within a well bore designed to collect junk primarily fall into two categories that are dependent upon the location of the tool on a work string. The first category relates to apparatus mounted at the bottom of the work string. This apparatus collects all fluids and materials within the well bore as fluids are circulated up the well bore or as the tool is run into the well bore. Such tools are typically referred to as junk catchers. This tool has a collection of petals arranged at the distal end of the work string. As the tool is run into the well, the petals are forced outward to the walls of the well bore where they act to siphon all material through a single large port on the longitudinal axis of the tool. When the tool is pulled from the well the petals close thereby catching large debris and pulling it from the well.
[0010] A significant disadvantage of this tool is that it must be positioned at the end of a work string and thus is typically used on a single run. To operate a dedicated run merely for the purposes of clearing junk is both time-consuming and expensive.
[0011] The second category of junk catchers can be mounted at any position on a work string to allow the tool to be run at the same time as other tools. The tool has a wiper or scraper blade arranged to prevent the fluid including the junk to pass up the annulus between the tool and the well bore wall. The fluid including the junk is forced into a port and through a passage in the tool around the wiper. A filter and a trap are positioned within the passage to catch the junk, which is too large to pass through the filter.
[0012] Such tools have an input port that is sized to ensure that a significant flow velocity is maintained to circulate the fluid through the tool. These tools generally include a by-pass means which rupture to allow the fluid to escape when the filter has been clogged with large debris. Thus, when large debris is present the tool cannot function correctly and, in fact, generally shuts down into a mode that allows the fluid including the junk to by-pass the tool. Additionally, junk tends to ‘ball-up’ at the scrapers or wipers as the larger pieces of junk are swept away from the inlet port up the annulus to become jammed or located around the wiper blades.
SUMMARY OF THE INVENTION
[0013] A device for removing junk from a well by attaching the tubing string to the mill body and lowering the assembly into a well. A movable collet located inside the core couples the mill body to the milling core and a check valve is located inside the core. The milling core is controllably separated from the mill body by dropping a ball bearing into the tubing and then feeding water under pressure into the tubing on top of the ball bearing.
[0014] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings.
[0016] FIG. 1 is an exploded diagram showing the pump off junk mill components; and
[0017] FIG. 2 is a flow diagram of the process of using the pump off junk mill.
DETAILED DESCRIPTION OF THE INVENTION
[0018] This invention relates to a pump off junk mill that does not have to be removed from a downhole. The tungsten carbide mill has a full opening through the center with a back pressure valve and core which is connected to a string of tubing that latches into the system. A check valve assembly and the mill core is removed from the tubing by dropping a ball bearing down the tubing and then pumping fluid. A collet located in the milling core is urged to shift, allowing the milling core and its components to be released and drop to the bottom leaving the mill body in tact with the tubing string.
[0019] Thus, the mill body can be used for future cleanouts without removing it from the tubing string.
[0020] Existing mills must be pumped off entirely which leaves the mill as “junk” in the well in addition to junk hanging up in perforations, all of which can result in blocking the well. With existing mills, the premature releasing of the mill prior to the completion of the drilling process can result in increased cost and added time to the drilling process. Current pump out cores use a one piece mill design that utilizes shear/set screws that will shear off during deployment in the well. When the shear/set screws shear, the mill separates from the tubing and drops down to the bottom of a well to become junk which cannot be used in the future.
[0021] The core here disclosed which is attached to a mill can be retrieved and a new core with valve assembly can be added resulting in a unit that can be used again. It is not left in the well as junk which may have to be removed at some future time.
[0022] Existing cores use shear/set pins which can shear and allow a mill to be released and drop down to the bottom of the well. Retrieving the dropped mill can be time consuming and costly. The core here disclosed has a collet that shifts, it does not shear, which allows the mill core to be released and subsequently retrieved when desired.
[0023] Referring to FIG. 1 there is shown an exploded view of the new improved milling core 10 . A check valve assembly 12 is located within a milling core 14 that is located within a mill body 16 . The check valve assembly comprises, as is shown in FIG. 1 , a collet 18 that is inserted into an upper housing 20 through an end 22 of the upper housing 20 . The upper housing 20 has openings that receive ball bearings 24 . A ball seat 26 is coupled to end 28 of the upper housing 20 , and receives seal ball 28 that is held against the ball seat by spring 30 . O rings are located between the various parts to provide fluid tight seals.
[0024] An assembly instruction pamphlet for assembling the various parts of FIG. 1 contains the following information.
[0025] Assemble the milling core and the check vale assembly, making certain that all the proper O rings are installed.
[0026] Put the collet in through the top of the check valve assembly and tap in with an assembly tool
[0027] Insert the spiral lock ring into the gland located inside the upper housing.
[0028] Lower the mill body over the entire check valve assembly and milling core.
[0029] Using a “Tap-in tool”, strike the upper end gently until the collet bottoms out inside the upper housing. This will be about one inch of travel.
[0030] Insert the four ball bearings through holes in the upper housing. Place a small amount of grease on the ball bearings to hold in place, if necessary.
[0031] Using an insertion/retraction tool, screw the tool into the collet (located inside the CVA assembly) which will shoulder at the right depth. Put base plate on the shoulder of the assembly and screw on the nut provided.
[0032] Turn the nut clockwise until the collet is pulled up against the spiral lock ring. This is exactly one inch travel.
[0033] The assembly is now ready for shipment.
[0034] Prior art mills have shear/set pins which can be damaged and can result in the mill being released into the well. This results in a fishing job and additional cost. This can not happen with this invention.
[0035] Referring to FIG. 2 , the process begins by placing a junk mill on the bottom of a tubing string and placing the junk mill in a well. Block 50 . Then the tubing is hooked up to a Kelly and fluid water or drilling mud is pumped down the tubing, block 52 . The tubing is lowered until the junk in the well is contacted, block 54 . Now 2 barrels per minute of water or drilling mud are pumped through the tubing as the pipe is rotated to the right with about 2000 pounds of weight on the junk mill, block 56 . The particles are washed to the surface, block 58 . After all of the particles are removed, the tubing is pulled to a desired depth for producing gas, block 60 . A ball bearing having a diameter of 15/16 is dropped into the tubing, block 62 . Upon arrival of the ball bearing at the junk mill, water pressure of between 450 psi and 550 psi where a preferable pressure of approximately 500 psi is applied to the tubing, block 64 . The pressure shifts the collet inside the junk mill detaching the 2 inch core of the mill, block 66 . The core is released to the bottom of the well allowing gas or oil to flow up the tubing back to the production unit, block 68 .
[0036] The method eliminates the removal of the tubing string under pressure and subsequent reentry, and leaves a useful cleanout tool in the well for future flow problems.
[0037] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that various omissions and substitutions and changes of the form and details of the apparatus illustrated and in the operation may be done by those skilled in the art, without departing from the spirit of the invention.
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A device for removing junk from a well by attaching to a tubing string a mill body with a removable milling core and lowering the assembly into a well. A movable collet and check valve are located in the milling core. The milling core can be separated from the mill body by dropping a ball bearing into the tubing and then feeding water under pressure into the tubing behind the ball bearing.
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BACKGROUND OF THE INVENTION
The present invention relates to lubrication progressive divider valves and particularly to a modular filter section for a lubrication progressive divider valve assembly. Lubrication progressive divider valves are hydraulically controlled lube oil distributors for injecting small amounts of lubrication sequentially to plural lubrication destinations such as parts to a single machine or multiple machines. A lubrication distributor valve is disclosed for example in U.S. Pat. No. 4,312,425; 5,480,004; and 4,572,331. According to the embodiments disclosed in these patents, a modular design is employed for manufacturing flexibility to provide delivered lubrication for multiple users wherein the number of users can be changed easily by adding or subtracting valve modules. Each valve module is separated into a base block and a spool block, connected by bolts. The modules are connected in series with end modules being specialized. At one end is an inlet module and at the other end is a closure module.
In current practice, an in-line filter is installed in the tubing upstream of the lubrication progressive divider valve. This filter treats or cleans the lubricant being supplied to the divider valve. This filter is a potential source of leaks as it is jointed into the piping and is costly to provide and install due to the fact that it is a separately connected item.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a modular filter for use in a lubrication progressive divider valve which is easily installed, provides for effective maintenance of the filter and the divider valve, and is sized to be installable at numerous potential places in a series stack of valve modules to allow the filter to be easily removed from the equipment without violating the integrity of the lubrication system, i.e., without introducing air and other containments into the system.
It is an object of the invention to provide a filter component which can use a maximum of standard parts without adding any unnecessary machining operations.
It is an object of the invention to provide a filter assembly using the same center line and base dimensions as the valve modules. It is an object of the invention to provide a "filter clogged" indication option which triggers at a preselected pressure differential across the filter. It is an object of the invention to provide that the filter indication option can be readily changed out by replacing the particular spring of the mechanism. It is an object of the invention to provide a filter design which includes a start up mode and a normal operational mode; the start up mode being used during initial purge of the system and allowing a quick change out for normal operational mode. It is an object of the invention to provide an overall system which requires the modular filter to be installed before putting the lubrication progressive divider valve into service.
The objects of the invention are achieved by replacing the prior known separate in-line filter assembly with a modular filter to be installed in series with the valve modules as part of an entire modular divider valve assembly. Standard components can be used including a compatible, special base plate aligned in series with standard base plates for the valve modules. The filter is configured to be installable at any position along a stack of valve modules so that special services can have different filtering capabilities. Multiple module filters can be used in a divider valve assembly.
The filter is configured to have an easily replaceable filter element. During initial purge of the system, a fine filter can be used and thereafter changed to a more coarse filter for actual production. The start up filter can be color coded. Thus, if the system is dismantled, the presence of the start up fine filter after prolonged operation would indicate to the manufacturer whether the user has properly followed the start up and purge procedures.
The filter can be made tamper-proof and require the removal of the entire section for servicing. The system can be arranged to only be operable if there is a replacement filter installed. This arrangement eliminates the possibility of the lubrication system being run without the proper filtration in place. In one embodiment, the base section of the filter can be integral with an inlet section for the distributor valve.
The invention provides a stacked configuration of valve modules made up of spool blocks and base blocks with a modular arrangement of a filter having its own filter base sized to match with and connect to the base blocks. The filter provides a filter block with a convenient plug closure for replacing cylindrical filter elements. Additionally, an indicator is provided for determining the pressure drop across the filter element, for ascertaining when to change out the filter element. The indicator uses a spring loaded sensing piston within a bore, in the filter block, wherein the bore has a first port communicating with an inlet side of the filter element and a second port communicating with an outlet side of the filter element, said first and second ports flow connected by channels to opposite sides of the sensing piston. Against spring pressure, the piston is shifted in accordance with the differential pressure on opposite sides of the piston. A sensor is screwed into the filter block and is responsive to the position of the sensing piston to communicate visually or electronically to the user. The sensor can use a magnet to sense the position of the sensing piston, the magnet moved by the sensing piston and providing a magnetic signal to an outside of an otherwise sealed sensor. The signal can be a visual indication at the sensor or an electric signal received by control or monitoring equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a distributor valve of the present invention;
FIG. 2 is a top plan view of the distributor valve of FIG. 1;
FIG. 3 is a sectional view of a filter block assembly taken generally along line III--III from FIG. 2;
FIG. 4 is a bottom view of the filter block assembly of FIG. 3, unassembled and without the indicator;
FIG. 5 is a sectional view taken generally along line V--V of FIG. 4;
FIG. 6 is a top plan view of a filter base block;
FIG. 7 is a right side elevational view of the base block of FIG. 6;
FIG. 8 is a left side elevational view of the base block of FIG. 6; and
FIG. 9 is an elevational view, partly in section, of an indicator instrument.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a divider valve assembly 10 having valve modules 11 having spool blocks 12a, 12b, 12c, 12d mounted respectively to base blocks 14a, 14b, 14c, 14d. The spool blocks and base blocks communicate to each other through vertical channels and to adjacent base blocks in series as described in for example U.S. Pat. Nos. 4,312,425; 5,480,004; and 4,572,331. An inlet section 16 having an inlet port 17, and a closure section 18 are arranged on opposite ends of the base blocks 14a-14d. Between the inlet section 16 and the spool block 12d together with the base block 14d is a shut off valve module 20 and a filter assembly 22. The shut off block assembly 20 uses a solenoid actuator 24. The shut off valve 20 comprises a manifold block 20a fastened onto a shut off base block 20b. The manifold block houses the valve element and valve seat (not shown).
An indicator instrument 26 is provided in at least one of the spool blocks, in this case spool block 12d. This indicator instrument 26 senses movement of a reciprocating distributor spool (not shown) within the spool block 12d to monitor proper reciprocating operation.
The filter assembly 22 comprises a filter block 30 mounted onto a filter base block 32. The filter block 30 and the filter base block 32 approximate the size of the spool blocks 12a-12d and the base blocks 14a-14d. This is advantageous for tooling and configuration compatibility.
Mounted at one end of the filter block 30 into an opening 33 (shown in FIG. 3) is a indicator instrument 34, the function of which will be described hereinafter.
The base blocks 14a-14d and the spool blocks 12a-12d of each valve module 11 are held together by bolts 35. The inlet section 16 and the closure section 18, with the valve modules 11, filter assembly 22 and shut off valve module 20 between, are held together by threaded rods or bolts 36. Each bolt extends through each of the closure section 18, shut off valve module 20, filter assembly 22 valve base blocks 14a-14d, and into the inlet section 16. The bolts are either threaded into the inlet section 16 or otherwise secured therein, such as by cap screw heads, and fastened by nuts 37 at the closure section 18. The bolts 36 are received within and through bores of each of the elements which are all in registry.
The divider valve assembly 10 of FIG. 1 is a completely modular assembly with each of the inlet section 16, end section 18, valve modules 11, filter assembly 22, shut off valve module 20 being removable separately. Additionally, the spool blocks 12a-12d and base blocks 14a-14d are separable for service by unfastening the bolts 35. Also, as described below, a filter element is separable from the filter block 30 and filter base block 32. Each spool block has a bore extending the entire width thereof, in which a valve spool (not shown) is disposed and is movable by hydraulic actuation to selectively distribute lubricant in a sequence via an output port 38 in each of the base blocks 14a-14d. After the spools are placed in the spool blocks 12a-12d, the opening of the bores are closed by a threaded plug 39, to create a chamber for lateral sliding of the spools.
Each of the valve modules formed by base block and spool block is substantially identical. Each base block and spool block has a plurality of vertical non-communicating passages therein (not shown), which are in registry when the spool block is fastened down onto the base block. Dependent on the position of the spool within the bore as a result of hydraulic actuation, one or more of these passages is placed in fluid communication with a passage extending the length of the distributor valve assembly 10, which is, in turn, in fluid communication with the inlet port 17. Lubricant entering the valve assembly via the inlet port 17 is thereby directed in a sequence out of each output port 38, dependent on the respective positions of the spool in the bores of each spool block 12a-12d.
FIG. 4 illustrates the inner components of the filter block 30. The filter block 30 comprises a first bore 40 which holds therein a cylindrical filtering element 41, held in by a plug 42 screwed into the filter block 30. An inlet line 44 proceeds from an oil inlet 46 into an annular space 48 surrounding the screen element 41. The first bore 40 communicates through a channel 50 into a second bore 52. The first bore 40, channel 50 and second bore 52 are; aligned axially. An oil outlet line 54 proceeds from a first position 55 in the second bore 52 to an outlet 56. The inlet 46 and the outlet 56 are arranged spaced apart on a bottom face 30a of the filter block 30. A differential pressure line 58 proceeds from the inlet line 44 to a second position 59 open to the second bore 52. In the second bore 52 arranged between the first position 55 and the second position 59 is a piston 60. The piston 60 includes an O-ring 62 for sealing against the bore 52. A balance spring 66 is provided between the piston 60 and a front wall 68 of the bore 52. Thus, against the influence of the spring 66, the piston 60 moves within the bore 52 in accordance with the differential pressure sensed by the outlet line 54 and the differential pressure line 58 which senses the inlet pressure.
The indicator instrument 34 includes a magnet 70 reciprocal within a bore 72 aligned with the piston 60. The magnet includes a collar 76 upon which a spring 80 acts against the back wall 82 of the sensor 34 to bias the magnet 70 toward a forward position. Thus, approach and contact the piston 60 would thrust the magnet to the left in the figure. Surrounding a cylinder 84 for housing the magnet 70 is arranged a plurality of metal balls 86 held in an annular channel by a transparent housing cover 90. As the magnet moves toward the left, for example, magnetic force pulls the balls to move with the magnet. As shown in the figure, the balls are fully thrust to the left. This would indicate a high differential pressure between the inlet and the outlet, indicating a clogged filter element 41 other type indicator instruments known to the art would also be used. Alternately, as shown in FIG. 9, and described below, a proximity switch can be used to electronically monitor the position of a magnet.
Screws or bolts 90, 92 are provided to attach the filter block 30 to the filter base block 32. The screws 90, 92 are interfit within through bores 94, 96 shown in FIG. 5 which can be countersunk to receive a cap screw.
FIGS. 6-8 illustrate in isolation the filter base block 32 having bores 110, 112, 114 for receiving the bolts or threaded rods 36 for assembling the filter module 22 into the distributor valve 10. On a top surface 32a are located a lubricant delivery port 118 which delivers lubricant to the inlet 46 of the filter block 30 when the filter block surface 30a is flushly mated to the base block surface 32a. Also, a lubricant receiving port 120 is arranged to register with the lubricant outlet 56 on the surface 30a. The lubricant delivery port 118 is connected by a first L-shaped channel 124 to a lubricant: inlet 128. The lubricant inlet 128 is provided with a socket for receiving an O-ring or resilient grommet to seal against an outlet port 17a of the block inlet section 16 (shown in FIGS. 1 and 2). The outlet port 17a is connected by a channel 17b to the inlet port 17.
The receiving port 120 is connected by a second L-shaped channel 130 to a lubrication outlet 134 which communicates lubricant to an adjacent base block, to the shut off valve module 20.
Bolt bores 140, 142 are shown which are threaded to receive the bolts 90, 92 respectively to fasten the filter block 30 to the base block 32 at flush surfaces 30a, 32a. Seal O-rings or resilient grommets can be used to seal all registering ports which channel lubricant.
A number of additional ports 150a-150h are shown in FIG. 7 which are connected by straight through bores to further ports 160a-160h respectively on an opposite side of the block shown in FIG. 8. The additional ports 150a-150h are provided with sockets for receiving O-ring seal. The channels defined between the additional ports 150a-150h and further ports 160a -160h are provided for lubricant distribution in base blocks throughout the distributor valve, and longitudinal channels can be combined or modified by cross porting. A more detailed description can be found in U.S. Pat. Nos. 4,312,425; 5,480,004; and 4,572,331; herein incorporated by reference.
To increase similarity of ports for manufacturing economy and inventory reduction, it is advantageous that the base block 32 is an identical part to the valve base block 20b.
As a further exemplary embodiment (not shown), the filter base block and inlet section 16 can be combined into a compact, unitary inlet block which would provide the inlet port 17 and the thread or nut means to engage the threaded rods 36 to hold the distributor valve 10 together.
FIG. 9 shows a proximity switch 170 which can be screwed into the filter block bore 52, in lieu of the indicator 34. The switch includes a lead end 172 with an O-ring 174 for screwing into the opening 33. A magnet assembly 176 moves under magnetic influence of the piston 60 (shown in FIG. 3) through a front wall 178 against influence of a spring 180 to trigger a switch arm 182. A cable connector 186 is connected by cable (not shown) to an electronic monitor.
Other type proximity switches can be used such as those which sense in some way the magnetic field of an approaching or retreating magnetic position element.
Although the present invention has been described with reference to a specific embodiment, those of skill in the art will recognize that changes may be made thereto without departing from the scope and spirit of the invention as set forth in the appended claims.
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A filter for use in a distributor valve arrangement, the filter having a filter base block having an identical dimension with feeder base blocks and bolted thereto in a stacked arrangement. The filter can be located at an inlet end of the distributor valve or placed in sequence at any position within the stacked arrangement for special filtering applications. The filter has a filter block mounted to the filter base block, which has a bore therein for receiving a cylindrical screen element which is held in by an external screwed plug. On an opposite side of the filter block is provided a screwed bore for applying an indicator to sense differential pressure across the filter element to detect a clogged filter.
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FIELD OF THE INVENTION
This invention relates to an herbal composition for treating the symptoms of premenstrual syndrome, including menstrual cramps, aches and pains, and bloating. The invention also relates to a method for treating some of the symptoms associated with premenstrual syndrome, particularly aches, pains, and cramps using herbal compositions.
BACKGROUND OF THE INVENTION
The days preceding the onset of the menstrual period involve hormonal changes which can result in symptoms such as cramping, aches, bloating, and inflammation. These symptoms, commonly referred to as premenstrual syndrome, or PMS, are treated by a variety of means. Simple ones include taking ibuprofen or acetaminophen for aches and pains, and various other substances for bloating or water retention. Many over the counter remedies are available for these common symptoms, and in many cases may provide temporary or limited relief.
Other approaches involve attempts to correct apparent hormonal imbalances which may be present prior to menstruation. For example, according to U.S. Pat. No. 5,707,630 (Morrow), the symptoms of PMS and menopause can be treated with an herbal composition including red raspberry, bayberry, blue cohosh, capsicum, cascara sagrada, damiana, ginger, avalcrian administered orally in tablet form using a binding agent. The patentee claims that the foregoing herbal compound alleviates the symptoms associated with PMS and menopause.
U.S. Pat. No. 5,565,199 (Page) states that phytohormone, such as phytoestrogens and phytoprogesterone, from herbaceous plants provide means for balancing estrogen and progesterone levels in organisms without producing undesirable physiological side effects. According to the patent, herbaceous plants contain many types of regulating substances, some of which are known as phytohormone. These plants assertedly provide a source of natural base steroidal hormones which may provide estrogenic or progesterone hormone activity to enhance or supplement the hormonal levels in biological organisms.
The foregoing remedies do not provide complete or even satisfactory relief of cramps, bloating, and inflammation in many patients, and involve ingestion of substances which may introduce other difficulties or side effects. Therefore, there continues to be a need for a safe and effective composition to treat some of the aches and cramps associated with premenstrual syndrome or other ailments.
SUMMARY OF THE INVENTION
The invention provides an herbal composition comprising chickweed, yarrow, wormwood, motherwort, pennyroyal, and dandelion as active ingredients. The invention preferably includes a vehicle comprising olive oil and beeswax, and the vehicle may additionally contain tincture of benzoin or another compatible preservative. Preferably, the active ingredients are present in approximately equal amounts, in a range from about 75 mg to about 150 mg of each herb for every fluid ounce of vehicle. Cayenne may be used to increase absorption.
The invention also provides a method for treating menstrual or other cramps comprising applying an effective amount of a composition comprising chickweed, yarrow, wormwood, motherwort, pennyroyal, and dandelion as active ingredients to an affected area, such as a portion of the abdomen of an affected female. In another embodiment, the invention provides a method for relieving an ache or pain, such as a muscle ache, back ache, stomach ache, head ache, neck ache or similar minor ache or pain, which comprises applying an herbal composition comprising chickweed, yarrow, wormwood, motherwort, pennyroyal, and dandelion, preferably in a vehicle containing olive oil and beeswax, to an affected area of a patient. Optionally, the treatment can include application of heat for about five to ten or more minutes.
Further features and advantages of the invention will become apparent upon review of the following detailed description of the preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to an herbal compound and method for treatment which uses such a compound to aid in the relief of symptoms such as cramping, bloating, and inflammation caused by premenstrual syndrome. In one preferred embodiment, the herbal compound of the present invention comprises chickweed, yarrow, wormwood, motherwort, pennyroyal, and dandelion, preferably in a vehicle which contains olive oil and beeswax. The composition, usually in the form of an ointment, is rubbed on an affected area, such as the abdomen of a woman suffering from premenstrual cramps.
The following herbs are included in the preferred embodiments. Following each is a brief description of its activity:
______________________________________Herb Part Used Vitamins Actions Comments______________________________________Cayenne Berries Apsaicine, Aids digestion, Also called capacutin, improves capsicum, hot capasaicin, circulation, and pepper, red capsanthine, stops bleeding pepper. capsico, cobalt, from ulcers. folic acid, Acts as a pantothenic catalyst for acid, para- other herbs. aminobenzoic Good for the acid, zinc, heart, kidneys, vitamins A, B.sub.1, lungs, B.sub.2, B.sub.3, B.sub.6, and pancreas, C. spleen, andstomach.Useful forarthritis andrheumatism.Helps to wardoff colds, sinusinfections, andsore throats.Good for painwhen appliedtopically. Usedwith lobelia fornerves.______________________________________
______________________________________ Part Herb Used Vitamins Actions Comments______________________________________Dandelion Leaves, Bioflavonoids, Cleanses the The roasted roots, biotin, calcium, bloodstream root can be tops. choline, fats, and liver, and used as a folic acid, increases the coffee gluten, gum, production of substitute. inositol, inulin, bile. Used as a iron, lactupi- diuretic. Also crine, linolenic reduces serum acid, magnesi- cholesterol and um, niacin, uric acid. Im- pantothenic proves func- acid, para- tioning of the aminobenzoic kidneys, pan- acid, phos- creas, spleen, phorus, potash, and stomach. proteins, resin, Useful for ab- sulfur, zinc, scesses, anem- vitamins A, B.sub.1, ia, boils, breast B.sub.2, B.sub.6, B.sub.12, C, tumors, cirrho- and E. sis of the liver,fluid retention,hepatitis, jaun-dice, and rheu-matism. Mayaid in the pre-vention of agespots andbreast cancer. Wormwood Leaves, Absinthol, ace- Acts as a mild Often used tops. tylene, artemis- sedative, expels with black wal- ia ketone, es- worms, in- nut for removal sential oils, fla- creases stom- of parasites. vonoids, lignin, ach acidity, and Caution: phenolic com- lowers fever. Should not be pounds, pinene, Useful for vas- used during thujone. cular disorders, pregnancy, as itincluding mi- can cause spon-graine, and for taneous abor-intestinal tion. Not re-parasites. commended for long-term use, as it can be habit-forming.______________________________________
______________________________________Herb Part Used Vitamins Actions Comments______________________________________Yarrow Berries, Achilleic acid, Has healing Also called leaves. achilleine, cale- effects on mucous soldier's herb. divain, volatile membranes, re- Caution: oils, potassium, duces inflamma- Interferes with tannins, tion, improves absorption of vitamin C. blood clotting, iron and otherincreases per- minerals.spiration. Agood diuretic.Useful for fever,inflammatorydisorders, colitis,and viralinfections. Helpsto alleviatebleeding problem.______________________________________
Chickweed Reduces inflammation and aids in healing.
Pennyroyal (Hedeoma pulegioides)--the leaves of the herb are used in remedies; uses include upset stomach and as a gentle stimulant. It is also believed to be useful for menstrual cramps because it stimulates the uterine muscles.
Motherwort is believed to strengthen the nervous system, and is asserted to be a tonic for the whole body; it seems to help those who are prone to headaches and helps relieve menstrual discomfort.
The following examples are illustrative of the practice of the invention and are not meant to be limiting.
EXAMPLE I
The following amounts of each herb were mixed in the olive oil-beeswax vehicle, with tincture of benzoin added as a preservative. All herbs were produced by Frontier Bulk Herbs and Spices, Norway, Iowa.
chickweed--1 oz.
yarrow--1 oz.
wormwood--1 oz.
motherwort--1 oz.
pennyroyal--1 oz.
dandelion--1 oz.
2 cups olive oil, 3 oz.-beeswax, 1 tsp. Tincture of benzoin.
Yield: 12 2 oz. jars.
EXAMPLE II
A 45 year old female started menstruation at age 13 and experienced minor cramping and light bleeding until age 30. At age 30, she had her tubes tied and after that came heavier periods and moderate to severe cramping for the first two days of her cycle.
Female rubbed ointment (sample from example I) for the first time on her lower abdomen when she experienced her first sign of cramps. Cramps went away in 30 minutes. The second day cramps felt worse from first day, she rubbed ointment on abdomen and applied heat. Relief started to take place in 15 to 20 minutes. Cramps were gone after second treatment. Her period lasted a few more days cramp free. Same female used ointment for cramps in lower back with heat, and after 15 minutes, cramps lessened. She also experienced right hip pain, unrelated to menstruation, rubbed ointment on right hip and used with heat and that pain went away also.
EXAMPLE III
A woman who felt bad cramps on the first day of her period at 8:00 a.m applied the composition (ointment) to her abdomen. Relief felt in 20-30 minutes. At 3 p.m cramps returned. At 4:30 p.m., she applied more of composition. Relief occurred in 20 minutes. When cramps recurred at 8:30 p.m., she applied more. Second day cramps were severe. She used ointment in a.m. once and in p.m once. Cramps disappeared. On the third day she used ointment in a.m. to prevent cramps and it worked. Period lasted only three days.
EXAMPLE IV
______________________________________ 25 mg. Cayenne 105 mg. Chickweed 105 mg Yarrow 105 mg Wormwood 105 mg Dandelion 105 mg Motherwort 105 mg Pennyroyal 105 mg Tincture of benzoin______________________________________
The above ingredients were mixed into vehicle of 0.17 fluid ounce beeswax and 0.66 fluid ounce olive oil. One percent vanilla added as fragrance.
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An herbal composition is disclosed comprising as active ingredients chickweed, yarrow, wormwood, motherwort, pennyroyal, and dandelion in a vehicle of olive-oil and beeswax. The composition alleviates cramps, aches and pains, such as those associated with premenstrual syndrome.
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TECHNICAL FIELD
[0001] The present invention relates to the field of compression ignition engines, and more particularly to the field of electronic control of the power output of compression ignition engines.
BACKGROUND
[0002] Electronically controlled compression ignition engines are known in the art, but vary in the degree of sophistication in the control schemes they employ. In general, the electronic controllers associated with such engines are connected with fuel injection devices that inject a predetermined amount of fuel at a predetermined time into each of the cylinders of the engine based on a corresponding fuel injection signal produced by the controller. The fuel injection signals therefore determine the amount of fuel injected into the cylinders and the power output of the engine.
[0003] Depending on the specific application, the electronic controller may be connected with a variety of different operator inputs and other sensors including a throttle sensor input, cruise control settings, and various engine and transmission sensor inputs, among others. The electronic controller receives inputs from these sensors and determines the fuel injection signal which may be a function of many factors, including the overall amount of fuel to be injected, and the shape, number, duration and timing of individual injections for a particular engine cylinder. The characteristics of the fuel injection signal will determine the overall power output of the engine. In some engine applications there are fuel delivery limits that are stored in memory, or otherwise associated with the electronic controller. In particular applications where the operator, cruise control or other aspect of the electronic controller might otherwise request a fuel injection signal that would cause the engine to produce a power output greater than the rated horsepower output of the engine, the controller will limit the amount of fuel delivered as a function of the fuel delivery limit curve, which therefore limits the power output of the engine.
[0004] Those skilled in the art will recognize that engines used in work equipment applications are typically required to provide power to at least two different kinds of loads: work loads; and parasitic loads. In general, work loads are devices or systems that produce a net work output from the work equipment and generally include a transmission which demands power from the engine to propel the wheels, tracks, or other ground engaging propulsion mechanism, and a hydraulic system which demands power from the engine to move a bucket, for example, to dig and move dirt or earth. Parasitic loads, in contrast, are typically characterized as those loads that demand power output from the engine, but do not produce actual work output from the work equipment. Devices that may fall in this category include an engine cooling fan, a compressor for an air conditioning system, an alternator and other devices. For example, the engine cooling fan requires engine power to draw air through the radiator to cool the engine. The compressor requires engine power to run the air conditioning system and the alternator requires engine power to generate electrical power to recharge batteries and run electrical accessories. These parasitic loads reduce the amount of power that is available to the work loads.
[0005] Electronically controlled compression ignition engines that are known in the art do not vary the output power of the engine based on parasitic loads. Because the parasitic loads decrease the power available for work loads, the work load power of such engines will vary depending on the overall engine power output and the amount of power required by the parasitic loads. Because the parasitic load will vary depending on various conditions, work equipment operators are often unable to determine the amount of work power that will be available. For example, when the work equipment is operated in the morning and the temperature is relatively cool, the cooling fan may require little or no power to maintain a desired engine operating temperature. As the ambient temperature increases during the day, more power may be required by the cooling fan to maintain the desired engine temperature, and the operator may notice an undesirable decrease in the amount of engine power available to do work.
[0006] It would be preferable to have a system that generated a relatively constant workload power output. These and other aspects and advantages of present invention will become apparent upon reading the detailed description in connection with the drawings and appended claims.
SUMMARY OF THE INVENTION
[0007] In one aspect of the present invention a system for controlling fuel delivery to a compression ignition engine is disclosed. Prefereably the engine controllably powers at least a transmission or a work implement system, and one other device. The system includes an electronic control module connected with the other device and the transmission or work implement system. A fuel injection device is also connected with the electronic control module. The electonic control permits the engine to produce a first power output when the other device does not demand power, and a second power output when the other device demands power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a better understanding of the present invention, reference may be had to a best mode embodiment depicted in drawings, in which:
[0009] [0009]FIG. 1 generally illustrates an electronically controlled internal combustion engine system;
[0010] [0010]FIG. 2 illustrates a preferred embodiment of software control associated a preferred embodiment of the present invention;
[0011] [0011]FIG. 3 illustrates a preferred embodiment of software control associated with a preferred emboidment of the present invention in which the electronic controller controls the speed of a cooling fan; and
[0012] [0012]FIG. 4 generally illustrates an example of a fuel delivery limit curves that may be stored in a memory device associated with a preferred emboidment of the present invention.
DETAILED DESCRIPTION
[0013] The following is detailed description of a best mode embodiment of the present invention and is described in connection with its implementation on work equipment such as a hydraulic excavator, or other construction or earth moving equipment. The following description provides sufficient detail to permit someone skilled in the art to make and use the invention. The present invention, however, is not limited to the single preferred embodiment disclosed herein. On the contrary, the present invention encompasses all those devices and methods that fall within the scope of the present invention as defined by the appended claims and equivalents thereof. Throughout the description and the drawings like reference numbers will be used to refer to like elements.
[0014] Referring first to FIG. 1, a system level block diagram of a preferred embodiment of the electronic engine control system 10 of a preferred embodiment of the present invention is shown. In addition to various engine sensors and actuators, the engine control system 10 may include various work equipment and transmission sensor inputs and perform various work equipment and transmission control outputs. However, the present invention may also be performed within an engine control system 10 that does not include these additional work equipment and transmission features. The present description of the best mode, however, includes a description of some of the work equipment and transmission controls that may be included in the engine control system 10 .
[0015] As shown in FIG. 1, the engine control system 10 preferably includes an internal combustion engine 30 , which in a preferred embodiment is a compression ignition internal combustion engine. The engine 30 is connected with a transmission 32 which transmits engine power output to a final drive sprocket 33 , wheel or the like through appropriate gearing. The final drive sprocket 33 then is capable of transmitting power output of the engine 30 to a ground engaging propulsion device such as a track or a tire that can then propel the work equipment. As is known to those skilled in the art, a hydraulic excavator or other equipment with tracks will generally include two such drive sprockets, each driving a track on one side of the equipment. The engine 30 is also connected with a work implement system 36 , which in a preferred embodiment includes a hydraulic system including a hydraulic pump 37 connected to a work implement 39 through appropriate hydraulic conduits 38 . The work implement 39 may include a plurality of hydraulic cylinders 39 or the like, which in a hydraulic excavator may be associated with one of the various control aspects of the bucket, boom, or stick to permit the operator to accurately and efficiently dig and move dirt or other material.
[0016] A preferred embodiment of the electronic control system 10 includes an electronic control module (“ECM”) 15 , which preferably includes a microprocessor, a memory device and input/output ports that permit the microprocessor to receive sensor and operator inputs and issue commands to various engine and work equipment actuators. In a preferred embodiment, the microprocessor is a Motorola MC68HC11 manufactured by Motorola Corp. However, other microprocessors could be readily and easily used without deviating from the scope of the present invention. As is known to those skilled in the art, the memory device associated with the ECM 15 generally stores both software instructions and data. The software instructions stored in the memory device include, among other things, the specific code that controls the engine 30 . The data stored in the memory may either be permanently stored or may be temporarily written to the memory device by the microprocessor. The microprocessor is therefore generally able to both read data and software instructions from, and write to, the memory device.
[0017] As shown in FIG. 1, the ECM 15 is connected with a fuel delivery device 20 which is associated with an engine 30 . The ECM 15 calculates or determines a desired amount of fuel to be injected into the individual cylinders in the engine 30 and delivers corresponding fuel delivery signals over an electrical connector 25 which, at least in part, determine the power output of the engine 30 . Although the electrical connector 25 to the fuel delivery device 20 is shown as a single connector, those skilled in the art will recognize that this representation may include a plurality of connections between the ECM 15 and the fuel delivery device 20 , especially in instances where the fuel delivery device 20 includes a plurality of fuel injectors, each associated with a specific engine cylinder.
[0018] The ECM 15 is also connected with various engine sensors 35 over a connector 40 . These sensors typically include an engine speed sensor, engine temperature and other sensors capable of producing a signal on the connector 40 which is indicative of a particular operating state of the engine 30 . The connector 40 , although shown as a single connection, may include a plurality of connectors, each connected with a particular engine sensor 35 .
[0019] The ECM 15 is shown in FIG. 1 as being connected with transmission sensors 45 over a connector 50 and with actuators 55 over connector 60 . As is known to those skilled in the art, the sensors 45 typically may include a transmission speed sensor that produces a transmission speed signal. The ECM 15 generally is able to calculate the ground speed of the work equipment from the transmission speed signal, the transmission gear ratio and other operating parameters of the work equipment. The ECM 15 produces control signals on connector 60 to control various transmission actuators 55 , which may include solenoid controls that cause the transmission to engage one of a plurality of different gears.
[0020] The ECM 15 is also connected to a hydraulic cylinder 39 or other device to perform work on a work load through a connector 42 and controls the motion of a work implement associated with the hydraulic cylinder 39 through control signals issued on connector 42 . Typically, the ECM 15 generates the control signals as a function of various operator inputs 44 which produce signals on connector 46 that are inputs to the ECM 15 . However, the control signals may also be generated in response to other work equipment sensors or algorithms stored in the ECM 15 to permit a degree of autonomous motion.
[0021] The ECM 15 is connected with a variety of parasitic load devices 65 over connectors such as 70 . In a preferred embodiment, one such parasitic load 65 includes an engine cooling fan 66 . Other such devices might include an alternator or generator, a compressor for an air conditioning system, a power steering or power braking pump, among others. As shown in FIG. 1, the ECM 15 produces a cooling fan signal on connector 70 that controls the rotational speed of the engine cooling fan 66 and therefore can increase or decrease the amount of air travelling through the engine's radiator. In this manner, the ECM 15 can control the heat rejection capabilities of the radiator by increasing the speed of the fan 66 when increased cooling is required and decreasing the fan speed, or turning it off, when lesser cooling is required. Increased fan speed, however, comes at the expense of additional engine power being required to drive the engine cooling fan 66 .
[0022] Referring now to FIG. 2, a general block diagram of a preferred embodiment of software control associated with the present invention is shown. Program control begins in block 200 and moves to block 210 .
[0023] In block 210 , program control determines whether the parasitic loads are using any of the power output of the engine 30 . Those skilled in the art will recognize that there are a plurality of ways to determine the total parasitic load demand, any of which can be used in connection with the present invention. In a preferred embodiment, however, the ECM 15 uses a map, equation, calculation or other method to correlate the power requirement of a particular device to either the ECM 15 command for that device or another engine operating condition, for example engine speed. The ECM 15 is then able to determine the amount of power that is required to operate that particular parasitic load device. The ECM 15 preferably adds the power requirements for one or more parasitic load devices to determine a parasitic load power requirement. Program control then passes from block 210 to block 220 .
[0024] In block 220 , the ECM 15 permits the engine 30 to produce different maximum output power levels based on the amount of power required by the parasitic load devices 65 . For example, an engine may be capable of producing 350 horsepower when the parasitic load devices require less than a first determined amount of power and may be capable of an increased power output, for example 400 horsepower, when the parasitic load devices require more than a second determined amount of power. By doing so the ECM 15 , to some degree, maintains a relatively constant power output to the work implements and transmission. In a preferred embodiment of the present invention, at least two fuel delivery limit curves are stored in the memory associated with the ECM 15 . The ECM 15 uses the fuel delivery limit curves to limit the amount of fuel that may be injected into the engine cylinders over the engine's operating speeds and under certain operating conditions. Thus, if the operator inputs cause the ECM 15 to calculate a fuel delivery that exceeds the amount specified in the fuel delivery limit curve, then the fuel delivery limit curve limits the amount of fuel delivered. In this manner, the active fuel delivery limit curve determines the maximum power output of the engine 30 . In a preferred embodiment, the ECM 15 uses a first fuel delivery limit curve associated with lower power outputs when the parasitic load devices require less than a first predetermined parasitic load power and uses a second fuel delivery limit curve when the parasitic load demand is greater than or equal to a second predetermined parasitic load power. For parasitic load power levels between the first and second predetermined level the ECM 15 calculates or otherwise determines a fuel delivery limit based on said first and second fuel delivery limit curves. From block 220 , program control passes to block 230 and returns to the calling control loop.
[0025] Referring now to FIG. 3, a flow chart for a preferred embodiment of the software control associated with the present invention is shown for an embodiment in which the parasitic load includes an engine cooling fan 66 . In this embodiment, program control begins in block 300 and passes to block 310 . In block 310 the ECM 15 inputs an engine temperature signal produced by an engine temperature sensor 35 and responsively determines an engine temperature. Program control then passes to block 320 .
[0026] In block 320 the memory associated with the ECM 15 includes a map or equation to permit the ECM 15 to calculate or determine a desired cooling fan 66 speed based on the sensed engine temperature, among other factors. The ECM 15 preferably compares the engine temperature signal to the map stored in memory, determines a corresponding cooling fan command signal corresponding to a desired engine cooling fan 66 speed and produces the signal on connector 70 . The engine speed cooling fan 66 is designed to run within a specified tolerance of a desired speed corresponding to the cooling fan speed signal and operates under open loop control to thereby control the temperature of the engine. In general, as the temperature of the engine increases the need for cooling increases and the ECM 15 will produce engine speed cooling fan signals causing the engine cooling fan 66 speed to increase. Running the engine cooling fan 66 at faster speeds requires a greater amount of engine power than running the fan at lower speeds. Thus, when the engine is running a hotter temperatures, the ECM 15 will issue command signals that cause the fan speed to increase, thereby increasing the parasitic power load requirement from the engine 30 and decreasing the amount of power available for the work implement system 39 and the transmission 32 . Program control passes from block 320 to block 330 .
[0027] In block 330 , the ECM 15 determines the amount of power required by the engine cooling fan 66 and increases the maximum permitted power output of the engine 30 to compensate for any increase in parasitic load. In one embodiment, the memory associated with the ECM 15 includes a map or other method for recording or calculating a relationship between the engine cooling fan speed command and the amount of engine power required by the fan for that commanded speed. The ECM 15 then permits the rated power output of the engine to increase by an amount dependent on the parasitic power load, in an attempt to keep the maximum amount of power available for the work implement system 39 and the transmission 32 relatively constant. In this embodiment of the software control the memory associated with the ECM 15 preferably includes a table or map that includes at least two different engine power ratings. A first engine rating is used when the cooling fan is not rotating and therefore is requiring little, if any, engine power, and a second higher rating that is used when the fan is turning at or near maximum speed and therefore is requiring a maximum or near maximum amount of fan power. The engine power ratings are typically stored as fuel delivery limit curves as described in more detail below, with reference to FIG. 4. The ECM 15 then compares the commanded engine cooling fan speed to the cooling fan speeds associated with the first engine rating and the second engine rating. If the commanded engine cooling fan speed is zero, then the ECM 15 will use the first engine rating. If the commanded cooling fan speed is the maximum command, then the ECM 15 will use the second engine rating. Otherwise if the commanded cooling fan speed is between zero and the maximum speed, then the ECM 15 will calculate or otherwise determine an engine rating between the first and second engine ratings, as a function of the first and second engine ratings, preferably by interpolation. The ECM 15 will then use the calculated engine rating to control the maximum power output of the engine, thereby permitting the engine to produce an increased amount of overall power to compensate for parasitic power loss resulting from operating the engine cooling fan. Program control then passes from block 330 to block 340 and program control returns to the calling control loop.
[0028] [0028]FIG. 4 generally shows a map 400 of two engine power ratings that may be used in connection with an embodiment of the present invention. As described above, these engine power ratings may be stored as fuel delivery limit curves. As shown in the drawing, the map preferably includes a first engine power rating 420 associated with a first engine cooling fan speed and a second engine power rating 410 associated with a second cooling fan speed. FIG. 4 shows a generic representation of the engine power ratings that may be used in connection with the present invention. However, the present invention is not limited to the specific ratings shown in the drawing. To the contrary, it is contemplated that the specific ratings used will depend on the specific engine and work equipment configuration, including the engine cooling fan and other parasitic loads that may be connected with the engine.
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An electronic engine control is provided that compensates the engine's power output capability based on the parasitic power load demands.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a divisional of U.S. patent application Ser. No. 11/708,621, filed Feb. 20, 2007.
BACKGROUND OF THE INVENTION
The present invention relates to systems for restraining rotatable components, and more particularly to thermally operated systems for restraining rotatable components of turboalternators.
Foil bearings are a known type of bearing structure that utilize a thin metal journal lining to support a rotatable shaft and create a hydrodynamic film or air bearing with a working fluid (e.g., xenon gas). For example, certain closed Brayton cycle turboalternators can utilize a turboalternator shaft supported by foil bearings. At operational speeds, the rotating shaft is supported by the fluid pressure of the working fluid and generally does not contact the metal structures of the foil bearings. This means that no wear occurs due to direct physical contact with the rotating shaft during operation, although some contact with metal components of the bearings occurs during startup, shutdown and non-operational periods.
However, foil bearings are susceptible to damage, which can reduce or destroy bearing functionality. For instance, with foil bearings used in turboalternators for spacecraft, the turboalternator may not be used during a launch phase of a flight cycle and may only be activated for operation during a later orbital phase of the flight cycle. Because the launch phase will generally subject turboalternator components to stresses, vibration, displacement and other potential sources of damage, it is desired to restrain rotatable components of the turboalternator to prevent damage to the foil bearings during non-operational phases where a hydrodynamic film is not generated and rotatable components can contact the metal structures of the bearings. Active restraint systems, using solenoid actuators or the like, can be used to restrain the rotating components of the turboalternator during the launch phase, but those active systems contain moving parts that present undesirable reliability risks, especially under conditions of extreme ambient temperature variation that occur in aerospace applications.
BRIEF SUMMARY OF THE INVENTION
A turboalternator system according to the present invention includes a turboalternator having a rotatable member operatively engaged to a bearing set, a radial support element, and a contact structure engaged with the radial support element. The rotatable member defines a first end, a second end and an axis of rotation. The turboalternator system is configured to be thermally adjustable such that in a first thermal condition the contact structure is at a first radial position with respect to the axis of rotation and contacts the rotatable member to provide support, and in a second thermal condition the contact structure is at a second radial position with respect to the axis of rotation that is spaced further from the axis of rotation than the first radial position. The contact structure includes a ring having a groove formed in an outer diameter surface thereof, and the radial support element engages the groove in the contact structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional perspective view of a close Brayton cycle turboalternator having a restraint system according to the present invention.
FIG. 2 is a perspective view of the restraint system and turboalternator shaft of FIG. 1 , shown in isolation.
FIG. 3 is a perspective view of a portion of another embodiment of a restraint system according to the present invention.
FIG. 4 is a perspective view of a portion of another embodiment of a restraint system according to the present invention.
FIG. 5 is a cross-sectional perspective view of the restraint system of FIG. 4 .
DETAILED DESCRIPTION
FIG. 1 is a cross-sectional perspective view of a closed Brayton cycle turboalternator 10 that includes a turbine assembly 12 , a compressor assembly 14 , a rotatable alternator shaft 18 , permanent magnets 20 , a stator assembly 22 , alternator windings 24 , a gas thrust bearing assembly 26 , a cooling fan diffuser 28 , first and second foil bearing assemblies 30 A and 30 B, passive restraint assemblies 32 A and 32 B (collectively, restraint system 32 ), and an alternator housing 34 . The turbine assembly 12 and the compressor assembly 14 , both shown schematically in FIG. 1 for simplicity, are operably connected to the shaft 18 . In general, the turboalternator 10 operates by converting thermal energy from an external source into rotational energy that turns the shaft 18 . The shaft 18 then rotates the permanent magnets 20 with respect to the stator assembly 22 and the alternator windings 24 in order to generate an electrical current. In this respect, the turboalternator 10 can operate in a conventional manner as will be understood by those of ordinary skill in the art, and therefore it is not necessary to discuss further details of the configuration and operation of the turboalternator 10 . However, it should be noted that the turboalternator 10 of FIG. 1 is shown by way of example and not limitation, and the present invention is equally applicable to turboalternators having other known configurations.
The shaft 18 is operatively supported by the first and second foil bearing assemblies 30 A and 30 B, which are, in turn, supported by bearing carriers 36 and the housing 34 . The foil bearing assemblies 30 A and 30 B can be of a conventional type where, during operation, when the shaft 18 is rotating, the shaft 18 is supported by the fluid pressure of a working fluid (e.g., xenon gas) present between the shaft 18 and metallic structures of the foil bearing assemblies 30 A and 30 B. During operation, the rotating shaft 18 generally does not contact the metal components of foil bearing assemblies 30 A and 30 B. This means that generally no wear occurs due to direct physical contact between the rotating shaft 18 and the metallic structures of the foil bearing assemblies 30 A and 30 B during operation, although some incidental contact may occur.
The turboalternator 10 can be installed in a space shuttle or other aerospace vehicle (not shown) that typically will undertake a flight cycle that includes a launch phase, where the turboalternator 10 is not operational, and an orbital phase, where the turboalternator 10 is activated and operated. The restraint system 32 helps to secure the rotatable shaft 18 of the turboalternator 10 when not operational, such as during the launch phase, in order to help reduce the possibility of damage to the foil bearing assemblies 30 A and 30 B due to undesired movement of the shaft 18 .
FIG. 2 is a perspective view of the restraint system 32 and the shaft 18 , shown in isolation for clarity. As shown in FIG. 2 , the shaft 18 defines a first end 18 A and an opposite second end 18 B, and further defines an axis of rotation A. The first restraint assembly 32 A is positioned relative to the first end 18 A of the shaft 18 , and the second restraint assembly 32 B is positioned relative to the second end 18 B of the shaft 18 . The first and second restraint assemblies 32 A and 32 B are substantially identical in the illustrated embodiment, although the assemblies 32 A and 32 B could differ in alternative embodiments.
Each of the restraint assemblies 32 A and 32 B includes a ring 38 that is positioned about the shaft 18 (i.e., to encircle the shaft 18 ) and secured to the housing 34 (shown in FIG. 1 ), three extensions 40 , 42 and 44 that extend radially inwardly from the ring 38 toward the shaft 18 , and pads 48 , 50 and 52 (pads 52 are not visible in FIG. 2 ) that are supported by the extensions 40 , 42 and 44 , respectively. The extensions 42 , 44 and 46 are substantially equally spaced from each other and each curve toward the shaft 18 in a spiral-type configuration. The pads 48 , 50 and 52 are fixed to the radially inner ends of the extensions 40 , 42 and 44 , respectively, and have curved faces configured to form contact surfaces that can contact the shaft 18 . As shown in FIG. 2 , the restraint system 32 is engaged such that the pads 48 , 50 and 52 are in contact with the shaft 18 . Optional circumferential grooves 54 A and 54 B are formed along an outer surface of the shaft 18 relative to each restraint assembly 32 A and 32 B, and the pads 48 , 50 and 52 extend at least partially into the grooves 54 A and 54 B when engaged.
The extensions 40 , 42 and 44 are bimetallic structures that each comprise two layers 56 and 58 that are bonded or otherwise secured together. The radially outer layer 56 comprises a first material, and the radially inner layer 58 comprises a second material. The second material has a greater coefficient of thermal expansion than the first material, such that changes in ambient temperature cause the extensions 40 , 42 and 44 to change shape to move the pads 48 , 50 and 52 relative to the shaft 18 . The first and second materials of the extensions 40 , 42 and 44 can be bonded together using direct metal deposition, friction welding, or other suitable techniques. The restraint system 32 is configured such that increases in temperature cause the pads 48 , 50 and 52 to move away from the shaft 18 , while decreases in temperature cause the pads 48 , 50 and 52 to move toward the shaft 18 . Any materials having differing coefficients of thermal expansion can be used the first and second materials, for example, aluminum and steel. The particular materials used can be selected as a function of the particular thermal operating conditions for a particular application. It should be noted that the rotor 18 typically comprises a material with a low coefficient of thermal expansion, such as a nickel-based superalloy like Inconel®, and therefore is assumed to experience no change in size due as a result of temperature changes. The ring 38 can be made of a material having a coefficient of thermal expansion that is similar or identical to that of a material of the housing 34 .
When installed in the turboalternator 10 , the restraint system 32 is configured so that the pads 48 , 50 and 52 contact the shaft 18 and restrain the shaft 18 when ambient temperatures in the turboalternator 10 are relatively low. Engagement of the pads 48 , 50 and 52 in the optional grooves 54 A and 54 B provides some restraint in the axial direction, in addition to restraint provided in generally radial directions. As used herein, the term “restraining” means to limit displacement of the shaft 18 relative to the axis of rotation A. A first thermal condition is defined at relatively low temperature conditions when the turboalternator 10 is in a non-operational state and the restraint system 32 is engaged, such as during a launch phase of a flight cycle, and relates to a range of temperatures that are below an operating temperature of the turboalternator 10 . The particular operating temperature of the turboalternator 10 can vary for different applications.
When the turboalternator 10 reaches an operational temperature, the restraint system 32 is configured so that the pads 48 , 50 and 52 move away from the shaft 18 . A second thermal condition is defined at relatively high temperature conditions when the turboalternator 10 is in an operational state and the restraint system 32 disengages, such as during an orbital phase of a flight cycle, and relates to a range of temperatures that are at least as high as a minimum operating temperature of the turboalternator 10 . In the second thermal condition, the radial distance between the pads 48 , 50 and 52 increases relative to the axis of rotation A of the shaft 18 such that a gap is formed between the pads 48 , 50 and 52 and the outer surface of the shaft 18 . The gap can vary as desired for particular applications and is typically determined as a function of the configuration of the foil bearings 30 A and 30 B, however a gap of about 0.0254 mm (0.001 inch) or more will generally be sufficient. In the second thermal condition, the shaft 18 is essentially unrestrained by the restraint system 32 . However, where the gap between the pads 48 , 50 and 52 and the shaft 18 is small, the pads 48 , 50 and 52 can permit shaft rotation while acting as “bumpers” to limit incidental displacement of the shaft 18 relative to the axis of rotation A and help maintain proper alignment of the shaft 18 . In that situation, the contact surfaces of the pads 48 , 50 and 52 can optionally be coated with a suitable dry film lubricant in order to reduce friction if and when the shaft 18 contacts the pads 48 , 50 and 52 momentarily.
The temperature of the restraint system 32 is affected by ambient environmental temperatures as well as thermal energy from the external source that powers the turboalternator 10 during operation. More particularly, a coolant medium (e.g., lithium) will generally be warmed to the point of liquification before the turboalternator 10 is activated. As the coolant medium is heated and circulated, for instance, when passed through heat exchangers (not shown), thermal energy will radiate and conduct through the turboalternator 10 and to the restraint system 32 . Generally, a thermal conduction path within the turboalternator is formed through the housing 34 and then to the rings 38 and extensions 40 , 42 and 44 .
An optional heater can be connected to any of the restraint assemblies 32 A and 32 B in order to directly provide thermal energy to the restraint system 32 . An electric heater 60 connected to the ring 38 of the restraint assembly 32 A is shown schematically in FIG. 2 . The heater 60 can be used to help disengage the restraint system 32 more quickly, or to make disengagement of the restraint system 32 independent from the conduction of thermal energy through the turboalternator 10 from an external source.
It is contemplated that the restraint system of the present invention can have alternative embodiments. FIG. 3 is a perspective view of a portion of another embodiment of a restraint system 132 engaged to a portion of a shaft 18 , shown in isolation. The restraint system 132 includes a restraint ring 138 , three struts 140 , 142 and 144 , and pads 148 , 150 and 152 (pad 152 is not visible in FIG. 3 ). The ring 138 is positioned about the first end 18 A of the shaft 18 . The struts 140 , 142 , 144 extend radially inward from the ring 138 , and the pads 148 , 150 and 152 are supported by the struts 140 , 142 , 144 , respectively. The ring 138 comprises a first material, and the struts 140 , 142 , 144 comprise a second material. The first material is selected to have a relatively high coefficient of thermal expansion, while the second material is selected to have a relatively low coefficient of thermal expansion.
In general, the operation of the restraint system 132 is similar to the restraint system 32 described above in that during a first thermal condition the restraint system 132 is engaged to the shaft 18 and at a higher temperature second thermal condition the restraint system 132 disengages. However, unlike the restraint system 32 , the restraint system 132 operates due to the increase in a radial dimension of the ring 138 as the temperature of the restraint system 132 increases. The struts 140 , 142 , 144 undergo little or no change in size as temperature of the system 132 increases, but instead the struts 140 , 142 , 144 move the pads 148 , 150 and 152 relative to the surface of the shaft 18 and the axis of rotation A as the radial dimension of the ring 138 changes.
The housing 34 to which the ring 138 is secured can be made of a material with a coefficient of thermal expansion that is similar or identical to the ring 138 , in order to accommodate the changes in radial dimension of the ring 138 while still maintaining secure mechanical support.
FIG. 4 is a perspective view of a portion of another embodiment of a restraint system 232 engaged to a portion of a shaft 18 , shown in isolation. FIG. 5 is a cross-sectional perspective view of the restraint system 232 . The restraint system 232 includes an outer ring 238 , seven springs 240 A- 240 G (springs 240 E and 240 F are not visible in FIG. 4 ), and an inner ring 248 . The outer ring 238 is positioned to about the first ends 18 A of the shaft 18 , and is spaced from the outer surface of the shaft 18 . The springs 240 A- 240 G extend radially inward from the outer ring 238 in a substantially equally circumferentially spaced spiral-type configuration, and each of the springs 240 A- 240 G acts as a leaf spring. The inner ring 248 is positioned adjacent to the outer surface of the shaft 18 and acts like a circular pad for restraining the shaft 18 like the pads described above. A circumferential groove 270 is formed on a radially outer face of the inner ring 248 between a pair of axially spaced ramp structures 272 A and 272 B. The springs 240 A- 240 G are engaged in the groove 270 , which secures the inner ring 248 relative to the out ring 238 . The ramp structures 272 A and 272 B have a slope that facilitates assembly, by allowing the inner ring 248 to be slid into engagement inside the springs 240 A- 240 G.
The inner ring 248 comprises a first material having a relatively high coefficient of thermal expansion, and the outer ring 238 comprises a second material that can have a lower coefficient of thermal expansion. The springs 240 A- 240 G can be formed unitarily with the outer ring 238 and of the same material (i.e., the second material).
In general, the operation of the restraint system 232 is similar to the restraint systems 32 and 132 described above in that during a first thermal condition the restraint system 232 is engaged to the shaft 18 and at a higher temperature second thermal condition the restraint system 232 disengages. However, unlike the restraint systems 32 and 132 , the restraint system 232 operates due to the increase in a radial dimension of the inner ring 270 as the temperature of the restraint system 232 increases. As the temperature of the restraint system 232 increases, the inner ring 270 increases in a radial dimension as the first material expands. In the second thermal condition, a gap is formed between the inner diameter of the inner ring 270 and the outer surface of the shaft 18 . Spring force of the springs 240 A- 240 G helps keep the inner ring 270 centered about the axis of rotation A of the shaft 18 .
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. For instance, the particular configuration of the restraint system according to the present invention can vary as desired for particular applications. Furthermore, the restraint system of the present invention can be utilized with nearly any type of rotatable component. Moreover, optional features described above, such as circumferential grooves in the shaft, dry film lubricants, and heaters, can be utilized with any embodiment of the present invention.
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A turboalternator system includes a turboalternator having a rotatable member operatively engaged to a bearing set, a radial support element, and a contact structure engaged with the radial support element. The rotatable member defines a first end, a second end and an axis of rotation. The turboalternator system is configured to be thermally adjustable such that in a first thermal condition the contact structure is at a first radial position with respect to the axis of rotation and contacts the rotatable member to provide support, and in a second thermal condition the contact structure is at a second radial position with respect to the axis of rotation that is spaced further from the axis of rotation than the first radial position. The contact structure includes a ring having a groove formed in an outer diameter surface thereof, and the radial support element engages the groove in the contact structure.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to firearms and, more particularly, to a muzzle device that reduces the recoil, muzzle flash, and side concussion of a firearm allowing for better muzzle control, improved situational awareness of the shooter, and reduced visual signature to better conceal the shooter from enemy return fire.
[0003] 2. Description of Related Art
[0004] Many muzzle brakes, compensators, and flash hiders have been developed over the years that either suppress muzzle flash or reduce and redirect recoil. Many of these devices do an acceptable job of achieving one of these tasks, but none are able to achieve both tasks equally well. Furthermore, in recent years there has been an increasing number of so called “multipurpose” muzzle devices introduced to the market that claim to increase muzzle control through recoil reduction and redirection, as well as reduce muzzle flash and excessive side concussion. Most of these devices employ a small expansion chamber or passageway, and a multitude of small vent holes passing though the side of the device in order to redirect as well as regulate both the pressure and the flow rate of the exhausting propellant gases. However, since none of these devices employ an effective method of expanding and cooling the escaping gases, or disrupting shock wave formation, they are only able to provide a slight improvement in flash suppression over conventional muzzle breaks and compensators. In view of these problems associated with known firearms and known muzzle devices, there is a need for an improved muzzle device that can effectively and substantially reduce recoil and muzzle flash.
SUMMARY OF THE INVENTION
[0005] It is an objective of the present invention to redirect, expand, cool, and disrupt shock wave formation of the exhausting propellant gases to achieve a reduction as well as a redirection of recoil while concurrently suppressing muzzle flash.
[0006] According to one object of the present invention, a muzzle device for a firearm is provided comprising: a generally cylindrical body adapted for attachment to the muzzle of a firearm barrel and having an exterior; wherein the generally cylindrical body includes a coaxial passageway for removable communication with a muzzle; wherein the generally cylindrical body has at least one radial vent hole in communication with the coaxial passageway; wherein the generally cylindrical body includes a coaxial exit hole in communication with the coaxial passageway; wherein the exterior of the generally cylindrical body includes at least one slot, wherein each of the at least one slots are in communication with one of the at least one radial vent holes.
[0007] According to another object of the present invention, a muzzle device for a firearm is provided, the device comprising: a generally cylindrical body adapted for attachment to the muzzle of a firearm barrel; wherein the generally cylindrical body includes a coaxial passageway in front of and communicating with the muzzle; wherein the generally cylindrical body includes a coaxial exit hole in front of and communicating with the coaxial passageway; wherein the coaxial passageway and the exit hole are sufficiently large to allow the passage of the fired bullet; wherein the coaxial passageway includes at least ten radial vent holes that pass through a side of the generally cylindrical body communicating between the coaxial passageway and the outside atmosphere; wherein an exterior of the generally cylindrical body includes at least one slot in communication with and radiating away from one of the at least ten radial vent holes and wherein each of the at least one slots exit the side of the body.
[0008] According to yet another object of the present invention, a muzzle device for a firearm is provided, the device comprising: a generally cylindrical body adapted for attachment to the muzzle of a firearm barrel and having an exterior; wherein the generally cylindrical body includes a coaxial passageway in front of and communicating with the muzzle; wherein the generally cylindrical body includes a coaxial exit hole in front of and communicating with the coaxial passageway; wherein the coaxial passageway and the exit hole are sufficiently large to allow the passage of a fired bullet; wherein the coaxial passageway includes at least ten vent holes in the side of the generally cylindrical body between the coaxial passageway and the outside atmosphere; wherein the exterior of the generally cylindrical body includes at least three slots that communicate with, and radiate out from, one of the at least ten vent holes.
[0009] It is another objective of the present invention to redirect expand, cool, and disrupt shock wave formation of the exhausting propellant gasses to reduce side concussion to a level less than that of convention muzzle breaks and compensators.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 a - 1 d and FIG. 2 show a preferred embodiment of the invention. FIG. 1 a is a left side isometric view of the muzzle device showing the external features.
[0011] FIG. 1 b is a cropped view of FIG. 1 a at an enlarged scale detailing the patterns of slots that communicate with and diverge away from the radial vent holes as they pass through the exterior of the device.
[0012] FIG. 1 c is a left side cross section view of the muzzle device showing its internal features, particularly the coaxial passageway, which includes the annular baffles that are formed at the outer edge of the coaxial passageway by the intersections of radial vent holes in each annular pattern. The diverging slots are illustrated originating in each radial vent hole a short distance from the coaxial passageway and diverging away at an angle before passing through the exterior of the device.
[0013] FIG. 1 d is a cross section view of the muzzle device showing the radial holes converging and intersecting each other as they approach the coaxial passageway.
[0014] FIG. 2 is a cropped view at an enlarged scale to better illustrate the geometric relationship between the radial venting holes and the diverging slot pattern on the exterior of the device.
[0015] FIG. 3 a - 3 d and FIG. 4 show another preferred embodiment of the invention where there is only one slot diverging from each radial vent hole.
[0016] FIG. 3 a is a left side isometric view of the muzzle device showing the external features.
[0017] FIG. 3 b is a cropped view of FIG. 3 a at an enlarged scale detailing the pattern of oblong slots that are about the same width as the radial vent holes passing through the exterior of the device.
[0018] FIG. 3 c is a left side cross section view of the muzzle device showing its internal features, particularly the coaxial passageway, which includes the annular baffles, and the radial vent holes. The diverging slot is illustrated originating in each radial vent hole a short distance from the coaxial passageway and diverging rearward at an angle before passing through the exterior of the device.
[0019] FIG. 3 d is a cross section view of the muzzle device showing the radial holes converging and intersecting each other as they approach the coaxial passageway.
[0020] FIG. 4 is a cropped view at an enlarged scale to better illustrate the geometric relationship between the radial venting holes and the rearward diverging slot pattern on the exterior of the device.
[0021] FIG. 5 a - 5 d and FIG. 6 show another embodiment of the invention where the expansion of gas is accomplished using divergent conical nozzles instead of diverging slots.
[0022] FIG. 5 a is a left side isometric view of the muzzle device showing the external features.
[0023] FIG. 5 b is a cropped view of FIG. 5 a at an enlarged scale detailing the matrix of milled diverging cones, each starting shortly after the radial holes diverge from the coaxial passageway.
[0024] FIG. 5 c is a left side cross section view of the muzzle device showing its internal features, particularly the coaxial passageway, which includes the annular baffles, the radial vent holes, and the diverging conical nozzles.
[0025] FIG. 5 d is a cross section view of the muzzle device showing the radial holes intersecting at the coaxial passageway, and also the diverging cones that expand the gases from the radial holes.
[0026] FIG. 6 a is a left side isometric view of the muzzle device showing the external features.
[0027] FIG. 6 b is a cropped view of FIG. 6 a at an enlarged scale detailing the matrix of axial and circumferential slots that intersect at the center axis of the radial vent holes to create nodes.
[0028] FIG. 6 c is a left side cross section view of the muzzle device showing the internal features of the muzzle brake, particularly the axial passageway, which includes the coaxial annular baffles, and the radial vent holes.
[0029] FIG. 6 d is a cross section view of the muzzle device looking from the back side showing the radial vent holes as well as the non-venting bottom section.
[0030] FIG. 7 is a cropped view at an enlarged scale to better illustrate the relative size as well as the geometric relationship between the radial venting holes and the axial and circumferential slots that intersect at the center axis of the radial vent holes to create nodes.
[0031] FIG. 8 a depicts the virtual cylindrical wall of the radial vent hole along the exterior surface of the cylindrical body and the maximum width of the slot.
[0032] FIG. 8 b depicts the depth ( 204 ) measured from the exterior of the cylindrical body.
[0033] FIGS. 9 a , 9 b , 9 c and 9 d depict aspects of the present invention.
[0034] FIGS. 10 a , 10 b , 10 c and 10 d depict aspects of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] While this invention may be embodied in many different forms, as illustrated in FIGS. 1 a - 1 d , FIG. 2 , FIGS. 3 a - 3 d , FIG. 4 , and FIGS. 5 a - 5 d . A preferred embodiment is shown in FIGS. 1 a - 1 d , FIG. 2 . This embodiment has a cylindrical body ( 2 ) having a coaxial passageway ( 4 ) preferably between 1.1 and 1.5 bullet calibers in diameter and preferably between 5 and 7 bullet calibers in length, forward of and communicating with a coaxial threaded bore ( 22 ) for attaching the muzzle device to the threaded muzzle of a firearm barrel. The coaxial passageway ( 4 ) communicates with the longitudinal front slots ( 26 ) through the coaxial exit hole ( 18 ), which is preferably the same diameter or smaller than the coaxial passageway ( 4 ). The coaxial passageway and the coaxial exit hole are sufficiently large to allow the passage of a fired bullet. When the firearm is fired, the bullet exits the muzzle of the gun and travels along the coaxial passageway ( 4 ) of the attached muzzle device and exits through the coaxial exit hole ( 18 ), at the front end of the muzzle device.
[0036] The coaxial passageway ( 4 ) extends along the longitudinal axis of the muzzle device and includes a series of preferably between 6 and 10 closely spaced coaxial annular baffles ( 16 ) created by the annular patterns of radial vent holes as they converge and intersect toward the coaxial passageway ( 4 ). These annular baffles ( 16 ) divert propellant gases away from the path of the bullet into the respective circular array of radial vent holes ( 10 ) form which they are formed. These radial venting holes ( 10 ) channel propellant gases through the cylindrical body ( 2 ) of the muzzle device in a direction that is approximately orthogonal to the longitudinal axis of the muzzle device. The radial vent holes ( 10 ) are preferably about ⅓ calibers in diameter with preferably 10 to 18 holes in each circular array.
[0037] The exterior of the cylindrical body ( 2 ) is the portion on the outside of the cylindrical body ( 2 ) that is seen in FIG. 1 a . According to one embodiment, on the exterior of cylindrical body ( 2 ) of the muzzle device there is a pattern of three equally spaced diverging slots ( 31 ) located at and communicating with each radial vent hole ( 10 ). These patterns effectively increase the cross-sectional area of the radial vent holes ( 10 ) as the radius of the cylindrical body ( 2 ) increases. These slots ( 31 ) diverge in a radial direction away from the axis of the radial vent holes at an angle of approximately 15 degrees. When measured along the exterior surface of the cylindrical body ( 2 ) the slots ( 31 ) radiate away from the cylindrical wall of the respective radial vent hole from which they originate at ( 10 ) to a distance that is approximately equal to their respective maximum width. According to one embodiment, each slot ( 31 ) is of sufficient width with respect to the radial vent hole that it radiates from that there are three convex corners ( 11 ) formed at the circular wall of the respective vent hole ( 10 ). Each of the least one slots have a sufficient depth to effectively expand, cool, and disrupt shock wave formation of exhausting propellant gases. FIGS. 1 a and 1 b depict the slots ( 31 ) as three convex corners ( 11 ) at the exterior. A set of three slots may be drilled and milled to form a “Y” shape. This is the embodiment in which each of the at least one slots is further comprised of three slots (or sub-slots) and each of the three slots (or sub-slots) have convex corners at the exterior. This may also be described as a “Y” shape and there would be many “Y” shaped slots as depicted in FIG. 1 a . For example, FIG. 1 a depicts approximately one hundred and twenty slots each made up of three slots (or sub-slots). According to other embodiments, by way of example, you may have one slot with two convex corners to form the shape of “I.” There may be two slots with two convex corners to form a “V,” there may be three slots with three convex corners that form the shape of “Y,” or there may be four slots with four convex corners that form the shape of “X.” There may also be 2 slots in the shape of “V” that have 1 convex corner at the bottom, there may be three slots in the shape of a “Y” which have 3 convex corners, there may be four slots in the shape of an “X” which have four convex corners, and so on and so forth. It is important to note that the convex corners may be where two slots intersect or may portions of a single slot. For example, FIGS. 3 a , 3 b and 4 depict the embodiment where each of the at least one slots ( 32 ) are oblong shaped at the exterior. The oblong shaped slot may be said to have convex corners at either end of a single slot. FIGS. 5 a and 5 b depict the embodiment wherein each of the at least one slots ( 33 ) are circular shaped at the exterior. FIGS. 1 c , 3 c , and 5 c depict each of the at least one slots gradually increasing in diameter from the radial vent hole to the exterior.
[0038] When the firearm is fired, high pressure gases travel through the coaxial passageway ( 4 ) where it impinges on the annular baffles ( 16 ) diverting it away from the bore axis though the radial vent holes ( 10 ) into each pattern of diverging slots ( 31 ), where due to increased cross section and surface area, the gases are expanded and cooled before escaping to atmosphere. It is also believed that the three convex corners ( 11 ), act in a similar manner as prongs on modern high efficiency open prong flash hiders, by disrupting shock wave formation, which is a necessary process in the generation of muzzles flash. If the matrix of diverging slots ( 31 ) is of a sufficient relative depth, the propellant gases will be cooled and the shock formation reduced to a sufficient level that the unburned gas components will be less susceptible to ignite upon entering the oxygen rich outside atmosphere, and secondary flash will be suppressed. For effective flash suppression the diverging slots ( 31 ) should begin soon after the radial vent holes ( 10 ) cease to intersect one another near the coaxial passageway ( 4 ). Another important feature of this invention is that the coaxial passageway ( 4 ) is only slightly larger than bullet diameter which effectively reduces the internal volume of the device and therefore minimizes the amount of oxygen available to mix with hot propellant gasses in the interior of the device during the firing cycle. This greatly reduces this component of muzzle flash and in particular the first round flash which is due to this phenomenon.
[0039] There may be, according to one embodiment, three longitudinal front slots ( 26 ) at the front of the muzzle device that communicate with the coaxial passageway ( 4 ) though the coaxial exit hole ( 18 ). The longitudinal front slots ( 26 ) disrupts shock wave formation while expanding and cooling the unburned propellant gases escaping through the coaxial exit hole ( 18 ) into the oxygen rich outside atmosphere, and in doing so prevent ignition and flash at the front of the muzzle device.
[0040] A muzzle device for a firearm comprising: a generally cylindrical body ( 2 ) adapted for attachment to the muzzle of a firearm barrel and having an exterior; wherein the generally cylindrical body ( 2 ) includes a coaxial passageway ( 4 ) for removable communication with a muzzle, the coaxial passageway ( 4 ) having a coaxial exit hole ( 18 ); wherein the generally cylindrical body ( 2 ) has at least one radial vent hole ( 10 ) in communication with the coaxial passageway ( 4 ); wherein the exterior of the generally cylindrical body ( 2 ) includes at least one slots (e.g. 31 , 32 , 33 ), wherein each of the at least one slots is in communication with one of the at least one radial vent holes. There may be at least one coaxial annular baffle ( 16 ) created by the annular patterns of radial vent holes ( 10 ) as they converge and intersect toward the coaxial passageway ( 4 ). FIGS. 1 c , 3 c and 5 c depict that each of the at least one slots (e.g. 31 , 32 , 33 ) gradually increase in diameter from the radial vent hole ( 10 ) to the exterior.
[0041] According to one embodiment a muzzle device for a firearm is provided, the device comprising: a generally cylindrical body ( 2 ) adapted for attachment to the muzzle of a firearm barrel; wherein the generally cylindrical body ( 2 ) includes a coaxial passageway ( 4 ) in front of and communicating with the muzzle; wherein the generally cylindrical body ( 4 ) includes a coaxial exit hole ( 18 ) in front of and communicating with the coaxial passageway ( 4 ); wherein the coaxial passageway ( 4 ) and the exit hole ( 18 ) are sufficiently large to allow the passage of the fired bullet; wherein the coaxial passageway ( 4 ) includes at least one radial vent hole ( 10 ) that passes through a side of the generally cylindrical body ( 2 ) between the coaxial passageway ( 4 ) and the outside atmosphere; wherein an exterior of the generally cylindrical body ( 2 ) includes at least one slot (e.g. 31 , 32 , 33 ) in communication with and radiating away from one of the radial vent holes ( 10 ) and exiting the side (or exterior) of the generally cylindrical body ( 2 ). Each of the at least one slots (e.g. 31 , 32 , 33 ) radiates from one of the at least one radial vent holes ( 10 ). The coaxial passageway ( 4 ) may be less than 1.5 times the bullet diameter. According to one embodiment, there may be at least ten radial vent holes. As depicted in FIGS. 1 c , 3 c and 5 c , the coaxial passageway ( 4 ) may include several circular arrays of radial vent holes patterned in a linear direction along the axis of the coaxial passageway between the coaxial passageway and the outside atmosphere. The coaxial passageway ( 4 ) may also include a series of spaced coaxial annular baffles ( 16 ) formed by the convergence of radial vent holes ( 10 ) before they reach the coaxial passageway ( 4 ), wherein the spaced coaxial annular baffles ( 16 ) divert propellant gases away from the path of the bullet into the radial vent holes ( 10 ). The coaxial annular baffles ( 16 ) may be shaped to divert propellant gases away from the path of the bullet into the radial vent holes ( 10 ). They may be for example, chamfered. The effective cross-section at the point where the slot intersects the exterior of the generally cylindrical body ( 2 ) may be between 1.1 and 2 times the minimum full cylindrical diameter of the radial vent hole ( 10 ). According to one embodiment, the cross-section may increase at a rate equal to that of a geometric cone starting at the minimum full cylindrical diameter and diverging with an included angle of not more than 50 degrees. According to another embodiment, the cross-sectional area may increase at an approximately linear rate as a function of distance from the axis of the coaxial passageway.
[0042] With reference to FIGS. 8 a and 8 b , the shortest distance measured from the virtual cylindrical wall ( 201 ) of the radial vent hole along the exterior surface of the cylindrical body ( 2 ) to the farthest point ( 202 ) that the slot ( 31 ) radiates outward may be greater than half of the maximum width ( 203 ) of the slot. The depth ( 204 ) measured from the exterior of the body may be greater than the maximum width ( 203 ) of the slot.
[0043] While this invention may be embodied in many different forms, there is illustrated in FIGS. 61 a - 6 d and FIG. 7 a preferred embodiment comprising a cylindrical body ( 102 ) having a coaxial passageway ( 104 ) preferably less than 2.5 bullet calibers in diameter and preferably between 5 and 8 bullet calibers in length, forward of and communicating with a coaxial threaded bore ( 122 ) for attaching the muzzle device to the threaded muzzle of a firearm barrel. The coaxial passageway ( 104 ) communicates with the longitudinal front slots ( 126 ) through the coaxial exit hole ( 118 ), which is preferably smaller than the coaxial passageway ( 104 ), but sufficiently large to permit passage of a fired bullet. When the firearm is fired, the bullet exits the muzzle of the gun and travels along the coaxial passageway ( 104 ) of the attached muzzle device and exits through the coaxial exit hole ( 118 ) at front end of the muzzle device.
[0044] The coaxial passageway ( 104 ) extends along the longitudinal axis of the muzzle device and includes a series of preferably between 5 and 15 closely spaced coaxial annular baffles ( 116 ) that divert propellant gases away from the path of the bullet into a single circular array of radial vent holes ( 110 ) at the root of each annular baffle ( 116 ). The series of coaxial annular baffles may divert propellant gases away from the path of the bullet into the vent holes. These radial venting holes ( 110 ) channel propellant gases through the cylindrical body ( 102 ) of the muzzle device with a velocity vector that is preferably orthogonal to the longitudinal axis of the muzzle device. The radial vent holes ( 110 ) are preferably between 0.045 and 0.065 inches in diameter with preferably between 10 and 20 holes in each circular array. The vent holes may have a cross-sectional area small enough to impede the shock wave propagation and flow of exhausting propellant gases through the side of the generally cylindrical body to a level sufficient to reduce the concussion imposed on personnel to the side and rear vicinity of the device; wherein the cross-sectional area may be less than the fraction of one divided by two hundred and fifty ( 1/250) of a square inch.
[0045] The circular arrays of radial vent holes ( 110 ) may be arranged in such a way that the bottom of the muzzle device is closed ( 124 ) to prevent the vectoring of propellant gases downward, effectively reducing ground disturbance while at the same time creating a reaction force that pushes the muzzle downward to counteract muzzle climb.
[0046] On the exterior cylindrical body ( 102 ) of the muzzle device adjacent to the axial passageway ( 104 ) there is a series of axial slots ( 114 ) and circumferential slots ( 112 ). These slots are positioned in such a way that they intersect at the points where the radial vent holes ( 110 ) exit the cylindrical body ( 102 ) of the muzzle brake forming nodes ( 111 ). A preferred embodiment is shown in FIG. 7 in which the axial slots ( 114 ) and circumferential slots ( 112 ) are of sufficient width that the four corners at each node ( 111 ) formed by the intersection of the two slots, either slightly touch or come close to touching the walls of the radial vent holes ( 110 ).
[0047] When the firearm is fired, high pressure propellant gases are channeled through the radial vent holes ( 110 ) into each node ( 111 ) of the matrix of axial slots ( 114 ) and circumferential slots ( 112 ), where due to the increased cross-section and increased surface area, the gases are expanded and cooled before being released to the atmosphere. It is also believed that the four corners of each node ( 111 ) function in a similar manner as the prongs do on modern high efficiency open prong flash hiders, by disrupting shock wave formation, which is known to be a necessary process in the generation of muzzle flash. If the matrix of axial slots ( 114 ) and circumferential slots ( 112 ) are of a sufficient relative depth the propellant gasses will be cooled and the shock formation reduced to a sufficient level that the unburned gas components will be less susceptible to ignite upon entering the oxygen rich outside atmosphere, and secondary flash will be suppressed. For effective flash suppression, the depth of both the axial slots ( 114 ) and circumferential slots ( 112 ) may range from as little as one time the width of the slot, to as much as five times the width of the slots. The slots are of a sufficient relative depth necessary to effectively expand, cool, and disrupt shock wave formation of exhausting propellant gasses. The depth measured from the exterior surface of the body may be greater than the maximum width of the slot.
[0048] There may be, according to one embodiment, three longitudinal front slots ( 126 ) at the front of the muzzle device that communicate with the axial passageway ( 104 ) through the coaxial exit hole ( 118 ). The longitudinal front slots ( 126 ) disrupt shock wave formation while expanding and cooling the unburned propellant gases escaping through the coaxial exit hole ( 118 ) into the oxygen rich outside atmosphere, and in doing so prevent ignition and flash at the front of the muzzle device.
[0049] FIGS. 9 a , 9 b , 9 c and 9 d depict another embodiment with a 1.5 caliber diameter coaxial passageway ( 4 ) with an exit hole ( 18 ) that is sufficiently large to pass a fired bullet. The coaxial annular baffles ( 16 ) may further be chamfered or shaped in a way to more efficiently divert propellant gases away from the path of the bullet into the radial vent holes. The top and bottom of brake are closed in this embodiment to direct more gas out the sides of the brake and reduce ground disturbance.
[0050] FIGS. 10 a , 10 b , 10 c and 10 d depict another embodiment. In this embodiment, there are shaped coaxial annular baffles ( 16 ). Also, each vent hole ( 10 ) communicates with four slots ( 112 and 114 ).
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A muzzle device that may be attached to the barrel of a forearm that includes structures which influence the flow characteristics of exhausting propellant gases for suppressing muzzle flash, counter acting the rearward and upward motion of the muzzle during firing, and reducing the concussion directed towards the shooter as well as personnel to the sides of the shooter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/546,472 filed Aug. 24, 2009 issued as U.S. Pat. No. 8,430,147, which is a continuation of U.S. application Ser. No. 11/185,927 filed Jul. 19, 2005,which issued as U.S. Pat. No. 7,578,333 on Aug. 25, 2009, which claims the benefit of U.S. Provisional Application No. 60/589,748 filed Jul. 20, 2004, the entire content of which are expressly incorporated herein by reference thereto.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in the manufacture of air filled cushions. In particular, although not exclusively, this invention relates to air cushions of thin-walled plastic sheet, which can be used as infill or cushioning in the packaging and transportation of fragile articles.
2. Description of Related Art
Conventionally, air filled cushions are manufactured from a roll of plastic tubing. A typical example of a method of manufacturing these cushions is described in International Patent Application WO 01/21391, incorporated by reference herein in its entirety. In this method the plastic tubing is drawn through the machine from a supply roll. The walls of the plastic tubing are separated by drawing the tubing over a separator member. Air is then injected into the space between the wall through a needle, which pierces one of the walls of the tube, the hole left by the needle later being isolated by a heat seal. This process requires careful coordination of the position of the separator member and the air injecting needle, and good control of the air injecting needle so that only one wall of the tubing is pierced.
A different way of manufacturing air filled cushions is to pre-perforate the plastic tubing and blow air into the tube through the perforations. Again, this requires careful coordination of the position of the injection head and the plastic tubing.
Both of these processes are stop-start processes, in that the movement of the plastic tubing through the machine must be halted whilst the cushion is filled. Other references disclosing such processes include U.S. Pat. Nos. 4,049,854, 3,868,285, 3,667,593, and 3,366,523, each of which is incorporated by reference herein in its entirety. The throughput rate of the machines is therefore limited. Furthermore, since both processes inject air into the cushions through relatively small holes, a high pressure air injection system, including an air compressor, can be required.
Various attempts have been made to develop a continuous process for filling air cushions, but have been only partially successful, problems being encountered in a number of areas. The difficulty of injecting air into a moving cushion leads to problems with under and over inflation of the cushions. One solution to this has been to inject air into the cushion using high pressure bursts of air, but this requires a high pressure air injection system and a complex control system. Such systems are described in, for example, U.S. Pat. Nos. 4,017,351, 3,817,803, 6,582,800, 6,659,150, 6,209,286, 5,824,392, 6,410,119 and U.S. Patent Publication No. US 2003-0163976, each of which is incorporated by reference herein in its entirety.
An additional problem relates to the heat sealing mechanism. When the machine must be stopped the heat sealer cools down, and when it is restarted the heat sealer takes a small amount of time to reach operating temperature, so that one or more air cushions can not be formed properly.
Moreover, further difficulties are encountered in conventional machines, including difficulty of machine set-up, particularly in drawing the tubing into and through the machine.
SUMMARY OF THE INVENTION
The purpose and advantages of the present invention will be set forth in and apparent from the description that follows, as well as will be learned by practice of the invention. Additional advantages of the invention will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described, the invention includes a machine for the production of air filled cushions including a drive mechanism which is operative continuously to move plastic tubing through the machine along a predefined path, and an injector located in the predefined path disposed within the plastic tubing as the tubing is moved through the machine.
In further accordance with the invention, the injector has an inlet and an outlet and the drive mechanism is operative to move the plastic tubing over the outlet of the injector, whereby air can be injected through the injector into the plastic tubing. In this way, relatively low pressure air can be used, allowing for the use of a simpler air delivery and/or control system. Preferably the pressure is less than 5 psi, and most conveniently a pressure of 1-2 psi is used. The injector can be provided with a single outlet, but preferably has two or more outlets, arranged around its periphery, each outlet being operative to inflate a portion of the plastic tubing. Preferably the injector is provided with a cutter, upstream of the inlet, to cut a surface of the plastic tubing, allowing the plastic tubing to pass around the inlet.
In further accordance with the invention, the machine can be adapted for use with plastic tubing having two rows of transverse, parallel, welds, the welds of each row extending toward a longitudinal centerline of the tubing from a respective one of the side edges. Furthermore, a weld of one row can be generally co-linear with a weld of the other row, with an unwelded section between them. In use, the injector can be located generally within the unwelded section, whereby at least one outlet of the separator member can be operative to inflate portions of the plastic tubing defined by adjacent welds in each row.
In further accordance with the invention, the machine can include a sealing mechanism. The sealing mechanism can be located downstream of the outlet so as to seal the plastic tubing longitudinally. Preferably the sealing mechanism is a heat sealer mechanism, which has an operating position in which it abuts the plastic tubing and a standby position in which it is removed from the plastic tubing and the heat sealer can be moved from the operating position to the standby position when the machine is stopped. In a preferred embodiment the heat sealer comprises at least two spaced elongate bars, which are preferably generally equal in length to the air filled cushions produced by the machine. This ensures a good seal can be achieved.
In further accordance with the invention, the machine can further include a perforator. The perforator can be located downstream of the sealing mechanism, whereby the perforator is operative to perforate the plastic tubing longitudinally. Preferably the machine further comprises a barrier, upstream of the injector, which is operative to maintain portions of the tubing deflated. The machine can also include a pressure sensor which is operative to place an outlet in fluid communication with the inlet if the pressure in the injector becomes too high. The machine can be provided with further sensors and control mechanisms, such as a speed sensor and control and an inflation sensor and control.
In accordance with another aspect of the invention, there is further provided a roll of tubing that is sealed transversely at a succession of spaced intervals along its length by pairs of seals, each seal extending in a line from a respective opposite edge of the plastic tubing to a short distance from the centre thereof. Preferably the seals have little or no significant longitudinal components. The tubing can be made of a plastic material, but can also be made at least in part from other materials such as paper that is sealed using an adhesive or other means.
In further accordance with the invention, a method is provided of producing air filled cushions. The method includes providing a roll of tubing being sealed transversely at a succession of spaced intervals along its length, by pairs of seals, each seal extending in a line from a respective edge of the plastic tubing to a short distance from the centre thereof, continuously inflating the tubing between successive seals to form inflated cushions, and sealing the tube along at least one longitudinal line. Preferably, the tube is sealed along at least two longitudinal lines where each longitudinal seal extends across two transverse seals.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the invention claimed.
The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the method and system of the invention. Together with the description, the drawing serves to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, selected by way of example, will now be described, with reference to the following drawings, in which:
FIG. 1 shows schematically a perspective view of internal components of a machine suitable for the manufacture of air-filed cushions;
FIG. 2 shows schematically a section view of the internal components of the machine during the manufacturing process;
FIG. 3 shows schematically a section view of the internal components of the machine when opened to load or unload plastic tubing;
FIG. 4 shows schematically a top view of the internal components of the machine during the manufacturing process;
FIG. 5 shows schematically a portion of plastic tubing suitable for use in the machine;
FIG. 6 shows schematically a rear view of the machine; and
FIG. 7 shows schematically a second embodiment of the invention, having a more compact structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. The method and corresponding steps of the invention will be described in conjunction with the detailed description of the system.
The methods and systems presented herein may be used for providing packaging cushions for cushioning articles during shipment. For purpose of explanation and illustration, and not limitation, an exemplary embodiment of the system in accordance with the invention is shown in FIG. 1 and is designated generally by reference character 10 .
The internal components of a machine for the manufacture of gas-filled (preferably air-filled) cushions is illustrated in FIG. 1 . The machine 10 comprises an air barrier 11 , an injector 12 , heat sealers 14 , and pull rollers or drive rollers 16 , which incorporate a perforator 18 . These components of the machine 10 define a path along which tubular film passes through the machine 10 .
A variety of materials can be used for the film material. Most preferably, a plastic material of varying weights of polyethylene can be used. However, other types of plastic films can be used as desired, including metallized plastic films and the like. Moreover, other materials such as paper based films can also be used that are sealed with adhesive material, or paper films having a thin polyethylene coating to facilitate sealing can also be used.
As depicted herein, the air barrier 11 is disposed upstream of the injector 12 and includes two tracked belts. These belts are preferably made from spongy, rubberized tracking material. The injector 12 comprises an elongate hollow tube having an air inlet 20 and a plurality of outlets 22 . At its upstream end it has a smooth rounded tip 24 . The outlets 22 are disposed close to the tip 24 and comprise a pair of elongate slits which are disposed diametrically opposite from each other on the circumference of the injector 12 .
In further accordance with the invention, as depicted herein, heat sealers 14 are disposed downstream of the injector, adjacent to the outlets. Since heat sealers 14 are identical, only one heat sealer will be described. As depicted herein, for purposes of illustration and not limitation, heat sealer 14 includes two belts 40 , each belt 40 arranged around four wheels: a drive wheel 42 , a tensioner wheel 44 and two idler wheels 46 , 48 . The two belts 40 run parallel and adjacent to each other between the idler wheels 46 , 48 and between them define a path through which the plastic tubing is drawn. Four heat sealing blocks 50 , 52 , 54 , 56 are disposed along this portion of the belts arranged in pairs of blocks of which one is positioned above and one is positioned below the belts. The upper upstream one of these blocks 50 is heated sufficiently to weld the plastic tubing together and all four blocks 50 , 52 , 54 , 56 are spring loaded to press together and close the belts onto the plastic tubing, providing sufficient pressure to complete the seal.
For purposes of illustration and not limitation, as embodied herein, the inlet 20 is a hollow tube, which is disposed downstream of the sealing rollers. Inlet 20 projects downwardly from the injector 12 . A cutter, preferably a knife 30 , is disposed at the upstream end of the inlet 20 , and projects diagonally between the inlet 20 and the injector 12 . It should be noted that a hot wire could be used instead of or in addition to a cutter. The inlet 20 also supports the machine 10 , being attached to a superstructure (not shown) which hold s the injector 12 in a fixed position in use. Various of the rollers and drive band wheels are also supported, being attached to the side of the machine by axles 60 , 62 , as shown in FIG. 4 . The pull rollers 16 are arranged just downstream of the inlet 20 and the injector 12 . The perforator 18 is arranged along the centerline of the machine 10 , to perforate between the seals produced by the heat sealers 14 .
For purposes of illustration and not limitation, as embodied herein, FIG. 2 illustrates the machine 10 in use, with polythene tubing being drawn through it. FIG. 4 provides a top view of the air cushion production process. A tube 32 of polythene film, typically 400 mm wide, is provided.
The tube 32 of film can be provided on a roll mounted on an unwind shaft as depicted, or can be supplied in fan-folded form in a box, as desired. Moreover, a support cradle can alternatively be used as depicted in WO 01/21391. Such a cradle can be advantageous in that a roll of film 32 can be placed thereon with a minimum of effort. Using a cantilevered unwind shaft can be disadvantageous to the extent that the roll of film 32 has to be further manipulated to fit it over the shaft. Merely requiring the roll to be placed on top of two rollers in a cradle arrangement minimizes the need to maneuver the roll, thereby minimizing the time required for an operator to hold the roll of film 32 . This results in a time savings, and, more importantly, reduces the chances for operator injury (particularly back strains) as rolls of film 32 can be quite heavy if they are large.
The tubing, shown in FIG. 5 , has two rows of transverse, parallel welds or seals, 34 , 35 . The tube 32 can also be pre-perforated across its width, along the line of the transverse seals 34 , 35 . The rows of seals 34 , 35 extend toward a longitudinal centerline of the tubing 32 from a respective one of the side edges, a weld of one row 34 being generally co-linear with a weld of the other row 35 , and the rows of welds having an unwelded portion between them.
As an alternative to perforations, score lines can additionally or alternatively be used to separate cushions from one another. Score lines can present the additional advantage that air leakage is minimized during inflation. Moreover, not having perforations across the inflation channel of the roll of film 32 can prevent the film from getting caught on the inflation tube, as it is known that perforations can cause such problems, thereby requiring the machine to be shut off, thereby reducing efficiency. Score lines can be formed on the roll of film 32 by mechanical deformation. More preferably, the score lines can be formed by way of laser scoring. Laser scoring is advantageous in that it permits precise control of the depth of the score line, permitting unprecedented flexibility and control on the amount of force needed to separate air filled cushions from one another.
To load the polythene tubing 32 onto the machine, the air barrier 11 is lifted apart, as shown in FIG. 3 , and the injector 12 is inserted into the tubing at the unwelded portion between the rows of the transverse seals 34 , 35 . The upper halves of the heat sealers 14 can be pivoted into a standby position, as shown in FIG. 3 so that the plastic tubing 32 can be drawn over the injector 12 and positioned between the pull rollers 16 . The polythene tubing 32 is drawn through the machine 10 by the tracks which make up the air barrier 11 , by the belts 40 of the heat sealers 14 and by the pull rollers 16 . The pull rollers 16 operate marginally more quickly than the rest of the machine which places the tubing 32 under tension, even to the extent where some slippage through the rest of the machine can occur. In normal operation the tubing 32 is continually drawn from the roll of film 32 through the air barrier 11 by its tracks. The two layers of the tubing 32 are separated in its central, unwelded portion on reaching the smooth, rounded tip 24 of the injector 12 . Air, at atmospheric pressure, enters the injector member 12 at the inlet 20 and is continually blown through the injector member to the outlets 22 .
The presence of the air barrier 11 prevents excess upstream inflation. As the tubing 32 is drawn past the outlets 22 the portions of the tubing defined by adjacent welds 34 , 35 in each row become inflated, as shown in FIG. 2 . Since the injector 12 is disposed centrally in the tubing, with outlets 22 directed to either side, two portions, one at either side of the injector 12 are inflated as the tubing 32 is drawn over the outlets 22 . To encapsulate the air in each portion the open side of each portion is sealed by heat sealers 14 . These produce two longitudinal welds 36 which each join a pair of transverse welds 34 , 35 , sealing off the inflated air cushions. The downstream sealing blocks 54 , 56 compress the tubing over the longitudinal weld 36 , making it more secure.
Once sealed the tubing 32 must pass the inlet 20 of the injector member. To allow the tubing to pass around this inlet 20 the lower face of the tubing 32 is slit as it passes the knife 30 disposed just upstream of the inlet. The pull rollers 16 draw the tubing toward the perforator 18 . The perforator 18 produces a row of perforations 38 in the centre of the bottom face of the tubing, between the longitudinal welds. These perforations allow the tubing to be separated longitudinally if desired. Alternatively, roll of film 32 can be provided with perforations pre-formed therein.
Finished cushions 64 , supported by a cushion bed plate 66 are shown in FIG. 6 , just before they leave the machine. This machine 10 has a much higher output rate than previous machines, both because it is able to run continually, and because it can produce two streams of air cushions at once. Since the air can be injected through relatively large outlets 22 there is no need for compressed air to be used. The machine, 10 is, therefore, simple to use, having just an on-off and a temperature control. Further controls, such as a speed control and an inflation control could be added to the system if desired.
The machine 10 is able to produce air cushions which are joined together to form a matrix of cells. Since these cells are more difficult to force apart they are more effective at protecting packages with irregular shapes. Furthermore, since the machine 10 can inflate multiple cushions through one central tube it uses the plastic tubing more efficiently than previous machines and generates less waste.
Although the machine 10 is designed to run continually it is sometimes necessary to stop it during a production run to maintain or repair the equipment. This can cause problems with the heat sealers 14 , since conventionally the heated block 52 has to be cooled, to prevent the tubing being melted, and thus, when production is restarted, there is a warm-up time before it becomes operationally effective, during which cushions are unsealed and lost. This machine provides a facility for such eventualities. A top half of the heat sealer 14 is defined by the upper belt 40 , its four wheels 42 , 44 , 46 and includes the upper heated sealing block 50 and the other upper sealing block 54 . This half of the heat sealer is pivotally mounted along the axis of drive wheel 42 so that it can be swung away from its operative position, in which the portion of the belt between the idler wheels abuts the plastic tubing, to a standby position in which the belt lies away from the plastic tubing. This means that, should the machine need to stop during a production run the upper upstream sealing block can remain hot, ideally being maintained at a somewhat lower, standby, temperature by a thermostat. When the machine 10 is restarted the top section of the heat sealer 14 is pivoted back into its operating position and, since the heated sealing block 52 is still hot the sealing process can be immediately continued without losing any cushions.
A second embodiment will now be described only in as much as it differs from the first embodiment, the same reference numerals being used for the same parts. If desired the machine 10 a can be made more compact, as shown in FIG. 7 . The injector 12 a has been shortened in this embodiment so that the inlet 20 a projects downwards just downstream of the heat sealing blocks 50 a , 52 a , 54 a , 56 a . Furthermore the pull rollers 16 a form the driving element for the heat sealer belts 40 a , the other wheels 42 a, 44 a, 46 a , being idler wheels. The perforator 18 a is thus arranged just downstream of the inlet 20 a . Since the upper heat sealer 14 a is still capable of pivoting to a standby position the perforator 18 a is arranged on the lower pull roller 16 a . Since the injector 12 a is significantly shorter in this arrangement even less pressure is required to cause air to flow to the outlets 22 a , making the machine 10 a even more efficient to run.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, can, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof. Such combinations extend to novel combinations of devices and methods expressly disclosed herein, alone or in combination with devices and references incorporated herein by reference.
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A device and method are disclosed for forming air filled cushions. The device includes a drive mechanism to move inflatable tubing through the apparatus, and an injector, optionally including an outlet, located continuously within, or within a portion of, the tubing. This arrangement can permit the formation of air filled cushions in a continuous stream. Also disclosed is a roll of plastic tubing that is sealed transversely at a succession of intervals, with each pair of seals stopping just short of a longitudinal center line of the tubing. Such tubing might be used in conjunction with the apparatus, the central gap between the seals allowing passage of the injector.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable communication apparatus such as a mobile telephone or the like, and more particularly, to a portable communication apparatus having a function of informing a user carrying the same of occurrence of an incoming call.
2. Description of Related Art
A portable telephone is a typical mobile communication apparatus. In general, the portable telephone is provided with an alert device for informing the user, by sound and/or silent vibration, of the occurrence of an incoming call. The user can select one or both of the audible alert and the vibration alert.
In the case where only the silent vibration alert has been selected, however, the user cannot be informed without having such a portable telephone on his/her person or making physical contact with it. Therefore, when the portable telephone is put in a bag or the like, the silent vibration alert is made in vain. To avoid such a case, many users select the audible alert.
In the case where the audible alert has been selected, however, a sounder sounds alert tone when an incoming call occurs, making a nuisance of itself. As a function of stopping the audible alert as soon as possible, an Any-key answer function has been proposed in Japanese Patent Application Laid-open Publication No. 10-107874. The Any-key answer function stops the sounder and start communication by the user depressing not only a start key but also any key of ten keys, 0-9, symbol keys (*, #) and other keys. Therefore, the user can stop the sounder without looking at the keypad provided in the portable telephone, resulting in rapid alert stop.
The portable telephone disclosed in the above Japanese Patent Application Laid-open Publication No. 10-107874 also provides another useful function called a response hold function. The response hold function is useful in the case where the user cannot respond to an incoming call immediately. More specifically, when an end key is depressed on incoming call, the sounder is stopped and the portable telephone sends a caller a message such that the called party cannot respond to this call immediately, and the caller is put on hold. When a start key is depressed, the telephone communication can be made.
However, according to the above-described conventional portable telephone, when the user depresses any key in the Any-key answer mode, the audible alert is stopped and, at the same time the portable telephone responds to the incoming call to be set to the communication mode. This would cause the calling party to start talking. If the calling party receives silence from the called party, the calling party may determine that some failure occurs and then is likely to disconnect the established line. To avoid such disconnection, the called party must start conversation, which will conversely make a nuisance of itself.
On the other hand, the response hold function provides transmission of a message that the called party cannot respond to this call immediately. Therefore, it is not necessary to start conversation immediately. However, there is a strong possibility that the calling party promptly disconnects the call because it is determined that it makes a nuisance of itself or partly because it cannot be determined how long the calling party is kept waiting. When the called party depresses the start key, the incoming call would be disconnected already.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a portable communication apparatus and a control method that can stop an alert indicating an incoming call so that the calling party does not disconnect the call.
According to an aspect of the present invention, a portable communication apparatus includes an alert device for producing an alert when an incoming call occurs and an input device having a plurality of keys. The alert device producing the alert is controlled to stop the alert while holding the incoming call depending on a first predetermined operation of the input device.
The portable communication apparatus is capable of responding to the incoming call held when a second predetermined operation of the input device is performed after the first predetermined operation.
According to another aspect of the invention, a portable communication apparatus further includes a key function changer for changing logical functions of the plurality of keys based on a predetermined rule depending on a change in operation mode of the portable communication apparatus. The alert device producing the alert is controlled to stop the alert while holding the incoming call when a key having a predetermined logical function is operated.
The key function changer preferably includes a memory storing a table of correspondence between the plurality of keys and a plurality of logical functions for an alert operation mode. Referring to the table, it is determined whether the key having the predetermined logical function is operated.
Preferably, a plurality of keys have the predetermined logical function assigned thereto. All the keys may have the predetermined logical function assigned thereto. All the keys other than a predetermined key may have the predetermined logical function assigned thereto and the predetermined key has a logical function of responding to the incoming call assigned thereto. Further, all the keys other than a plurality of predetermined keys may have the predetermined logical function assigned thereto and the respective predetermined keys have a logical function of responding to the incoming call assigned thereto. Alternatively, a single key may have the predetermined logical function assigned thereto.
The key function changer preferably includes a first memory for storing function setting data Including a quick-silence function flag and a second memory storing a table of correspondence between the plurality of keys and a plurality of logical functions for each of an alert operation and alert stopped modes in a case where the quick-silence function flag is set. Referring to the function setting data and the table, it is determined whether the key having the predetermined logical function is operated.
According to further another aspect of the present invention, a control method for a portable communication apparatus including an input device having a plurality of keys, includes the steps of: assigning a silence function to at least one of the plurality of keys for an alert mode; producing an alert when an Incoming call occurs; and stopping the alert while holding the incoming call when a key having the silence function assigned thereto is operated.
Further, the method preferably includes the step of: assigning a response function to at least one of the plurality of keys for an alert stopped mode; and responding to the incoming call hold when a key having the response function assigned thereto is operated.
As described above, according to the present invention, the alert indicating the occurrence of an incoming call can be stopped while holding the incoming call. Since the incoming call is maintained, the calling party continues to hear a ringing tone when the alert has been stopped at the called party, resulting in a reduced possibility that the calling party disconnects the call.
Further, in the case where a silence function is assigned to a plurality of keys, the alert can be stopped while holding the incoming call by depressing any of the silence keys, resulting in rapid alert stop.
Furthermore, in the case where a response (off-hook) function is assigned to a plurality of keys after the alert has been stopped, the response to the incoming call can be rapidly performed by depressing one of the plurality of response keys.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing an internal circuit structure of a portable telephone as an embodiment of a portable communication apparatus according to the present invention;
FIG. 2 is a perspective view of the portable telephone according to the present embodiment of FIG. 1;
FIG. 3 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a first embodiment of the present invention:
FIG. 4 is a format diagram showing a function setting area of an BEPROM included in the portable telephone as shown in FIG. 1;
FIG. 5 is a diagram showing examples of display according to a Quick-silence setting operation;
FIG. 6 is a flow chart showing a control operation when an incoming call occurs according to the present invention;
FIG. 7 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a second embodiment of the present invention;
FIG. 8 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a third embodiment of the present invention;
FIG. 9 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a fourth embodiment of the present invention;
FIG. 10 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a fifth embodiment of the present invention; and
FIG. 11 is a diagram showing an example of a table for the correspondence of physical keys and logical keys according to a sixth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, inside a portable telephone according to an embodiment of the present Invention, there are built an antenna 101 , a radio system 102 , a control unit 103 , and other circuits as described below.
The antenna 101 is connected to the radio system 102 , which performs transmission/reception of a radio signal under the control of the control unit 103 including a channel controller, a speech processor, and a microprocessor (CPU). The control unit 103 controls the operations of the portable telephone using a read-only memory (ROM) 104 , a random access memory (RAM) 105 and a non-volatile memory 106 . The ROM 104 stores control programs, which run on the microprocessor of the control unit 103 , and other necessary control data including a physical-logical key correspondence table as described later. The RAM 105 temporarily stores various kinds of data. The non-volatile memory 106 may be an electrically erasable programmable ROM (EEPROM), which stores function setting data and an identification number (here, the telephone number of its own).
A user's instruction is input by a user operating an input device 107 composed of a plurality of keys including numerical and symbol keys and other function keys (see FIG. 2 ). The portable telephone is provided with an alert device composed of a sounder and/or a silent vibrator. In this embodiment, the control unit 103 controls a sounder driver 108 to drive a sounder 109 so that an audible alert indicating occurrence of an incoming call is produced. Alternatively, the control unit 103 can be set to control a vibrator driver 112 to drive a vibrator 113 so that a silent alert indicating occurrence of an incoming call is produced. Both the sounder 109 and the vibrator 113 can be also driven to produce the audible and silent alerts when an incoming call occurs. The control unit 103 controls a speaker driver 110 to drive a speaker 111 so that the voice of the opposite party is produced. The control unit 103 receives the voice signal of the user from a microphone 115 through an amplifier 114 . Further, the control unit 103 controls a display driver 116 to drive a display device 117 such as a liquid crystal display (LCD) and an incoming call Indicating lamp 118 such as a light-emitting diode. The incoming call indicating lamp 118 blinks as a visible alert when an incoming call occurs. It should be noted that a power supply circuit including a battery is not shown in this figure for simplicity.
Referring to FIG. 2, the portable telephone 100 has the antenna 101 and the incoming call indicating lamp 118 on the top thereof. The speaker 111 , the microphone 115 , the display 117 and the input device 107 are provided in the main surface of a housing of the portable telephone 100 . The input device 107 has a layout of various keys 201 - 211 . The sounder 109 is provided on the back side of the housing and an earphone-microphone jack 119 is provided in the side wall of the housing.
In this embodiment, the input device 107 is composed of a display operation keys: a left-arrow key 201 , center key 202 , right-arrow key 203 , and backtrack key 204 . The input device 107 is further composed of a ten-key pad 205 consisting of numerical keys 0 - 9 and symbol keys * and #, voice key 206 , power key 207 , manner key 208 , start key 209 , redial key 210 and end key 211 . A total of 22 keys are provided in a predetermined layout.
When a physical key is depressed, the input device 107 outputs a key code identifying the depressed key to the control unit 103 . The control unit 103 determines a logical key corresponding to the depressed physical key by referring to the physical-logical key correspondence table previously stored in the ROM 104 . As described hereafter, a physical key serves as a logical key depending on the current operation mode.
Referring to FIG. 3, a physical-logical key function correspondence table is previously stored In the ROM 104 . Each of the physical keys 201 - 205 provided in the input device 107 as shown in FIG. 2 changes its operation role depending on an operation mode of the portable telephone. In this embodiment, the operation mode has standby state and incoming call state, the incoming call state having quick-silence function ON mode and any key answer function ON mode, and the quick-silence function ON mode having two states: audible-alert state and alert stop state. As shown in this figure, in the case where the audible alert is being produced by the sounder 109 in the quick-silence function ON state when an incoming call occurs, the control unit 103 logically sets the left-arrow key 201 , the right-arrow key 203 , the backtrack key 204 , the voice key 206 , the redial key 210 , and the ten-key pad 205 for a silence key. Therefore, when the user depresses one of these keys 201 , 203 - 206 , and 210 in this audible alert state, the audible alert is stopped while holding the incoming call. The details of respective keys will be described hereinafter.
As shown in FIG. 3, the power key 207 functions as a power on/off key in any of the operation modes. More specifically, when the power key 207 is depressed for a duratlon of, for example, one second in the power-off state, the portable telephone is powered on and its operation mode becomes the standby state. On the contrary, when the power key 207 is depressed for a duration of, for example, two second in the power-on state, the portable telephone is powered off.
In the case of the standby state, the left-arrow key 201 , the right-arrow key 203 , the backtrack key 204 and the end key 211 do not function, which is referenced by “-” in FIG. 3 . The other keys 202 and 205 - 210 function as logical keys, respectively. The ten-key pad 205 including numerical keys 0 - 9 and symbol keys * and # function as logical keys for inputting numerals 0 - 9 and the symbols * and # and the start key 209 functions as a calling key. Therefore, when the user operates the ten-key pad 205 to input a destination telephone number, the destination phone number is displayed on the display 117 . After checking the displayed phone number, the user depresses the start key 209 to dial. The radial key 210 , which is a well-known function key, is used to read the previously dialed phone number to display it on the display 117 . Then, when depressing the start key 209 , the previously dialed phone number is redialed.
The voice key 206 is used to activate a voice-search function, which is a voice-activated function for stored phone numbers or various functions. The manner key 208 is used to set the telephone for manner mode which is a silent operation mode such that a confirmation sound is not made when a key is depressed, a silent vibration alert indicating the occurrence of an incoming call is produced instead of the audible alert. The center key 202 functions as a menu key in any of the operation states. In the case of menu mode, menu items are displayed on the display 117 and one of the menu items can be selected by operating the left-arrow and right-arrow keys 201 and 202 .
In the incoming call state, the center key 202 and the power key 207 function respectively as the menu key and the power on/off key without changing in logical role among the standby state, the quick-silence function ON state, and the any key answer function ON state. The manner key 208 changes in logical function from the manner mode key to a manner mode and message key when the operation mode changes from the standby state to the incoming call state. In the incoming call state, the logical function of the manner key 208 is kept at the manner mode and message key regardless of whether the operation mode is in the quick-silence function ON state or the any key answer function ON state. The manner mode and message key functions such that a message of the caller is recorded in the manner mode. The start key 209 changes in logical function from the calling key to a response key, or an off-hook key, when the operation mode changes from the standby state to the incoming call state. In the incoming call state the logical function of the start key 209 is kept at the response key regardless of whether the operation mode is in the quick-silence function ON state or the any key answer function ON state. The end key 211 changes in logical function from a nonfunctioning key to a response hold key for activating a repose holding function when the operation mode changes from the standby state to the incoming call state. In the incoming call state, the logical function of the end key 211 is kept at the response hold key regardless of whether the operation mode is in the quick-silence function ON state or the any key answer function ON state.
On the other hand, the respective logical functions of the left-arrow key 201 , the right-arrow key 203 , the backtrack key 204 , the voice key 206 , the redial key 210 , the ten-key pad 205 change depending on whether the operation mode is in the quick-silence function ON state or in the any key answer function ON state. In the any key answer function ON state, these keys 201 , 203 - 206 , and 210 function as the response key as in the case of the start key 209 . In the quick-silence function ON state, however, when the audible alert is being generated, these keys 201 , 203 - 206 , and 210 function as the silence key and, after stopping the audible alert, these keys 201 , 203 - 206 , and 210 do not function.
Referring to FIG. 4, the EEPROM 106 stores the function setting data of the quick-silence/any-key function, the audible alert, and the silent vibration alert, which are used by the control unit 103 to control the respective functions.
As shown in FIG. 4, the function setting area includes a quick-silence function flag 401 , an audible alert flag 402 , and a silent vibration flag 403 . In the case where the quick-silence function flag 401 is set, the quick-silence function is set to “ON” and the any key answer function to “OFF”. Contrarily, in the case where the quick-silence function flag 401 is reset, the quick-silence function is set to “OFF” and the any key answer function to “ON”. In the case where the audible alert flag 402 is set, alert is by the sounder 109 when an incoming call occurs. In the case where the audible alert flag 402 is reset, the sounder 109 does not function even when an incoming call occurs. In the case where the silent vibration flag 403 is set, the vibrator 113 is activated when an incoming call occurs. In the case where the silent vibration flag 403 is reset, the vibrator 113 does not function even when an incoming call occurs.
As shown in FIG. 5, the quick-silence function flag 401 is set by the user operating the keys 201 - 203 and 211 . In the standby screen as shown in FIG. 5 ( a ), for example, date and the time of day are displayed on the display 117 . In this standby screen, the user inputs a predetermined menu number by depressing the center key 202 followed by the corresponding numeral key of the ten-key pad 205 . This causes the control unit 103 to start a quick-silence function setting program to display an operation screen on the display 117 , as shown in FIG. 5 ( b ). Here, since “OFF” is positioned by a highlight bar, the quick-silence function flag 401 is reset.
When the user depresses the left key 201 in such a state, the highlight bar is moved in the left direction and positions “ON” as shown in FIG. 5 ( c ), which means that the quick-silence function flag 401 changes in setting state from Reset to Set. When the user depresses the right key 203 in such a state, the highlight bar is moved in the right direction back to “OFF” as shown in FIG. 5 ( b ), which means that the quick-silence function flag 401 changes in setting state from Set to Reset.
In the state of the quick-silence function flag 401 setting as shown in FIG. 5 ( c ), when the user depresses the end key 211 , the quick-silence function is set to “ON” and the screen of the display 117 returns to the standby screen as shown in FIG. 5 ( d ). Similarly, the other audible alert flag 402 and the silent vibration flag 403 can be set.
Referring to FIG. 6, when an incoming call occurs, the control unit 103 changes its operation mode from the standby state to an incoming-call state and starts the mode control according to the physical-logical key correspondence table as shown in FIG. 3 .
In the case of the incoming-call state, the control unit 103 controls the driver 116 so that a predetermined mark indicating the occurrence of the incoming call is displayed on the display 117 and the lamp 118 blinks and, further selectively controls the sounder driver 108 and the vibrator drover 112 depending on the audible alert flag 402 and the silent vibration flag 403 of the EEPROM 106 (step S 601 ).
Subsequently, the control unit 103 cheaks whether the quick-silence function flag 401 is in the set state (step S 602 ). In other words, it is determined by checking the quick-silence function flag 401 whether the quick-silence function is set to “ON” and the any key answer function to “OFF”.
In the case where the quick-silence function is set to “ON”, and the any key answer function to “OFF” (YES In step S 602 ), the control unit 103 waits for key input (steps S 603 -S 605 ). When receiving a key code from the input device 107 , the control unit 103 determines the logical function of the depressed physical key by referring to the physical-logical key correspondence table as shown in FIG. 3 and then performs the corresponding operation.
More specifically, in the incoming-call state and the audible alert state, as shown in FIG. 3, the respective logical functions of the left-arrow key 201 , the right-arrow key 203 , the backtrack key 204 , the voice key 206 , the redial key 210 , the ten-key pad 205 function as the silence key. Therefore, when the user depresses any of these keys 201 , 202 - 206 and 210 (YES in step S 603 ), the control unit 103 stops the sounder 109 in the case of the audible alert and stops the vibrator 113 in the case of the silent vibration alert while maintaining the incoming call (step S 606 ). At this time, the display alert is still displayed on the display 117 . Since the incoming call is held, from the view of the base station calling this telephone, the calling operation continues.
After having stopped the alert, the control unit 103 waits for key input (steps S 607 and 610 ). When receiving a key code from the input device 107 , the control unit 103 determines the logical function of the depressed physical key by referring to the physical-logical key correspondence table as shown in FIG. 3 . When the response key is depressed (YES in step S 607 ), the display alert is stopped (step S 608 ) and the control goes to the communication mode allowing conversation between the calling and called parties (step S 609 ), since the alert is stopped in the quick-silence function ON state, only the start key 209 functions as the response key as shown in FIG. 3 . When another key is depressed (YES in step S 610 ), the operation mode is changed to the corresponding mode according to the physical-logical key correspondence table as shown in FIG. 3 (step S 611 ). For example, when the end key 211 which now functions as the response hold key is depressed, the control unit 103 changes its operation mode to the response hold mode.
On the other hand, after the quick-silence function has been set to “ON” (YES in step S 602 ), when the response key (here, the start key 209 ) is depressed (YES in step S 604 ), the control unit 103 stops the display alert as well as the audible/vibration alert as in the case of the step S 606 (step S 612 ) and then changes its operation mode to the communication mode (step S 609 ). When any key other than the response key and nonfunctioning keys is depressed (YES in step S 605 ), the operation mode is changed to the corresponding mode (step S 613 ). For example, when the end key 211 which now functions as the response hold key is depressed, the control unit 103 changes its operation mode to the response hold mode.
In the case where the quick-silence function is set to “OFF” and the any key answer function to “ON” (NO in step S 602 ), the control unit 103 waits for key input (steps S 614 and S 617 ). When receiving a key code from the input device 107 , the control unit 103 determines the logical function of the depressed physical key by ref erring to the physical-logical key correspondence table as shown in FIG. 3 . When the response key is depressed (YES in step S 614 ), the control unit 103 stops the display alert as well as the audible/vibration alert as in the case of the step S 612 (step S 615 ) and then changes its operation mode to the communication mode (step S 616 ). As shown in FIG. 3, in this case, the physical keys 201 , 203 - 206 and 210 function as the response key.
When a key other than the response keys is depressed (YES in step S 617 ), the operation mode is changed to the corresponding mode (step S 618 ). For example, when the end key 211 which now functions as the response hold key is depressed, the control unit 103 changes its operation mode to the response hold mode.
As described above, in the quick-silence function ON state and the any key answer function OFF state, when an incoming call occurs and the audible/vibration alert Is by the sounder/vibrator, the user can stop the alert by depressing a silence key while maintaining the incoming call. Since any of the keys 201 , 203 - 206 and 210 functions as the silence key as shown in FIG. 3, the user can easily and rapidly stop the audible/vibration alert.
On the other hand, when the quick-silence function is set to “OFF” as shown in FIG. 5, the any key answer function is automatically set to “ON”. In the any-key answer function ON state, any of the keys 201 , 203 - 206 and 210 functions as the response key as shown in FIG. 3, allowing prompt off-hook operation. It should be noted that the line is disconnected when the calling party performs an on-hook operation before the response key is depressed and the control program shown in FIG. 6 is terminated.
A different assignment of the logical functions to the physical keys can be implemented by modifying the physical-logical key correspondence table as shown in FIGS. 7-11.
As shown in FIG. 7, in the case of the audible-alert state in the quick-silence function ON state, the silence key is assigned to only the left-arrow key 201 and other keys 203 - 205 and 210 do not function. The remaining operations are the same as the case of FIG. 3 and the control flow for the table of FIG. 7 is the same as FIG. 6 .
As shown in FIG. 8, all the keys other than the start key 209 may function as the silence key in the case of the audible-alert state in the quick-silence function ON state. In this case, it is necessary to modify the control flow as follows.
Since only the start key 209 function as the response key after the quick-silence function has been set to “ON” (YES in step S 602 ), the steps S 605 and S 613 are deleted from FIG. 6 and, when the response key is not depressed (NO in step S 604 ), the control goes back to the step S 603 . Therefore, in the case where the quick-silence function is set to “ON” and the any key answer function to “OPP” (YES in step S 602 ), the control unit 103 waits for key input (steps S 603 and S 604 ) and, as shown in FIG. 8, the respective logical functions of all the keys other than the start key 209 function as the silence key. When the user depresses the silence key (YES in step S 603 ), the control unit 103 stops the sounder 109 in the case of the audible alert and stops the vibrator 113 in the case of the silent vibration alert while maintaining the incoming call (step S 606 ). After having stopped the alert, the control unit 103 waits for key input (steps S 607 and 610 ). When the response key (here, only the start key 209 as shown in FIG. 8) is depressed (YES In step S 607 ), the display alert is stopped (step S 608 ) and the control goes to the communication mode allowing conversation between the calling and called parties (step S 609 ). When another key is depressed (YES in step S 610 ), the operation mode is changed to the corresponding mode according to the physical-logical key correspondence table as shown in FIG. 3 (step S 611 ). The following control operation is the same as in the case of FIG. 3 .
As shown In FIG. 9, all the keys 210 - 211 may function as the silence key in the case of the audible-alert state in the quick-silence function ON state. In this case, it is necessary to modify the control flow as follows.
Since no key functions as the response key after the quick-silence function has been set to “ON” (YES in step S 602 ), the steps S 604 , S 605 , S 612 and S 613 are deleted from FIG. 6 and, the control unit 103 waits for the silence key to be depressed. In other words, the control unit 103 waits for any of the keys 210 - 211 to be depressed. When any of the keys 210 - 211 is depressed (YES in the step S 603 ), the control unit 103 stops the audible/vibration alert (step S 606 ) and changes its operation mode to the alert stopped state. The following control operation is the same as in the case of FIG. 3 . Therefore, if the user wants to respond to the incoming call, then the user depresses any key followed by the start key 209 .
After having stopped the audible/vibration alert, the response key may be assigned to a plurality of physical keys.
As shown in FIG. 10, in the case of the audible-alert state in the quick-silence function ON state, the silence key is assigned to the physical keys 201 , 203 - 206 and 210 as in the case of FIG. 3 . After having stopped the audible/vibration alert by depressing the silence key, however, these keys 201 , 203 - 206 and 210 function as the response key. The remaining assignments are the same as the case of FIG. 3 and the control flow for the table of FIG. 10 is the same as FIG. 6 .
As shown in FIG. 11, in the case of the audible-alert state in the quick-silence function ON state, the silence key is assigned to the physical keys 201 , 203 - 206 and 210 as in the case of FIG. 3 . After having stopped the audible/vibration alert by depressing the silence key, however, all the keys 201 - 211 function as the response key. Although the remaining assignments are the same as the case of FIG. 3, the control flow for the table of FIG. 10 is modified as follows. Namely, in the control flow of FIG. 6, the steps S 610 and S 611 are deleted.
In the above embodiments, the present invention is applied to the portable telephone which is provided with the input device 107 having the physical keys 201 - 211 . Alternatively, as the input device 107 , a touch-sensitive panel on the LCD may be employed. More specifically, the display 117 having the touch-sensitive panel thereon displays a layout of keys respectively corresponding to the physical keys 201 - 211 as a screen. The user touches a position corresponding to a desired function/numeral/symbol key to input desired data or instruction.
In the case where the portable telephone has a key invalidating function to avoid undesired key operations which may occur, for example, in a bag, when the key invalidating function is set, all the keys other than the start key 209 and the end key 211 are invalid. In other words, the key invalidating function is given priority over the quick-silence function and the any key answer function.
Further, the present invention can be also applied to a mobile communication device such as an automobile telephone, a cellular telephone, a digital cordless telephone such as PHS (personal handy-phone system).
|
A portable communication apparatus which can atop the alert indicating the occurrence of an incoming call while holding the incoming call is disclosed. A silence function is assigned to at least one key for an alert operation mode. When starting an alert due to an incoming call, the alert is stopped while holding the incoming call when a key having the silence function assigned thereto is operated. A response function in assigned to at least one of the plurality of keys for an alert stopped mode. The response to the incoming call held is performed when a key having the response function assigned thereto is operated.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is a sampling method and a device for obtaining real time, accurate measurements of the fluid composition and mass flow rates in conduits having uniform or non-uniform fluid composition, velocity and temperature profiles. The present invention includes the sampling of all fluids, including gases, aerosols, particulates, liquids and combinations of the same.
[0003] 2. Description of Related Art
[0004] The problem of obtaining real-time accurate measurements of aerosol and gas in processes in conduits with uniform or non-uniform gas velocity, composition, temperature profiles, swirl and turbulence is a common one. Simply inserting a single-point gas sampling probe into a conduit of unknown characteristics only samples the fluid composition in one location which is not representative of the entire flow field in the conduit. The largest error is generally due to the velocity which can easily vary by a factor of five, the composition by a factor of three and temperature by 50% in combustion applications such as in a large coal-fired boiler, for example. In this example, measurement of the excess oxygen and carbon monoxide is a vital parameter to control combustion and improve plant efficiency. Measurement of the emission of particulates from all processes is very important for pollution control. The present invention can also be used to measure particulates as well.
[0005] The applicant is aware of the following references which relate to sampling and measurement of fluid flowing in a conduit.
[0000]
Pat. No.
Inventor(s)
2,523,721
Russell et al
2,614,423
Carbone
4,115,229
Capone
4,290,315
Grönberg
6,164,142
Dimeff
6,642,720
Maylotte et al
6,843,104
Busch
6,862,915
Staphanos et al
2003/018,586
Orieskie et al
[0006] Russell et al disclose an apparatus for analyzing gaseous fuel before it is delivered into the heating chamber. A sample is collected and burned under controlled conditions. The combustion products are analyzed.
[0007] Carbone discloses the measurement of fluid flow through a conduit across the cross-sectional area of the conduit. The mean total differential between the impact pressure and the static pressure actuates a measuring and recording metering mechanism.
[0008] Capone discloses a gas analyzer for analysis of explosive mixtures. A correction loop flow circuit is used to bring a sample past a gas sensing element and back to a common inlet-outlet chamber.
[0009] Gröberg discloses an apparatus for determining the differential pressure and the volumetric fluid flow in a conduit. There is a pipe loop provided with a series of ports for sensing pressure.
[0010] Dimeff discloses an air flow measuring device which present a restricted orifice to the air flow and measure the pressure drop to determine the flow rate.
[0011] Maylotte et al disclose a wireless sensor assembly for measuring selected properties of a gas stream.
[0012] Busch discloses a system for measuring gaseous constituents in a flowing gas mixture. A mixing device in a flow homogenizes the gas mixture before it is detected by the sensor which detects individual gas constituents.
[0013] Staphanoes et al disclose a combustion gas analyzer for measuring the concentration of a gas constituent in an exhaust gas stream.
[0014] Orieskie et al disclose a process flow device which has a self-averaging orifice plate. The volumetric rate of flow is measured by a differential pressure process.
[0015] None of these references disclose a method of using one or more sampling nozzles which direct the fluid sample flow into a manifold wherein the flow rate and composition of the conduit fluid may be analyzed from a small sample stream of fluid having the same properties of the fluid in the conduit, nor a method in which the sample streams are collected independent of each other and collect a sample that represents the product of the fluid composition and the conduit mass flow rate at each nozzle or hole in the probe.
SUMMARY OF THE INVENTION
[0016] It is an object of the present invention to provide a multi-point self-averaging mass velocity and flow area-weighted sampling method for measurement of fluid composition in conduits and the mass flow rate in the conduit.
[0017] In accordance with the teachings of the present invention there is disclosed a sampling device for measuring fluid and particulate composition and flow rates in a conduit having a uniform or a non-uniform composition, velocity, and temperature profiles. The sampling device has a sampling loop having at least one probe mounted on a wall of the conduit with at least one nozzle mounted on the at least one probe and extending outwardly from the at least one probe. At least one sampling nozzle is oriented within the conduit facing into the flow wherein the pressure in the conduit forces a sample through the at least one nozzle into a sample collection manifold connected to the at least one sampling nozzle. Means are provided to adjust the static pressure within the sample collection manifold to be equal to the static pressure within the conduit. A composition measurement chamber is connected to the sample collection manifold. A fluid composition analyzer is connected to the composition measurement chamber wherein a sample is analyzed for each desired constituent, thereby providing a fluid composition representative of the flow in the conduit. A mass flow meter is connected to the composition measurement chamber wherein the flow rate in the composition measurement chamber is measured. Further, the mass flow meter is connected to the conduit through a static pressure port. The product of the flow rate times the fluid composition for each desired constituent provides a mass velocity weighted fluid composition.
[0018] Further in accordance with the teachings of the present invention, there is disclosed a sampling device for measuring fluid composition and flow rates in a conduit having a uniform or a non-uniform composition, velocity, and temperature profiles. The sampling device has a plurality of sampling nozzles disposed across a cross-sectional area of the conduit. Each sampling nozzle communicates with a sample collection manifold. A pressure adjusting means is in communication with the sample collection manifold. A composition measurement chamber is connected to the sample collection manifold. A gas analyzer is connected to the composition measurement chamber. A means for measuring flow rate is connected to the sample collection manifold. In this manner fluid from the conduit is collected in the sampling nozzles and directed into the sample collection manifold. The static pressure in the sample collection manifold is adjusted to be equal to the static pressure in the conduit. The fluid in the composition measurement chamber is analyzed for composition and for flow rate.
[0019] Still further in accordance with the teachings of the present invention, there is disclosed a method for taking a sample of a fluid flowing in a conduit, the fluid having a uniform or a non-uniform fluid composition, velocity, and temperature profile. At least one probe is mounted in the conduit. At least one sampling nozzle is mounted on the at least one probe and extends outwardly from said probe. The at least one sampling nozzle is placed in the conduit facing into the flow at a sampling point, thereby generating a flow of fluid having a mass velocity within the at least one sampling nozzle. Said flow of fluid is linearly proportional to a mass velocity in the conduit at the sampling point. The flow of fluid is directed into a sample collection manifold wherein a sample stream at a static pressure is formed having gas composition properties the same as the fluid in the conduit. The static pressure within the sample collection manifold is adjusted to be equal to the static pressure in the conduit. The flow of fluid is directed from the sample collection manifold into a composition measurement chamber. The composition of the fluid in the composition measurement chamber is measured using a gas analyzer. The flow rate of the fluid in the composition measurement chamber is measured using a mass flow rate meter. The fluid from the flow rate meter is directed back into the conduit through a static pressure point.
[0020] These and other objects of the present invention will become apparent from a reading of the following specification taken in conjunction with the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a diagram of the Sample Loop of the present invention.
[0022] FIG. 2 is a top plan view of the Sampling Probe.
[0023] FIG. 3 is a cross-sectional view taken along the lines 3 - 3 of FIG. 2 .
[0024] FIG. 4 is a cross-sectional view taken along the lines 4 - 4 of FIG. 3 .
[0025] FIG. 5 is a graph showing the Operating Characteristics of the present invention.
[0026] FIG. 6 is a graph showing Pitch and Yaw Data.
PRINCIPLE OF OPERATION
[0027] FIG. 1 shows a simplified drawing of the preferred embodiment of a sampling loop for a single sampling probe assembly. Several such probe assemblies are required for large conduits. Each probe has sample nozzles located at the centroid of equal flow areas in the conduit 10 . The number of sample nozzles and probes is determined by the severity of the non-uniform properties of the velocity, temperature and fluid composition profiles. The Sampling Probe 12 consists of one or more sample nozzles 14 connected to a Sample Nozzle Collection Manifold 16 in which the sampled streams mix and flow through the Particulate Analyzer 38 (if desired), the Particulate Filter 18 (if required), the Fluid Composition Measurement Chamber 20 , Fluid Analyzers 32 , 34 any other measurement devices, Mass Flow Meter 22 and Vacuum Pump 24 or equivalent device. The Sample Nozzle Collection Manifold 16 has Static Pressure Ports 26 mounted flush with the inside wall. The average Conduit Static Pressure Ports 28 are located on the surface of the outer wall of the sampling probe. The preferred embodiment takes advantage of the pressure distribution over a circular tube in cross-flow for which the Conduit Static Pressure occurs at an angle of about 35° on both sides of the flow stagnation point on a circular cylinder. The Conduit Static Pressure Ports 28 are used to obtain the average conduit static pressure. This method gives a very good average static pressure in the presence of swirl and non-axial fluid velocity components in the duct.
[0028] A simplified drawing of the internal structure of the Sampling Probe 12 is shown in FIG. 2 for a two-nozzle sampling system. The basic concept is to use the dynamic pressure of the fluid in the conduit to force a mass-velocity proportional sample flow into each nozzle. The sample stream from each nozzle is collected together and mixed in the Sample Nozzle Collection Manifold 16 and then flows into the Sample Loop depicted in FIG. 1 . The following terms are applicable to FIG. 2 .
M=M A +M B =total mass flow of probe, nozzles A & B M A =ρ A V A2 ×A=mass flow through nozzle A M B =ρ B V B2 ×A=mass flow through nozzle B V A2 is sample nozzle velocity at nozzle A V B2 is sample nozzle velocity at nozzle B
[0000]
A
N
=
area
of
each
flow
nozzle
=
π
d
2
4
d=sample nozzle internal diameter
D=I.D. of sample collection manifold D>>d
θ=static pressure port angle from stagnation point on circular cylinder
ρ A =fluid density at nozzle A
ρ B =fluid density at nozzle B
C A , C B =fluid concentrations at nozzles A, B
T A , T B =fluid temperatures at nozzles A, B
P SA1 =conduit stack pressure at nozzle A
P SB1 =conduit stack pressure at nozzle B
P sa2 =pressure at entrance to nozzle A
P SB2 =pressure at entrance to nozzle B
P SM =static pressure of sample nozzle collection manifold
g c =32.15 ft/sec 2
[0047] FIG. 3 is a drawing, (including definitions of all the variables) for a two-nozzle sample probe. Applying Bernoulli's Equation, the total pressure of the fluid streamlines at Nozzle A is:
[0000]
P
SA
1
+
1
2
ρ
A
V
A
1
2
g
c
=
P
SA
2
+
1
2
ρ
A
V
A
2
2
g
c
Equation
1
[0000] The available pressure difference to drive the sample flow into the sample nozzle and sample manifold is:
[0000]
P
SA
2
-
P
SA
1
=
1
2
ρ
A
V
A
1
2
g
c
-
1
2
ρ
A
V
A
2
2
g
c
Equation
2
[0000] If V A2 =0 then no flow can occur and the device functions as a Pitot Tube and responds to the average pressure in the Sample Nozzle Collection Manifold 16 .
[0048] For sampling purposes, it is desired that the nozzle velocity V A2 be proportional to the local conduit mass velocity V A1 . The sample flow through the nozzles and into the Sample Nozzle Collection Manifold 16 is dependent on the pressure of the Sample Nozzle Collection Manifold Static Pressure (P SM ). Therefore, the following equation applies:
[0000]
P
SA
2
-
P
SM
=
1
2
ρ
V
A
1
2
g
c
-
1
2
ρ
V
A
2
2
g
c
Equation
3
[0049] The maximum sample flow rate occurs when the sample loop is “short-circuited”. If P SA2 −P SM is forced to be equal to 0 then it is obvious that V A1 =V A2 and the system is a self-driven linearly proportional sampler; however, there is a pressure drop caused by the sample nozzle. This pressure drop ΔP n is shown in Equation 4:
[0000]
Δ
P
n
=
C
D
(
1
2
ρ
A
V
A
2
2
g
c
)
Equation
4
[0000] where C D is the nozzle pressure drop coefficient.
[0050] This pressure drop must be accounted for by subtracting it from the right-hand side of Equation 3 as shown below:
[0000]
P
SA
2
-
P
SM
=
1
2
ρ
A
V
A
1
2
g
c
-
ρ
A
V
A
2
2
g
c
-
C
D
1
2
ρ
A
V
A
1
2
g
c
=
1
2
ρ
A
V
A
1
2
g
c
-
(
1
+
C
D
)
(
1
2
ρ
A
V
A
2
2
g
c
)
If
we
set
P
SA
2
-
P
SM
=
0
Then
1
2
ρ
a
V
A
1
2
g
c
=
(
1
+
C
D
)
1
2
ρ
A
V
A
2
2
g
c
Equation
5
V
A
2
=
V
A
1
1
+
C
D
Equation
6
[0051] Equation 6 demonstrates that the method provides a sample nozzle velocity directly proportional to the local conduit velocity. Therefore, if the static pressure in the Sample Nozzle Collection Manifold is maintained equal to the Conduit Static Pressure the sample nozzle velocity V A2 will be proportional to the local conduit velocity (V A1 ). In practice V A2 is about 90% of V A1 , for gases, for example.
[0052] Additional sample loop pressure drop caused by friction, bends, fittings, valves, Particulate Filter, Gas Composition Analyzers, Mass Flow Meter and will greatly affect the performance of the invention as the Sample Nozzle Manifold Static Pressure will rise above the conduit static pressure and cause the sample rate to decrease; and the nozzle velocity will not be proportional to the local conduit velocity, therefore, not meeting the desired average fluid concentration nor total duct mass flow rate. The solution to this problem and the essence of the present invention is to use a Vacuum Pump 24 or other suitable device to offset any sample loop pressure drops in order to obtain the same result as given in Equation 6. The other devices may be a jet eductor, a fan, a blower or other devices known to persons skilled in the art. By meeting the criteria the operators of each nozzle is independent of the other nozzles, which is a required condition for mass-velocity weighted composition measurements.
[0053] This is accomplished by using an Active Control System 30 in which the Differential Pressure Transmitter 42 measures the difference between the Sample Nozzle Collection Manifold Static Pressure Port 26 and the Conduit Static Pressure Ports 28 and controls the Vacuum Pump 24 (or other device) to increase or decrease the Sample Nozzle Collection Manifold Static pressure whereby offsetting any pressure drop in the Sample Loop.
[0054] Using Equation 5 and incorporating any additional sample loop pressure drop, ΔP, it can be shown that this invention solves the pressure drop interference problem:
[0000]
P
SA
2
-
P
SM
=
1
2
ρ
V
A
1
2
g
c
-
1
2
ρ
V
A
2
2
g
c
(
1
+
C
D
)
-
Δ
P
Equation
7
[0000] ΔP=P SM −P SA1 =The difference between the Sample Nozzle Collection Static Pressure Manifold and the Conduit Static Pressure, as defined previously.
Then:
[0055]
P
SA
2
-
P
SM
=
1
2
ρ
V
A
1
2
g
c
-
1
2
ρ
V
A
2
2
g
c
(
1
+
C
D
)
-
P
SM
+
P
SA
1
[0000] So that:
[0000]
P
SA
2
-
P
SM
=
1
2
ρ
V
A
1
2
g
c
-
1
2
ρ
V
A
2
2
(
1
+
C
D
)
g
c
Equation
8
[0056] This gives the same result as Equation 5 which verifies that the Active Static Pressure Controller feature is essential to obtain a truly mass-velocity weighted fluid composition and mass flow rate measurement, and is the preferred embodiment of this invention.
Operating Characteristics:
[0057] FIG. 5 shows the operating characteristics of the present invention. The ordinate P SA2 −P SM is the difference between the pressure at the entrance to Nozzle A and the Sample Collection Manifold Static Pressure (P SM ). The abscissa (V A2 ) is the velocity in the sample nozzle. FIG. 5 is a plot of Equation 8 previously described.
[0000] There are four operating modes for the present invention:
[0058] 1) Mass-Velocity Proportional Sampling Mode
[0059] 2) Under-Sampling Mode
[0060] 3) Over-Sampling Mode
[0061] 4) Pitot Tube Velocity Mode
A) Mass-Velocity Proportional Sampling Mode: This mode uses an Active Control System to maintain the Sample Manifold Static Pressure equal to the Conduit Static Pressure by means of a vacuum pump 24 or other device. The operating point for this Mode is labeled A on FIG. 5 . This insures that there is no flow circulation between sample nozzles 14 , and that the various sample flows are independent of each other. The fluid composition is mass-velocity weighted at each sample nozzle and the mixture of all the sample inputs collected in the Sample Nozzle Collection Manifold 16 represents the true mass-velocity and conduit flow area-weighted sample for all fluid constituents. For gases, the velocity in the sample nozzles is about 90% of the local conduit velocity and the total sample flow is about 90% of the ideal sample flow. The velocity ratio can be experimentally determined so that knowing this ratio, the flow area of the conduit, the sample flow rate and the total sample nozzle area, the total mass-flow rate of the conduit can be accurately obtained over the entire range of operations.
The sample nozzles in the preferred embodiment are insensitive to swirl and non-axial duct velocity components because of the nozzle design ( FIG. 6 ).
[0000]
TABLE 1
Ref.
Velocity
Sample
Normalized
Cosine
(SFPM)
(SCFM)
Pitch (°)
Sample
Response
3854
2.766
−20
0.932
0.940
3812
2.8613
−15
0.964
0.966
3825
2.9403
−10
0.991
0.985
3826
2.978
−5
1.003
0.996
3823
2.9683
0
1.000
1.000
3812
2.954
5
0.995
0.996
3810
2.932
10
0.988
0.985
3804
2.854
15
0.961
0.966
3813
2.701
20
0.910
0.940
1576
1.0777
−20
0.951
0.940
1570
1.0967
−15
0.968
0.966
1575
1.1307
−10
0.998
0.985
1580
1.137
−5
1.003
0.996
1570.5
1.13343
0
1.000
1.000
1570
1.131
5
0.998
0.996
1577
1.1142
10
0.983
0.985
1570
1.08233
15
0.955
0.966
1570
1.02045
20
0.900
0.940
The essential feature of this preferred embodiment is that pressure drops created by the Fluid Composition Analyzers 32 , 34 , Particulate Filters 18 , Sample Mass Flow meters 22 and any other pressure drop causing devices in the sample loop 10 can be canceled out provided that the Sample Manifold Static Pressure and the Conduit Static Pressure are equal to each other. This is the preferred embodiment for all situations for clean or dirty fluids.
B) Under-Sampling Mode: The operating range, labeled B on FIG. 5 , is between the Pitot Tube Velocity Mode, labeled D on FIG. 5 , and the Mass Velocity Proportional Sampling Mode, labeled A in FIG. 5 . The Sample Nozzle Collection Manifold static pressure is higher than the Conduit Static Pressure such that the sample rate is lower and incorrect compared to the Mass-Velocity Proportional Mode. Lower velocity areas of the conduit will not be sampled properly, and flow circulation will occur between the nozzles, such that the sample flows from each nozzle are not independent of each other which is a necessity of this invention. This Mode is affected by pressure drops in the sample loop. This mode can only be used for certain applications in which the sample loop pressure drops are very small and constant over time.
C) Over-Sampling Mode: In this mode the Sample Manifold Static Pressure is much less than the Conduit Static Pressure, such that a larger sample flow rate is achieved due to a vacuum pump 24 or other device. There is a special condition in which the Active Control System can operate the sample system at an average isokinetic condition (nozzle velocity equals local conduit velocity) labeled C on FIG. 5 , but not all sample nozzles will be isokinetic nor independent of each other. The samples are not mass-weighted.
D) Pitot Tube Velocity Mode: This mode is labeled as D on FIG. 5 . The Sample Nozzle Collection Manifold 16 is shut-off so the sample flow rate is zero. This mode operates as a multi-point Pitot Tube which the average differential pressure minus the Conduit Static Pressure. These devices do not give the accurate average velocity reading due to internal circulation between the sample nozzles unless the velocity profile is very uniform. This mode is not a sampling mode and is included in this disclosure only to show the complete operating characteristics of the present invention method and devices.
Mass Flow Measurement Method:
[0067] The total mass flow rate for the conduit can be determined from the mass flow rate of one or more sampling assemblies that are appropriately located in the conduit and use the preferred embodiment. The ratio of the sample nozzle velocity to the conduit velocity is a function of the sample nozzle pressure drop coefficient (C D ) as shown in Equation 6. The total mass flow of the conduit for one sampling assembly as depicted for the two-nozzle sampling example of FIG. 3 is:
[0000]
M
T
=
(
1
+
C
D
)
(
M
A
+
M
B
)
×
A
C
2
A
N
Equation
9
Where:
M T =Total Sample Mass Flow Rate
[0068] C D =is experimentally determined nozzle pressure drop coefficient
M A =Mass Flow Rate through Nozzle A
M B =Mass Flow Rate through Nozzle B
A C =Flow Area of Conduit
[0069] A N =Area of each nozzle
Effect of Non-Axial Conduit Velocity:
[0070] Several nozzle designs have been tested to find the best shape to produce the largest sample flow rate for the lowest nozzle pressure drop and have good pitch and yaw behavior. The ideal response is for the nozzle to have a “cosine” response to pitch and yaw angles of the velocity vector. Many nozzle shapes have been tested including rounded inlets, sharp-edge nozzle inlets, inside and/or outside tapered nozzle inlets and holes in the probe instead of nozzles. The preferred embodiment is a constant diameter nozzle having a rounded inlet at the nozzle tip protruding into the flow stream. The preferred embodiment is a good compromise between a having high sample nozzle velocity and pitch and yaw characteristics and dirt accumulations. When a protruding nozzle is used, it has been found that by having the nozzle tip extend from the probe surface one or two diameters better pitch and yaw performance are obtained. This is due to the fact that the pressure distribution around a circular tube probe structure changes very rapidly with angle, and when a nozzle with an extended tip is used, it is less affected by the probe structure.
[0071] FIG. 6 shows the pitch and yaw response data of the preferred embodiment compared to the ideal cosine response. This response is much better than most other fluid sampling devices known by the inventor.
[0072] The only accurate sampling mode is the Mass-Velocity Proportional Sampling Mode as described above although the present invention includes other modes of operation. It produces an independent sample rate at each nozzle, compensates for all pressure drops in the sample loop, has good off-axis velocity response characteristics and pneumatically performs the provides a mathematically correct fluid composition equations for the average fluid composition and the conduit mass flow rate over a wide range of fluid velocities, fluid composition, temperature, pressure, and dirty fluids.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0073] A diagram showing the system of the present invention is shown in FIG. 1 . The present invention is a mass-velocity weighted sampling probe and is used to obtain truly representative samples for the analyzers. The present invention pneumatically performs the mass-velocity and area averaging according to the following equation which is the correct definition of the True Concentration Average.
[0000]
C
i
_
=
∫
∫
ρ
(
x
,
y
)
V
(
x
,
y
)
C
(
x
,
y
)
i
x
y
∫
∫
ρ
(
x
,
y
)
V
(
x
,
y
)
x
y
Where:
[0074] C i is the mass-velocity and area average concentration in the conduit of fluid component i, ρ(x, y) is the fluid density, V(x, y) is the fluid velocity and C(x, y), is the concentration of Component i.
[0075] As shown in FIG. 1 , a probe 12 is installed which extends perpendicularly into the conduit, vent, duct or stack 10 in which the measurements are to be taken. Preferably, a plurality of probes 12 are used to effectively sample over the area of the conduit. Each probe 12 is located at the centroid of equal flow area locations within the conduit. At least one, and preferably, a plurality of Sampling Nozzles 14 are mounted on each probe 12 . The nozzles extend outwardly from the probe. The Sampling Nozzles 14 are oriented so that the flow of fluid within the conduit is directed into the opening in the nozzle. This opening communicates with the Sample Nozzle Collection Manifold 16 . The number of Probes 12 and Sampling Nozzles 14 is determined by extent of the non-uniform properties of the velocity, temperature and fluid concentration profile in the conduit. Preferably, the plurality of probes and nozzles are arranged on a cross-sectional area of the conduit.
[0076] Thus, there is a least one Sampling Nozzle 14 placed at equal areas within the conduit facing the flow, each of which has a mass velocity that is linearly proportional to the local mass velocity of the fluid in the conduit such that the resulting flow rate from all the nozzles represents a truly representative sample of the aerosol and gases in the conduit. This sample flows through the Particulate Analyzer 38 (if used) the Particulate Filter 18 (if used) the Fluid Composition Measurement Chamber 20 , the In-Line Mass Flow Meter 22 , through the Vacuum Pump 24 (or other suitable device) and is exhausted back to the Conduit 10 , thus completing the Sample Loop.
[0077] The mass rate of the Sample Loop is proportional to the mass flow rate for the area of the conduit being measured. One or more such multi-point sampling probe assemblies may be used to obtain the average fluid concentration and the mass flow rate of the entire conduit. The sum of the product of the mass flow rate and the concentration fluid constituent for each sampling probe assemblies divided by the number of sampling probe assemblies provides the mass-velocity weighted average concentration for each constituent that is being measured. The average mass flow rate of all the systems times the total area of the conduit times the nozzle velocity compared to the local conduit velocity provides an accurate and repeatable mass flow rate in the conduit as previously described in the Principle of Operation Section of the disclosure.
[0078] It is well known that elbows, obstructions and area changes in conduits cause swirl, turbulences and non-axial fluid velocity vectors. The shape of the sampling nozzles 14 for the preferred embodiment provide a good response to pitch and yaw angles of the velocity in the conduit compared to the ideal cosine response FIG. 6 .
[0079] An important application for the present invention is for measuring and controlling the combustion process in fossil-fueled power plants. Accurate measurement of the excess Oxygen and Carbon Monoxide are required to optimize the efficiency. It is well known that fly ash is a major problem in coal-fired power plants. For such dirty applications, the preferred embodiment includes a Particulate Filter 18 in the Sample Loop. The filter cleans the sample fluid before it enters the Fluid Composition Measurement Chamber 20 and the Mass Flow Meter 22 . All Sample Loop Pressure Drops are canceled by the Active Static Pressure Control 30 Embodiment.
[0080] The concentration of particulates in the Conduit 10 is measured by the Particulate Analyzer 38 which is placed in series with the Sample Nozzle Collection Manifold 16 and upstream of the Particulate Filter 18 . Detection of any other fluid properties can be made by placing the appropriate analyzer in series with the Sample Nozzle Collection Manifold 16 either upstream or downstream of the Particulate Filter 18 , as required.
[0081] The active Static Pressure Control System 30 uses a Differential Pressure Transmitter 42 to measure the difference between the Sample Nozzle Collection Manifold Pressure Port 26 and the Conduit Static Pressure Port 28 and controls the Vacuum Pump 24 (or other suitable device) to make this difference equal to zero. The active Static Pressure Control System 30 constitutes the essence of the present invention. FIG. 4 shows a cross section of the sampling probe and Conduit Static Pressure Ports.
[0082] The Mass Flow Meter 22 is located at the Sample Loop shown in FIG. 1 . The preferred embodiment is an In-Line Thermal Mass Flow Meter having a low pressure drop and high flow turn down performance.
[0083] Another preferred embodiment of the present invention shown in FIG. 1 is the Air Purge Cleaning Controller 36 for dirty fluid applications. It uses a “blow-down” tank of compressed air that flows through a heater (if required) to clean the Particulate Filter 18 , Sample Nozzle Collection Manifold 16 , the Sample Nozzles 14 , Sample Nozzle Manifold Static Pressure Ports 26 and Conduit Static Pressure Ports 28 . The cleaning air with the collected dirt is discharged to the conduit. There is a Valve 40 mounted on the end of the probe 12 that opens up when the cleaning cycle is activated and allows the accumulated dirt to escape into the Conduit 10 . Control Valves 44 are used to direct the purge air into the appropriate components and vent the purged air to the conduit.
[0084] The preferred embodiment utilizes a Fluid Analyzer Measurement Chamber 20 which is essentially a pipe in which the sample gas flows in at one end and out of the other end into the Mass Flow Meter 22 . The Fluid Composition Analyzers 32 , 34 are in-situ instruments that are usually inserted into a conduit. It is also possible to use extractive gas analyze similar to those used for US EPA CEM Stack Monitors by extracting the samples from the sample loop directly.
[0085] Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein.
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A sampling device and method for use with a conduit for fluid which has at least one sampling nozzle or sample hole. The sample collected is directed to a manifold where an analysis is conducted and flow rates are measured. The sampled fluid is returned to the conduit. The Static Pressure Control System uses a vacuum pump or other device to equalize the static pressures of the sample nozzle collection manifold and the Static Pressure of the Conduit to achieve the mass-velocity and area-weighted average fluid composition and mass flow rate.
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BACKGROUND OF THE INVENTION
After a well has been drilled and casing has been placed in the well, the next step typically undertaken to complete the well is to perforate the well. The perforations are ideally formed opposite a formation from which oil and gas will hopefully be obtained. If the formation is perhaps 100 feet thick, locating the formation along the cased hole is not too difficult. Moreover, perforations placement into the formation is not quite so critical in view of the relative thickness of the formation. Thus, if there are perforations above or below the formation, it typically may not cause too much of a problem. Considering this example; if it is known that the formation is about 100 feet thick, a tubing conveyed perforating (TCP) assembly having perforating guns spanning about 100 feet is lowered into the well. When the TCP assembly is positioned in the well, misalignment relative to the formation is not a great problem by virture of the relative large thickness of the formation.
In the situation where the producing formation is only 10 feet thick, proper positioning of the TCP assembly is much more important. Assume that the formation of interest has a thickness of 10 feet; in that instance, registration of the TCP assembly may be crucial. Assume that the formation of interest is located about 12,000 feet deep in a well which has been drilled 10,000 feet. An error of 1% in measuring the depth from the surface to the formation is an error of 100 feet, 10 times larger than the formation thickness. Any measurement error of this magnitude could easily cause the perforations to completely miss the location of this thin formation. Thus, it is very difficult to align the TCP assembly solely from measurements obtained from the surface as, for example, by measuring the length of tubing in the well. The tubing is subject to elongation, and wireline supported tools are also subject to elongation.
In the past, one technique to overcome this problem has involved the use of a radioactive logging tool to obtain a correlation log to locate the formation of interest. Thus, the radioactive logging tool is used to make measurement through the wall of the casing and the surrounding cement holding the casing in place. This sequence of operation involves lowering a radioactive logging tool on a wireline or logging cable to a depth sufficient to move the logging tool past the formation of interest. The logging tool provides continuous data output to the surface such that the data is evaluated, thereby determining the location of the formation of interest. When it is found, the depth of the logging tool in the well is then determined. This is difficult if the logging tool is at a significant depth, but there are procedures available such that the elongation of the supporting cable connected to the logging tool can be evaluated and a precise location is then obtained. Knowing this depth, the TCP assembly is then positioned in the well opposite the formation of interest. As an example, the tubing string and the TCP assembly affixed to the bottom can be lowered almost to the bottom of the well, significantly past the estimated location of the formation of the interest. The logging tool is then used to locate the formation. The logging tool is removed and tubing is also removed to adjust the location of the TCP assembly. This procedure is continued until the TCP assembly is located opposite the target formation. Then, detonation can be initiated. The TCP assembly is detonated by dropping a weight in the tubing string, actuation of a pressure signal for pressure actuated detonating devices or dropping an electric line in the tubing string to connect with the TCP assembly for detonation by electrically triggered means.
This procedure just described primarily involves locating the formation with the logging tool, movement of the tubing string to relocate the TCP assembly opposite the formation while removing the logging tool. The latter two steps may be reversed in sequence. It also requires the detonation sequence to be initiated by means well known in the art. As mentioned above, three typical systems used including the dropped weight, pressure actuated detonation, or electric signal detonation using electric line. This sequence of TCP assembly positioning can require substantial amounts of rig time.
By contrast, the method of the present disclosure enables the formation to be located through the use of a logging tool, the logging tool being left in the tubing string even after the formation has been located. Moreover, a radioactive logging tool of conventional construction and supported on a conventional logging cable is provided with an electric line connector cooperative with a mating connector at the top end of the TCP firing head. The TCP firing head is affixed to the TCP assembly above the perforating guns. With this arrangement of apparatus, the TCP assembly positioning sequence then is simplified. The TCP assembly is lowered on the tubing string to a depth greater than the location of the formation. The radioactive logging tool is then used to precisely locate the formation of interest. Recall that the radioactive logging tool is able to find the formation through the casing and cement which isolates the well from the formation. As before, it is required to locate the formation also through the tubing as well as the casing. This can be readily accomplished. Once it is located and the depth of the formation is then noted, the tubing string is raised in the well to bring the TCP assembly into registration with the formation. This may require raising of the tubing string and is accompanied by raising of the logging tool also. However, they are only repositioned, not retrieved fully from the well. Once registration is obtained, the logging tool can then be lowered to make operative connection with a cooperative plug and socket whereby the electric line initiator is operatively connected to the TCP assembly. This enables a signal to be sent from the surface through an electric line to the TCP assembly for proper operation of the perforating guns.
DETAILED DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
The single FIGURE shows a TCP assembly supported on a tubing string in a well and further illustrates a radioactive logging tool having an electric line connector means affixed to the bottom thereto for connection with the TCP assembly to be registered opposite a formation, prior to perforating into the formation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the single drawing, the numeral 10 identifies a casing which is placed in a well during completion procedures. The casing is held in location by cement 12 placed around the casing. The well is of substantial depth passing through many different horizons, one of the horizons including a formation 14. The well is to be perforated at the formation 14. For purposes of illustration, assume that the formation 14 is relatively thin, perhaps only a few feet in thickness. Moreover, assume that it is quite deep in the well, and assume that the well is deeper than the formation 14. Typically, at the time that the well is cased and cemented, the approximate location of the formation is then known. The precise depth and thickness of the formation may not be fully known until appropriate logging procedures are undertaken. In any event, the partially completed well is cased and casing is held in location by placing cement around the casing.
Assuming that the formation 14 is thought to be located between about 10,000 and 11,000 feet deep in the well, and further assuming as an example that the well has been drilled to 12,000 feet, the next step is to assemble the TCP assembly 16. The TCP assembly includes one or more perforating guns. They span a length which is determined at the time of putting the assembly together. So to speak, the number of perforating guns in the assembly can be increased substantially without limit so that it may be several hundred perforating guns. They are deployed with a density to achieve a desired number and orientation of perforations in the well. The TCP assembly 16 thus includes a plurality of perforating guns. The guns are triggered or fired by an electrically operated firing head 18. The firing head incorporates an upwardly facing connector 20. The connector is at the top end of the TCP assembly. It is located at the bottom end of the tubing string 22. The tubing string threads to and makes up with the TCP assembly 16 with the connector 20 exposed, facing upwardly in the tubing string 22. The tubing string is assembled joint by joint until the TCP assembly 16 is at a substantial depth in the well. Using the example mentioned above, it might be appropriate to locate the TCP assembly 16 at perhaps 11,500 foot depth. Moreover, this method of assembly is a well known procedure undertaken with a view of locating the TCP assembly at any selected depth. As needed, one or more packers are placed in the well. A packer is shown at 24, located above the formation 14 to be perforated. Precise location of the packer relative to the formation typically is estimated, the packer being located to isolate the region of the well where the perforations are formed. If need be, a bridge plug is located below this region also, perhaps limiting downward travel of the TCP assembly. Again, packers and plugs are implemented through practice of routine procedures in completion of the well.
A logging truck 26 located adjacent to the well includes a supply reel or drum 28 which provides an armored logging cable 30. The cable 30 includes sufficient conductors to enable data to be sent up the cable to the logging truck 26. In addition, a conductor is included to provide an electrical signal for operation of the firing head 18. The cable 30 is spooled over a sheave 32 and extends into the tubing string 22. The cable 30 supports a radioactive logging tool 34. The precise nature of the radioactive logging tool is subject to variation and is described generally as a tool which is able to perform logging operations in cased holes. In other words, it operates through the surrounding metal tubular members and the cement on the exterior to locate the formation 14. This is a type of correlation log which is correlated with an open hole log or other geophysical data obtained previously. Thus, the logging tool is used to obtain correlation data locating the formation 14. to this end, the logging tool is of conventional construction supported on the cable 30 through a cable head 36. It is modified primarily by the incorporation of a downwardly facing connector means 38. Connector means 38 is affixed to the bottom end of the logging tool. It is constructed and arranged to mate with the connector means 20 at the TCP assembly therebelow. A conductor path through the logging cable is also included, the conductor extending to the connector means 38 to provide an operative signal from the surface. This sequence will be described in detail hereinafter.
Consider the present procedure in the context of this example. Assume that the formation is only 10 feet in total depth. Assume also that it is somewhere between 10,000 and 11,000 feet in the well which extends down to about 12,000 feet. Among the preliminary preparatory steps is the step of placing the packer 24 at some depth in the well. Perhaps this would be at 9,500 feet in this example. The precise location of the packer is not crucial. Moreover, the tubing string 22 is assembled to lower the TCP assembly 16 to a depth of about 11,500 feet. Once the TCP assembly 16 is located at a depth well below the formation 14, the radioactive logging tool 34 is then lowered on the cable 30 into the well. If it is known that the formation of interest is somewhere between 10,000 and 11,000 feet depth in the well, the logging tool 34 is lowered to some distance past 11,000 feet and is then used to conduct correlation logging operations moving up the well. This requires logging operations to be conducted through both the wall of the tubing and casing and through the surrounding cement layer. This obtains data which can be correlated with other information known about the formations and the precise location of the formation 14 is then determined. Once it has been located, the depth of the radioactive logging tool can be determined through use of a depth indicator 40. It is connected by suitable electronic or mechanical means to the sheave 32. Suitable correction techniques are well known to compensate for cable elongation. This enables determination of the precise location of the formation 14.
Once the precise location of the formation is known, it is then compared with the temporary location of the TCP assembly 16. This location is known by measuring the tubing string or alternatively by placing a radioactive collar at a specified location in the tubing string. The numeral 42 identifies the location of a radioactive collar placed in the tubing string. It is used as a marker. Thus, the logging tool 34 locates the radioactive collar 42. Once the collar is located relative to the formation 14, this enables the tubing string to be moved to register the TCP assembly 16 opposite the formation. This movement is dependent on knowing the precise distance between the TCP assembly 16 and the collar 42. This distance can be determined at the time of making a tubing string and placing the collar 42 in the tubing string.
Consider as an example that the collar 42 is precisely 500 feet above the TCP assembly 16. Assume further that the formation 14 has been located precisely 100 feet below the radioactive collar 42. This data would then require that the tubing string be raised 400 feet to be brought into registry with the formation 14. The tubing string is then raised by this distance. For the moment, the logging tool 34 can be pulled upwardly by a few hundred feet to be retracted to a position out of the way of the TCP assembly 16. Once the TCP assembly 16 is located adjacent to formation 14, the logging tool 34 is then lowered. It is lowered until it rests on the firing head 18. The cooperative plug and socket are then connected. They are connected by the weight of the logging tool 34 which forces the means 20 and 38 together to achieve connection. When this connection is made, this assures the availability of a signal path utilizing the logging cable 30. The signal path is used to apply a firing signal down the cable 30 from surface equipment provided for such an operation, and the signal is conducted through the means 38 and also the means 20. This delivers the electrical firing signal to the firing head 18. This in turn fires the perforating guns. The signal will ignite the charges to form the perforations necessary to complete the well into the formation 14. For instance that the formation is 10 feet in thickness, perforations might be located every 4 or 5 inches vertically with 3 or 4 perforations on a common horizon to form radially divergent perforations into the formation at all points of the compass. When this is accomplished, the perforations are properly vertically registered relative to the formation location. It is particularly desirable to accomplish precise registration by virtue of the fact that the formation is relatively small. After firing, the logging tool 34 is retained on the cable and removed from the tubing. The tubing string may be left in place and the well produced or tested. The well operator has various options including tubing removal. If a permanent packer is set, the tubing cannot be pulled from well borehole. This is called a permanent type completion. If the object is to remove the fired TCP assembly, a retrievable packer is set. The well operator can unseat the packer and remove the packer and TCP assembly when he desires. This is called a temporary completion. Suitable production tubing and other production equipment is then installed after the well has been cleared of the TCP assembly 16.
An important feature of the present procedure is the fact that the wireline can be left in the well without retrieving the logging tool 34, enabling subsequent connection of the plug and socket. There is a significant reduction in the number of trips out of the well and back into the well with the logging apparatus.
While the foregoing is directed to the preferred embodiment, the scope is determined by the claims which follow.
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A method of registering perforating guns in a tubing conveyed perforating assembly as set forth. On a tubing string, a TCP assembly is lowered in a cased well. In the tubing string, a logging cable supported radioactive logging tool is then moved along the well to controllably locate the formation of interest. After the depth of this formation is known, the tubing string is moved to reposition the TCP assembly in registry with the formation of interest. The logging tool is retrieved only partially and is then lowered to operative contact with the TCP assembly to provide a signal path for operation of a firing mechanism to fire the shaped charges to form perforations into the formation.
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FIELD OF THE INVENTION
[0001] This invention relates to an road and freeway interchange that can be built at a lower cost than prior art interchanges, and can allow traffic to not stop at intersections, which saves fuel, and reduces time sitting at stop lights.
BACKGROUND OF THE INVENTION
[0002] A safer and cost effective interchange layout applicable to primary road interchanges at a freeways as well as freeway to freeway Interchanges is sorely needed for areas with limited right of way (ROW) or limited budgets. The current interchange library consists of designs with several conflict points regulated by using signals or stop operations. It is inferred from safety records and cost data for the current systems that an alternative is needed.
[0003] The present invention is a new tool for interchange designers and for Transportation Agencies to consider. This may also be referred to as a road grade separation. The present invention has the potential to become the interchange standard for the country.
[0004] A safer and cost effective interchange layout applicable to Primary Road To Freeway Interchanges as well as Freeway to Freeway Interchanges. It primarily relies on traffic free flow movement within the interchange without signals or stop operations. Benefits of using the present invention include (1) increased safety, (2) efficient, (3) simple, (4) flexible, (5) less expensive to construct, (6) environmentally friendly ( 7 ) relies on tested construction and design procedures.
[0005] There is a need to create a road and freeway interchange that is intuitive to users.
[0006] There also exists a need to create an interchange that does not need traffic signal, and also eliminates the need for emergency power generators for signals.
[0007] There is also a need to eliminates hot spot emissions associated with signalized urban interchanges.
[0008] There is also a for an interchange that reduces chances of wrong-way entry onto freeways.
[0009] There is also a need for an interchange to perfect maintenance of traffic during construction since most of the system can be built off-line.
[0010] There is also a need for an interchange that is very effective at depressed freeway locations.
[0011] There is also a need for an interchange that has multiple road safety advantages, including, but not limited to:
a Eliminates directional conflict points for all movements b. Eliminates platooning associated with signals c. Eliminates weave-merge movements on freeways d. Provides turning radii twice as long as loop ramps for the same ROW e. Redundant ramp (FTF) system allowing for a bypass in case of accidents
There is also a need for an interchange that has multiple road design advantages:
a Eliminates weave-merge movements on freeways b. It requires a small foot print making it applicable for tight ROW locations c. Accommodates sharply skewed road alignments d. Accommodates irregular intersections and multi-leg roads at interchanges e. Applicable to divided and undivided highways
[0022] There is also a need for an interchange that has multiple bridge advantages:
a Eliminates the need for high and long ramp bridges for indirect freeway to freeway movements b. Reduces a four level freeway interchange to a three level freeway interchange c. Eliminates the need for separate infrastructures for AM and PM peak traffic volumes d. Requires shorter span bridges allowing for smaller beams sections and increased vertical clearance without raising approach roadways.
[0027] There is also a need for an interchange with the following advantages, replacing eight ramps with four; easy maintenance of traffic (MOT) since the new bridges and circular road can be built off main line; eliminates weave merge lanes on the freeway; no collector-distributor (CD) roads, as required for modern Cloverleaf Interchanges; reduces chances of wrong-way entry onto the freeway; no traffic signals are needed; eliminates the need for emergency power generators for signals; it requires a small foot print allowing it to fit the ROW; it requires a small foot print making for proper and grading without guardrail; eliminates emission hot spots associated with signalized urban interchanges; reduces the pavement area on ramps and roads. Lane splitters can be added, if needed for capacity
[0028] Multiple embodiments of the system are disclosed herein. It will be understood that other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings.
SUMMARY OF THE INVENTION
[0029] One aspect of the current invention is A road interchange ( 10 ), comprising: a freeway ( 20 ); a road ( 30 ); a west east bound off ramp ( 120 ) extending from said west bound freeway lane ( 250 ) to a north bound on ramp ( 160 ), said north bound on ramp ( 160 ) extending to a north bound road lane ( 260 ); an east bound off ramp ( 140 ) extending from an east bound freeway lane ( 240 ) to a south bound on ramp ( 180 ), said south bound on ramp ( 180 ) extending to a south bound road lane ( 270 ); a south bound off ramp ( 170 ) extending from a south bound road lane ( 270 ) to a west bound on ramp ( 130 ), said west bound on ramp ( 130 ) extending to a west bound freeway lane ( 250 ); a north bound off ramp ( 190 ) extending from a north bound road lane ( 260 ) to a east bound on ramp ( 150 ), extending to an east bound freeway lane ( 240 ); a circular road ( 40 ) connecting said west bound off ramp ( 120 ) to said north bound on ramp ( 160 ); said circular road ( 40 ) connecting said east bound off ramp ( 140 ) to said south bound on ramp ( 130 ); said circular road ( 40 ) connecting said south bound off ramp ( 170 ) to said west bound on ramp ( 130 ); and said circular road ( 40 ) connecting said north bound off ramp ( 190 ) to said east bound on ramp ( 150 ).
[0030] Another aspect of the present invention is a freeway interchange ( 10 ), comprising: a freeway ( 20 ); a second freeway ( 280 ); a west east bound off ramp ( 120 ) extending from said west bound freeway lane ( 250 ) to a north bound on ramp ( 160 ), said north bound on ramp ( 160 ) extending to a north bound freeway lane ( 290 ); an east bound off ramp ( 140 ) extending from an east bound freeway lane ( 240 ) to a south bound on ramp ( 180 ), said south bound on ramp ( 180 ) extending to a south bound freeway lane ( 300 ); a south bound off ramp ( 170 ) extending from a south bound freeway lane ( 300 ) to a west bound on ramp ( 130 ), said west bound on ramp ( 130 ) extending to a west bound freeway lane ( 250 ); a north bound off ramp ( 190 ) extending from a north bound freeway lane ( 290 ) to an east bound on ramp ( 150 ), said east bound on ramp ( 130 ) extending to an east bound freeway lane ( 240 ); a circular road ( 40 ) connecting said west bound off ramp ( 120 ) to said north bound on ramp ( 160 ); said circular road ( 40 ) connecting said east bound off ramp ( 140 ) to said south bound on ramp ( 130 ); said circular road ( 40 ) connecting said south bound off ramp ( 170 ) to said west bound on ramp ( 130 ); and said circular road ( 40 ) connecting said north bound off ramp ( 190 ) to said east bound on ramp ( 150 ).
[0031] 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
[0032] FIG. 1 is a top view of one embodiment of the road to freeway interchange of the present invention;
[0033] FIG. 2 is a side view of one embodiment of a road to freeway interchange of the present invention;
[0034] FIG. 3 is a side view of another embodiment of a road freeway interchange of the present invention;
[0035] FIG. 4 is a top view of one embodiment of the freeway to freeway interchange of the present invention;
[0036] FIG. 5 is a side view of one embodiment of FIG. 4 ;
[0037] FIG. 6 is a side view of another embodiment of FIG. 4 ;
[0038] FIG. 7 is a top view of a third embodiment of the present invention;
[0039] FIG. 8 is a side view of FIG. 7 ; and
[0040] FIG. 9 is another side view of FIG. 7 .
DETAILED DESCRIPTION
Reference Numerals
[0000]
10 road and freeway interchange
20 freeway
30 road
40 circular road
50 ramp
60 road merge lane
70 road to freeway interchange
80 freeway to freeway interchange
90 bridge
91 bridge over circular road and under second freeway
100 Interchange counterclockwise traffic direction
110 primary road traffic direction
120 west bound off ramp
130 west bound on ramp
140 east bound off ramp
150 east bound on ramp
160 north bound on lanes
170 south bound off lanes
180 south bound on lanes
190 north bound off lanes
240 east bound freeway lane
250 west bound freeway lane
260 north bound road lane
270 south bound road lane
280 second freeway
290 north bound freeway lane
300 south bound freeway lane
310 first bypass
320 second bypass
330 third bypass
340 fourth bypass
350 bridge
360 two-level interchange
370 three-level interchange
[0075] The following detailed description is of the best currently contemplated modes of carrying out 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.
[0076] Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly,” “downwardly,” “rightwardly,” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the system and designated parts. Said terminology will include the words specifically mentioned, derivatives, and similar words. Also, “connected to,” “secured to,” or similar language includes the definitions “indirectly connected to,” “directly connected to,” “indirectly secured to,” and “directly secured to.”
[0077] The directional terms, east, west, north, and south are for descriptive purposes, and any configuration may be rotated or realigned.
[0078] Circular, oval, teardrop and a combination thereof can be used for counter clock movement.
[0079] As illustrated in FIG. 1 , the present invention 10 may be used in to connect a primary road 30 to a freeway 20 , and it may be a two-level interchange 360 .
[0080] In one embodiment, the components of a road to a freeway interchange 70 may be four ramps 50 connecting the freeway 20 to a circular road 40 .
[0081] One circular road 40 may be straddling the freeway 20 and connecting the freeway ramps 50 to the road merge lanes 60 .
[0082] Two road merge lanes 60 for each road leg—shown, on and off merge lanes per road leg.
[0083] Subject to capacity analysis, the two bridges 90 must have the proper number of lanes. Most locations will require single lane bridges 90 .
[0084] In one embodiment a freeway 20 may have an east bound freeway lane 240 , and a west bound freeway lane 250 . A road 30 may have a northbound lane 260 and a southbound lane 270 .
[0085] A west bound off ramp 120 may extend from the west freeway lane 250 to a northbound on ramp 160 . An east bound off ramp 140 may extend from an east bound freeway lane 240 to a south bound on ramp 180 .
[0086] A south bound off ramp 170 may extend from a south bound road land 270 to a west bound on ramp 130 . A north bound off ramp 190 may extend from a north bound road lane 260 to an east bound on ramp 150 .
[0087] A circular road 40 may connect the west bound off ramp 120 to the north bound on ramp 160 . The circular road 40 may connect the east bound off ramp 140 to the south bound on ramp 130 . The circular road 40 may connect the south bound off ramp 170 to the west bound on ramp 130 . The circular road 40 may connect the north bound off ramp 190 to the east bound on ramp 150 .
[0088] In use, a circular road 40 may split the primary road traffic that travels in a primary road traffic direction 110 into a single counter clock wise movement 100 allowing for four diamond ramps 50 to accommodate all movements from the circular road 40 to the freeway 20 . The concept applies to multiple roads intersecting the freeway.
[0089] Traffic can flow from the circular road 40 to either the west bound on ramp 130 , the east bound on ramp 140 , the south bound on ramp 180 , or the north bound on ramp 160 . Also, traffic can flow from either the west bound off ramp 120 , east bound off ramp 140 , south bound off ramp 170 or the north bound off ramp 190 to the circular road ( 40 ).
[0090] As illustrated in FIG. 2 , the circular road 40 may be in a single plane and disposed above the freeway 20 . Alternatively if may be disposed under the freeway 20 as illustrated in FIG. 3 .
[0091] FIG. 4 illustrates another embodiment of the present invention 10 . Here, the present invention 10 may be used to connect a freeway 20 to another freeway 280 , and it may be a three-level interchange 370 , as shown in FIGS. 5 and 6 .
[0092] In one embodiment the components of a freeway to freeway interchange may include four ramps 50 in a diamond layout connecting the two freeways 20 , 280 for direct movements; four ramps 50 connecting the two freeways 20 , 280 to the circular road 40 for indirect movements; one circular road 40 straddling both freeways 20 , 280 and connecting up to eight freeway ramps 50 to the circular road. The circular road and its four bridges must be in a single plane; four bridges; two over the E-W freeway and two under the N-S freeway. Subject to capacity analysis, the four bridges must have the proper number of lanes. Most locations will require a single lane bridge. The center bridge 350 is for the N-S freeway 280 over the E-W freeway 20 , or vice versa.
[0093] FIG. 4 illustrates a freeway interchange 10 having a freeway 20 crossing over, or under a second freeway 280 .
[0094] A west east bound off ramp 120 may extend from the west bound freeway lane 250 to a north bound on the circular road and then onto ramp 160 . The north bound on ramp 160 may extend to a north bound freeway lane 290 .
[0095] An east bound off ramp 140 may extend from an east bound freeway lane 240 to the circular road and then to a south bound on ramp 180 . The south bound on ramp 180 may extend to a south bound freeway lane 300 . A south bound off ramp 170 may extend from a south bound freeway lane 300 to the circular road and then to a west bound on ramp 130 . The west bound on ramp 130 may extend to a west bound freeway lane 250 .
[0096] A north bound off ramp 190 may extend from a north bound freeway lane 290 to the circular road and then to an east bound on ramp 150 , the east bound on ramp 130 may extend to an east bound freeway lane 240 .
[0097] A circular road 40 may connect the west bound off ramp 120 to the circular road and then to the north bound on ramp 160 .
[0098] In one embodiment the circular road 40 may connect the east bound off ramp 140 to the south bound on ramp 180 ; and the south bound off ramp 170 to said west bound on ramp 130 ; and the north bound off ramp 190 to the east bound on ramp 150 .
[0099] Also a first bypass 310 may connect the west bound freeway lane 250 to a north bound freeway lane 290 . A second bypass 320 may connect the said south bound freeway lane 300 to a west bound freeway lane 250 . A third bypass 330 may connect the east bound freeway lane 240 to a south bound freeway lane 300 . And a fourth bypass 340 may extend or connect from the north bound freeway lane 290 to an east bound freeway lane 240 .
[0100] As illustrated in FIG. 4 , the bypasses 310 , 320 , 330 , 340 may be located inwardly with respect to the circular road 40 .
[0101] As illustrated in FIG. 7 , the bypasses 310 , 320 , 330 , 340 may be located outside of the circular road 40 .
[0102] In a further embodiment, one or more bypass may be disposed inside the circular road 40 , and some may be outside of the circular road 40 .
[0000] The apparatus of claim 6 , wherein said circular road ( 40 ) is disposed above said freeway ( 20 ) and said circular road ( 40 ) is supported by 4 bridges ( 90 ).
[0103] As seen in FIGS. 5 and 6 , in use, the interchange 10 may be a three levels interchange 370 with the circular road 40 being the mid level allowing traffic to rotate 270 degrees to accommodate indirect traffic movements such as northbound to westbound and westbound to southbound. All traffic movement within the circular road must be a single direction, typically counterclockwise. The circular road 40 may be disposed above, or below the freeway 20 . The circular road 40 may be disposed above or below the second freeway 280 . And the freeway 20 may be above or below the second freeway 280 . A bridge 350 may support the freeway 20 , or second freeway 280 . Bridge 91 may support second freeway 280 over the circular road 40 .
[0104] FIG. 5 illustrates the second freeway 280 supported by a bridge 350 and disposed above the freeway 20 , and above the circular road 40 . The freeway 20 may be at ground level or depressed below grade level.
[0105] FIG. 6 illustrates the second freeway 280 supported by a bridge 350 and disposed above the freeway 20 and above the circular road 40 .
[0106] In use, traffic can flow from said circular road 40 to any of the west bound on ramp 130 , the east bound on ramp 150 , the south bound on ramp 180 , or the north bound on ramp 160 . Also, traffic can flow from either the west bound off ramp 120 , east bound off ramp 140 , south bound off ramp 170 or the north bound off ramp 190 to the circular road 40 .
[0107] As illustrated in FIG. 8 , the second freeway 280 may be supported by a bridge 350 above the freeway 20 and above the circular road 40 .
[0108] Where ROW is tight, diamond ramps can be located inside the circular road, as shown. This layout will require wider bridges along the circular road to accommodate the four diamond ramps.
[0109] The present invention may also provides redundant ramp system to facilitate future ramp repairs and alternate routes in case of accidents on a ramp
[0110] 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.
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An interchange for road and freeways that allows for a constant movement of traffic via entrances and exits from a circular road accessible from all directions.
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This application claims the benefit of provisional patent application No. 60/186,263, filed Mar. 1, 2000, which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to liquid ring vacuum pumps and compressors, and more particularly to constructions for such products which increase the number of parts that can be used in more than one product configuration. For ease of reference, the term “pump” or “pumps” is generally used herein as a generic term for both pumps and compressors.
Liquid ring pumps are typically designed so that a single pump design can serve a number of markets. Accordingly, the same basic pump may be used for different applications such as chemical processing, general industrial markets, and so on. Generally, chemical and petrochemical process applications require higher discharge and hydrostatic test pressure (i.e., liquid leakage pressure) capabilities and the use of special mechanical seals. These requirements are often not so stringent in general industrial applications. For example, in the chemical processing industry differential pressures to 30 psig and hydrostatic test pressures to 225 psig are common requirements. In comparison, for general industrial pumps the differential pressure capability required is typically about 15 psig and hydrostatic test is about 75 psig. Also, chemical industry pumps may have to meet certain industry specifications such as those set by the American Petroleum Institute or the Engineering Equipment and Materials Users Association.
Because a liquid ring pump may be needed for any of these markets, overall design is often based on meeting specifications for the more demanding chemical process applications. The resulting design is “optimal” for chemical applications, but may be “over-designed” for general industrial applications. Pumps of the type shown in Dudeck et al. U.S. Pat. No. Des. 294,266 (also known as the “SC” type of pump available from The Nash Engineering Company of Trumbull, Connecticut) are an example of this type of known pump design. To meet the more stringent requirements of chemical process applications, these pumps have removable bearing brackets to facilitate access to the mechanical seals. The seals are also provided with an external flush to cool the seal and help reduce erosive damage to the seal components. Features such as these are often not necessary for less demanding general industrial applications. Accordingly, the SC design may be a more costly one than is needed for such less demanding installations. On the other hand, it is also costly to provide completely separate designs that have been optimized for each possible application.
(It should be noted here that the SC pumps also use gas scavenging technology of the type shown in Schultze et al. U.S. Pat. No. 4,850,808, which is hereby incorporated by reference herein in its entirety.)
In view of the foregoing, it is an object of this invention to provide liquid ring pumps that can economically meet the requirements of several different types of service without all parts of the pump having to be entirely customized to each type of service.
It is another object of this invention to provide simplified lubrication of seals which can be used in at least some liquid ring pumps.
SUMMARY OF THE INVENTION
These and other objects of the invention are accomplished in accordance with the principles of the invention by providing liquid ring pumps having at least several major components that can be used or easily adapted for use in pumps having either of at least two significantly different designs, each of which is adapted to meet a respective one of two significantly different sets of service requirements. For example, although two different pumps may have such variations as different shaft diameter and shaft length between bearings, the two pumps may have several common rough parts such as the rotor, head, cone, and lobe, and may have common finished parts such as the lobe. To accomplish this in the case of the head, for example, that part may be cast with sufficient material in the shaft area so that this material can be machined out either for a relatively large shaft (for a higher pressure pump) or for a relatively small shaft plus a bearing (for a lower pressure pump). Similarly, in the case of the cone, that part may be cast with enough material in the shaft area so that it may be machined out either for the larger shaft or for a relatively small shaft plus mechanical seal components.
The pumps of this invention may also be constructed with features that simplify the provision and lubrication of seals, especially for pumps with less stringent seal requirements. For example, at one end of the pump the seals may be located inside the cone of the pump where they can be lubricated by the flow through the above-mentioned gas scavenging structure associated with the cone. At the other end of the pump, the rotor shroud may be perforated to facilitate a flow of liquid from the liquid ring to and past the seals at that end.
Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified sectional view of an illustrative prior art liquid ring pump.
FIG. 2 a simplified, composite, sectional view of portions of two different final pump constructions that can be made using several common or substantially common parts in accordance with the invention. In particular, the upper portion of FIG. 2 shows one of these two final pump constructions, and the lower portion of FIG. 2 shows the other of these two final pump constructions.
FIG. 3 is a simplified sectional view showing more of the pump shown in the upper portion of FIG. 2 .
FIG. 4 is a simplified sectional view showing more of the pump shown in the lower portion of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The typical prior art liquid ring pump 10 shown in FIG. 1 includes the following principal parts: stationary housing (or lobe) 20 ; stationary head 30 attached to one axial end of lobe 20 ; stationary cone (or port member) 40 mounted on head 30 and projecting into the interior of lobe 20 ; stationary bearing bracket 50 also mounted on head 30 ; stationary bearing bracket 60 mounted on the end of lobe 20 remote from head 30 ; shaft 70 rotatably mounted in bearings 52 and 62 in bearing brackets 50 and 60 , respectively; and rotor 80 mounted on shaft 70 for rotation therewith. As is conventional for liquid ring pumps, lobe 20 is eccentric to shaft 70 and contains a quantity of liquid (e.g., water) which the radially and axially extending blades 82 of rotor 80 form into a recirculating ring of liquid inside lobe 20 . On one circumferential side of pump 10 the inner surface of this liquid ring is moving radially out away from the central longitudinal axis of shaft 70 . Accordingly, on this side of the pump gas is pulled into the spaces between circumferentially adjacent rotor blades 82 via gas intake passages 32 and 42 in head 30 and cone 40 , respectively. On the other circumferential side of the pump the inner surface of the liquid ring is moving radially in toward the central longitudinal axis of shaft 70 . Accordingly, on this side of the pump gas is compressed between circumferentially adjacent rotor blades 82 and then discharged from the pump via discharge passages 44 and 34 in cone 40 and head 30 , respectively. (The connection of discharge passage 34 to the exterior is not visible in FIG. 1, but such a connection is nevertheless present in pump 10 .)
A stuffing box 36 is provided in head 30 around shaft 70 to accommodate packing or mechanical seals. Another similar stuffing box 26 is provided in lobe 20 around shaft 70 , again to accommodate packing or mechanical seals. (FIG. 1 actually shows packing in both stuffing boxes 26 and 36 .) Bearing brackets 50 and 60 are removable to facilitate maintenance of the packing or mechanical seals in boxes 26 and 36 . External liquid couplings (not shown) are provided to provide liquid to the packing or mechanical seals for such purposes as lubrication, cooling, contaminant flushing, etc.
With the various features that have thus been described, pump 10 is able to meet very stringent service requirements such as those that are often encountered in chemical processing.
FIG. 2 shows representative portions of two different pumps that can be constructed using several substantially common parts in accordance with this invention. Above the chain-dotted shaft centerline FIG. 2 shows a portion of a pump 110 a which is designed to meet relatively stringent service requirements like those met by pump 10 in FIG. 1 . Below the chain-dotted shaft centerline FIG. 2 shows a portion of a pump 110 b which is designed to meet less stringent service requirements. (The drive ends of the shafts in FIG. 2 are on the left rather than on the right as shown in FIG. 1.) Parts in FIG. 2 that are generally similar to parts in FIG. 1 have reference numbers that are increased by 100 from the reference numbers for the corresponding parts in FIG. 1 . (Although FIG. 1 suggests that the left-hand end of lobe 20 is closed by structure that is integral with the remainder of the lobe, FIG. 2 shows use of a separate end plate 190 a/b for that purpose.) Also in FIG. 2, parts of pump 110 a all have reference numbers with the suffix “a”, and parts of pump 110 b all have reference numbers with suffix “b”. Although a part may thus be shown in FIG. 2 with both suffix “a” and suffix “b”, that part may in fact be one common part (e.g., a common casting with common machining), or one substantially common part (e.g., a common casting with only somewhat different machining). Particular examples of this commonality of parts will be discussed in more detail below.
Principal differences between pumps 110 a and 110 b in FIG. 2 are as follows: Shaft 170 a is both longer between bearings 162 a and 152 a and larger in diameter than shaft 170 b . A more robust shaft is used in pump 110 a because the distance between bearings 162 a and 152 a is greater and because pump 110 a is designed for greater pressure. Pump 110 a has a greater distance between bearings 162 a and 152 a for the same reason that pump 10 has a comparable distance between bearings, namely, to allow more room for more elaborate stuffing boxes and mechanical seals, and to facilitate access to those elements. Pump 110 b , on the other hand, can have its bearings 162 b and 152 b closer together because pump 110 b does not need such elaborate stuffing boxes and mechanical seals. Because bearings 162 b and 152 b are closer together (and because pump 110 b is designed for lower pressures), shaft 110 b can be both shorter and smaller in diameter. At the right-hand end of pump 110 b bearing 152 b can be disposed directly in head 130 b and no projecting bearing bracket comparable to bracket 150 a is needed at all. In addition, mechanical seal 146 b can be located inside cone 140 b in lieu of stuffing boxes 136 a in head 130 a and an additional mechanical seal retainer 138 a mounted on the outside of head 130 a inside of bearing bracket 150 a . Similarly, at the left-hand end of pump 110 b , bearing 162 b can be disposed in end plate 190 b . Mechanical seal 126 b can be relatively close to the shrouded end of rotor 180 b . This is in contrast to the provision in pump 110 a of more elaborate stuffing box 126 a and bearing bracket 160 a and mechanical seal retainer 198 a mounted on the outside of end plate 190 a.
The pump constructions shown in FIG. 2 allow commonality of major components as follows: The same rough parts (e.g., the same castings) can be used for rotors 180 a and b , heads 130 a and b , cones 140 a and b , and lobes 120 a and b . The same finished parts (e.g., machined castings) can be used for lobes 120 a and b . For example, a generic rotor casting 180 can be made with a sufficiently small shaft opening that it can be machined out either by the relatively small amount required to accept relatively small diameter shaft 170 b or by the relatively large amount required to accept relatively large diameter shaft 170 a . Similarly, a generic head casting 130 can be made with a sufficient quantity of metal surrounding the central shaft opening so that this metal can be machined out either to receive relatively large diameter shaft 170 a and to form stuffing box 136 a or to receive relatively small diameter shaft 170 b plus bearing 152 b . In either case sufficient head metal remains to completely annularly surround elements 170 a and 136 a or elements 170 b and 152 b . However, not so much metal is provided in that part of generic head 130 that adequate gas intake and discharge passages (comparable to passages 32 and 34 in FIG. 1) are not also provided in head 130 . Generic head 130 is also configured to receive either bearing bracket 150 a and mechanical seal retainer 138 a or a much simpler end plate 200 b . As yet another example, a generic cone casting 140 can be made with sufficient material in the shaft area so that this material can be machined out to receive either relatively large diameter shaft 170 a or relatively small shaft 170 b plus mechanical seal 146 b.
Common finished parts are possible for lobes 120 a and b.
Examples of principal parts that are not common between pumps 110 a and 110 b include shafts 170 a and 170 b , left-hand end plates 190 a and 190 b , and the more elaborate bearing brackets 150 a and 150 b that have to be provided for pump 110 a . Nevertheless, the ability to construct pumps 110 a and 110 b with several principal parts that are common or substantially common is a great cost saving for both pump configurations.
FIG. 2 also illustrates other features of the invention which will now be described. As was mentioned earlier, pumps 110 a and 110 b may be constructed with gas scavenging like that shown in Schultze et al. U.S. Pat. No. 4,850,808. A passage 220 is provided through cone 140 a/b into the clearance between the outer surface of shaft 170 a/b and the inner surface of cone 140 a/b from just downstream of the compression zone of the pump. Any gas that does not exit from the pump via discharge passage 144 a/b can flow through passage 220 into the annular clearance inside cone 140 a/b around shaft 170 a/b . Just downstream from the intake zone of the pump another passage 222 is provided from this clearance through cone 140 a/b . Accordingly, gas that would otherwise be carried over from the compression zone to the intake zone, where it would reduce the intake capacity of the pump, is able to bypass the intake zone and therefore does not reduce the intake capacity.
The above-described bypass gas flow is typically accompanied by a substantial flow of liquid from the liquid ring. By constructing pump 110 b with mechanical seal 146 b inside cone 140 b where the mechanical seal comes in contact with this liquid flow, pump 110 b can take advantage of that flow to cool, lubricate, flush, and otherwise enhance the performance of seal 146 b . No external liquid supply is needed for seal 146 b . This is an additional cost saving and operating improvement of pump 110 b in accordance with this invention.
Similar advantages can be achieved or enhanced at the other axial end of pump 110 b . In accordance with yet another aspect of the invention, holes 232 are provided in the annular shroud 230 at the left-hand end of rotor 180 a/b . Holes 232 allow liquid from the compression side of the liquid ring to flow out into the clearance around shaft 170 b that is partly occupied by mechanical seal 126 b . On the intake side of the pump holes 232 allow this liquid to re-enter the liquid ring. This flow of liquid cools, lubricates, flushes, and otherwise enhances the performance of seal 126 b . Once again, this reduces or avoids the need for an external liquid supply to seal 126 b , with consequent cost savings and operating improvement for pump 110 b.
Although FIG. 2 is useful for facilitating direct comparison of pumps 110 a and 110 b , more of pump 110 a is shown in FIG. 3 and more of pump 110 b is shown in FIG. 4 . In addition to what is shown in FIG. 2, FIG. 3 shows the provision of external liquid supply conduits 240 and 242 for supplying liquid to seals 126 a and 136 a.
FIG. 4 shows more details of particularly preferred constructions of mechanical seals 126 b and 146 b . In particular, FIG. 4 shows seal 126 b constructed as a first annular component 126 b 1 mounted on shaft 170 b for rotation therewith, and a second annular component 126 b 2 mounted on stationary end structure 190 b . Portions of the annular, axial end faces of components 126 b 1 and 126 b 2 abut one another and thereby provide the desired mechanical seal. Liquid (e.g., from apertures 232 ) can reach components 126 b 1 and 126 b 2 (and especially the proximity of their abutting axial end faces) to lubricate, cool, flush, and otherwise help maintain the mechanical seal. Mechanical seal 146 b similarly includes a first annular component 146 b 1 mounted on shaft 170 b for rotation therewith, and a second annular component 146 b 2 mounted inside port member 140 b . Portions of the annular, axial end faces of components 146 b 1 and 146 b 2 abut one another and thus provide a mechanical seal. Liquid (e.g., from aperture 220 ) can reach at least portions of components 146 b 1 and 146 b 2 (especially the proximity of their abutting axial end faces) in order to lubricate, cool, flush, and otherwise help maintain mechanical seal 146 b.
It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. For example, although the illustrative pumps shown herein have conical (actually frustoconical) port members 140 a/b , the principles of the invention are equally applicable to pumps having port members or structures with substantially cylindrical, radially outer surfaces.
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Liquid ring pumps, of the type having a port structure that extends into an annular recess in an end of the rotor, have several parts that are designed so that they can be used to make pumps having either relatively demanding service requirements or substantially less demanding service requirements. Some of these parts can be substantially exactly the same in both final pump configurations. Others of these parts may be castings that differ substantially only in some subsequent machining in order to adapt them for each final pump configuration. Some of the final pump configurations have more compact mechanical seal structures and/or improved structures for supplying liquid to the seal structures.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is both a continuation in part of pending application Ser. No. 10/459,961, filed Jun. 12, 2003, and a non-provisional application of the earlier filed provisional application Ser. No. 60/700,104 filed Jul. 19, 2005, and claims the benefit of the priority date of the filing date Jul. 19, 2005, pursuant to U.S.C. Sec. 119(e).
FIELD OF INVENTION
[0002] This present invention relates generally to F-hole guitars, F-hole mandolins, and other stringed instruments having elongated sound openings, as well as to banjos and openable drums, and in particular to devices for enriching and amplifying the output sound of such instruments without the use of electronics.
BACKGROUND OF THE INVENTION
[0003] The volume, sound duration and richness of tone needed to create beautiful music with today's acoustic stringed instruments is difficult, at best, to achieve. The problem stems in large part from the fact that few adjustments can be made to change the sound characteristics of these instruments once they have been manufactured. An added handicap for small guitars, mandolins and acoustic-electric guitars is the small size of their sound chambers which tends to hinder the production of musical notes of low frequency.
[0004] Traditionally, success in making good sounding acoustic guitars, acoustic-electric guitars, mandolins, banjos and drums was largely determined by the quality of the materials used in construction, the quality of skilled craftsmanship in the manufacturing process, and a degree of good fortune as the various parts were brought together and the instrument was tested, primarily after completion. The intricacies of this approach insured that good sounding acoustic instruments made following its techniques would be expensive.
[0005] Further, tuning guitars and mandolins for optimum performance (defined herein as a state in which they exhibit a noticeable maximum available volume with a noticeably high quality of sound) was left up to the manufacturer. Banjos and drums, while tuneable for optimum performance to a degree, required the expenditure of considerable effort on the part of experienced players.
[0006] Players have had so little control over the characteristic sound or timbre (hereinafter “timbre”) of their acoustic stringed instruments that musicians often resorted to using several instruments to meet their needs for different sounds.
[0007] Not until recently has this situation improved significantly and only with respect to round-hole acoustic musical instruments. As described by Geiger in U.S. Pat. No. 6,861,581, a resonating and amplifying device, capable of improving the sound quality and volume of a conventional guitar, includes a cross-shaped resonator which when mounted within the guitar's sound chamber is cantilevered beneath its sound hole, partially covering it. Holding the device in position is a set of prongs formed in an extended arm of the resonator. In use, opposing upper and under prongs clip the device to the edge of the sound hole which then forms a wedge between them, Unfortunately, the geometry of this device is such that it cannot be readily attached to the edge of elongated sound openings such as are found in F-hole guitars, F-hole mandolins, and the like. Moreover, in placing the resonator on a guitar, one risks harming its body unless the prongs are handled gently.
SUMMARY OF INVENTION
[0008] The object of the present invention is to provide a mechanical device capable of increasing the volume, sound duration and richness of tone of all musical notes, the device being readily attachable to and removable from a wide variety of conventional musical instruments including those with F-holes and similar elongated sound openings, as well as banjos, drums and the like.
[0009] A further object is to provide such a mechanical device which the player of a musical instrument can use to easily change temporarily and significantly its volume, sound duration, and timbre.
[0010] A still further object is to provide such a mechanical device which a player can easily use to “tune” an acoustic instrument for optimum performance.
[0011] A still further object is to provide such a mechanical device which not only can be easily attached to and removed from a musical instrument without damaging it but also can be fabricated by unskilled craftsmen from common inexpensive materials, making good musical sound available from less expensive instruments and therefore available to more people.
[0012] In accordance with the present invention, there is provided an improved sound enhancing device which includes a sound emitter, an elongated fastener, and a bridge. The sound emitter comprises a stacked array having at least two nested cross-shaped elements and a timbre square, each of which is small and thin in shape and defines a central hole sized for slideably receiving the fastener. Aligned with the cross-shaped elements and the timbre square along the elongated fastener, the bridge contacts the body of the musical instrument itself, collecting inaudible sound surface waves thereon and transmitting them through the fastener to the sound emitter. The latter is mounted within the instrument's sound chamber.
[0013] The bridge, on the other hand, is mounted outside of the sound chamber whenever the device is used to enhance the performance of F-hole instruments and the like. Preferably formed as a wooden half-ball which has a generally flat bottom and defines a reverse-tapered hole extending perpendicularly thereto, the bridge is sized to straddle the instrument's elongated sound opening.
[0014] In use, opposing edges of the sound opening are wedged between the bridge's flat bottom and the sound emitter. Holding them together in assembled relation is the fastener which, in the preferred embodiment, includes a waxed, knot-free string, a retainer ring, and a tapered pin. The pin fits tightly in the smallest transverse cross-section of the reverse-tapered hole and, when so fitted, does not protrude from the bridge's flat bottom. The waxed string, which is doubled upon itself except where it contacts the retaining ring, passes through both the reverse-tapered hole and the central hole of each of the cross-shaped elements. Seated in the reverse-tapered hole, the pin is used to hold a length of the doubled waxed string securely against the hole's upper edge at the top of the half-ball once the string has been pulled tight, drawing the retaining ring and the sound emitter together.
[0015] In an alternate embodiment of the sound enhancing device which is used to enhance the performance of banjos, openable drums, and the like, the bridge is mounted inside the sound chamber. Compatible with the cylindrical wood rim which typically encloses the sound chamber in such instruments, the bridge is formed as a brass half-donut which has concentric, generally flat bottom edges for contacting the wood rim. Also defined by the half-donut is a reverse-tapered hole with a centerline which extends perpendicularly to the plane in which the concentric bottom edges lie.
[0016] In use, the concentric bottom edges of the bridge are pressed against the wood rim. The bridge is sized to have sufficient height or standoff to keep portions of the sound emitter which are contiguous thereto free of direct physical contact with the curved wood rim while the sound enhancing device is operating. Holding the bridge and the sound emitter together in assembled relation is the fastener which, in the alternate embodiment, includes a bolt or machine screw with threads which fit the banjo's (or drum's) existing “shoe” bracket. The bolt passes through both the reverse-tapered hole of the half-donut and the central hole of each of the cross-shaped elements and the timbre square. When the bolt is tightened by screwing it into the “shoe” bracket, the head of the bolt, which is positioned inwardly of the sound emitter, presses against it, drawing the nested cross-shaped elements, the timbre square, the half-donut, and the cylindrical wood rim together in assembled relation.
[0017] Common to both embodiments of the improved sound enhancing device is the sound emitter which receives surface waves, including those collected by the bridge, through a fastener slideably held within a central hole in each of the sound emitter's crossed-shaped elements and timbre squares. Sound waves are also transferred by direct physical contact to the sound emitter whenever one or its crossed-shaped elements or timbre squares touches vibration-active surfaces on the body of the musical instrument or the bridge itself.
[0018] As confirmed by testing, noticeable amplification of the instrument's sound results with the use of the improved sound enhancing device. Specifically, the volume was found to increase with every addition, at least up to a quantity of four, of a crossed-shaped element or timbre square to the sound emitter. Importantly, because of high frequency amplification, and the fact that the “pleasantness” of the sound depends upon the presence and high energy level in the first several harmonics, not only could one play the instrument louder but also it sounded better at all volume levels. While amplification was highly noticeable at all levels of playing effort, the sound increase was especially impressive when input energy was moderate to high, such as when the instrument was played vigorously.
[0019] These test results are consistent with the theory that in the sound emitter, surface sound waves radiate outwardly from the center of each cross-shape element and timbre square toward its outer edges. There, because of the difference in media density between the various materials in the sound emitter—primarily wood and metal—and air, the sound waves are reflected backwardly. In the process, they meet sound waves, with the same or similar frequencies, moving from different directions and set up patterns of constructive interference, causing amplification of the fundamental tones in the sound waves as well as their harmonics (frequency multiples).
[0020] In the preferred embodiment, each of the crossed shaped elements includes a generally flat central section and four three-sided arms which are formed integrally therewith. Contiguous arms in each cross-shaped element are disposed generally perpendicularly to each other, but only three of the arms have square edges. The remaining arm is preferably trapezoidal in shape.
[0021] In assembled relation, the generally flat central sections of the nested cross-shaped elements are in direct physical contact; but their respective arms, although they are paired in an orthogonal array, are spaced apart in such a way as to create small diverging air spaces which extend outwardly between the paired arms. Moreover, each of the arms is adjustable in position and, in use, is bent slightly so that its curvature differs substantially from that of the arm with which it is paired in the orthogonal array.
[0022] Transfer of surface sound waves from the sound emitter to the sound chamber's air occurs when their small motion in the diverging surfaces of the paired arms, as well as between an arm and a contiguous portion of the timbre square, compresses the air in the smallest spaces between these surfaces. In the case of nested cross-shaped elements, these air spaces range in size from zero where the contiguous center sections touch to approximately ⅛-inch or more at the outer extremities of the paired arms. The air compression creates audible sound in these smallest spaces; and the increasing amount of air space toward the outer edges of the paired arms, or alternately, an arm and a contiguous portion of the timbre square, due to their divergence, cause the sound in air to be amplified. In effect, the orthogonal array of paired arms in the nested cross-members amplifies sound in a manner analogous to that of four open-sided megaphones. Since the four sets of paired arms in the nested cross-shaped elements are disposed perpendicularly and are open on their sides, amplification in air also occurs between these open sides.
[0023] As found in practice, both the spacing between the paired arms of the nested cross-shaped elements and the arms' curvatures effect the quality and volume of instruments on which an improved sound enhancing device is mounted. When the sound emitter is mounted in a banjo, a player can easily change the spacing between the paired arms and their respective curvatures directly by hand, using only the sense of touch. For F-hole instruments, on the other hand, a simple tool is provided to help the player make these adjustments which are critical for optimizing the instrument's performance.
[0024] Not only is the instrument's timbre changed when sound surface waves move across the timbre square and cross-shaped elements of different materials but also the volume is affected. Preferably, the timbre square and cross-shaped elements included in the sound emitter are selected on the basis of the timbre and volume desired and are changed to meet different purposes. With the improved sound enhancing device, a wide variety of combinations using different materials and shapes (whether timbre squares or cross-shaped elembers) and also varying their order and the number of each in the sound emitter is possible.
[0025] Moreover, the timbre square and the cross-shaped element disposed contiguous thereto, in combination, comprise means for adjusting the sound duration of an instrument using the improved sound enhancing device. The sound duration is maximized whenever the timbre square is oriented generally diagonally with respect to the square shaped arms of the contiguous cross-shaped element.
[0026] In an alternate embodiment, provided to facilitate changing timbre in F-hole instruments, both the bridge and at least one cross-shaped element are mounted outside of the sound chamber. Very easily added without removing the sound emitter from the sound chamber, this externally mounted cross-shaped element greatly increases the volume as well as the timbre. Brightness and clarity are also increased if one or more of the cross-shaped element's arms is positioned over the F-hole. This brightness is further enhanced when a hole, preferably about ¼ inch in diameter is formed in each of the two opposing square-shaped arms of the elements; and these opposing arms are then positioned so that their holes are disposed over the F-hole,
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is an outside perspective of a the invention of a sound enhancing device according to the present invention, the device being depicted with its half-ball bridge astraddle the F-hole sound opening of a conventional mandolin, the mandolin being shown for illustrative purposes only and forming no part of the claimed invention;
[0028] FIG. 2 is close up perspective view of the sound enhancing device according to FIG. 1 and a fragment of the mandolin, portions of the device which are mounted beneath the F-hole sound opening within the mandolin's sound chamber, as well as part of the half-ball bridge above it, being shown;
[0029] FIG. 3 is a exploded perspective view of the sound enhancing device according to FIG. 1 ;
[0030] FIG. 4 is a plan view of the cross-shaped element and a timbre square, components which individual players can use in constructing the sound emitter device according to FIG. 1 , an alignment of its timbre square with the cross-shaped element in which maximum sound duration is achieved being shown;
[0031] FIG. 5 is an exploded perspective view of the sound enhancing according to FIG. 1 , portions of the device, as well as a fragment of the mandolin surrounding its F-hole sound opening, being shown in cross-section;
[0032] FIG. 6 shows schematically various positions along the length of an F-hole sound opening where one can mount the sound-enhancing device according to FIG. 1 , the best sounding location for a particular musical instrument being selected experimentally by sliding the half-ball bridge along the sound opening;
[0033] FIG. 7 is a plan view of a tool which can be used to install the sound emitter of the sound enhancing device according to FIG. 1 within the sound chamber of an instrument having an F-hole opening;
[0034] FIGS. 8 and 9 are perspective and exploded views, respectively, of an alternate embodiment of the sound enhancing device according to FIG. 1 which is mountable inside a banjo's sound chamber, the fragmentary portions of the banjo depicted in FIGS. 8 and 9 being shown for illustrative purposes only and forming no part of the invention; and
[0035] FIGS. 10 and 11 are outside and closeup inside perspective views, respectively, of a further alternate embodiment of the sound enhancing device according to FIG. 1 , the device being depicted with its half-ball bridge and a cross-shaped element contiguous thereto astraddle the F-hole sound opening of a conventional mandolin, the mandolin being shown for illustrative purposes only and forming no part of the claimed invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] In the drawings, an improved sound enhancing device for use with a stringed instrument 30 having elongated sound openings 41 , 41 ′ is indicated generally by the reference numeral 10 . The device 10 includes a sound emitter, a bridge 35 and a fastener which, in the first embodiment, is a waxed, knot-free string 20 .
[0037] Constructed of thin metal and wood strips in a stacked array, the sound emitter comprises at least two nested cross-shaped elements 11 , 21 and one or more timbre squares 31 , which define central holes 16 , 17 , 18 , respectively. Preferably, both the cross-shaped elements 11 , 21 and the timbre square 31 are fabricated from metal or two-ply veneer wood.
[0038] Metal timbre squares 31 are typically thin carbon steel, which measures approximately 0.007-inch thick and 1-inch square, and brass squares of the same size but which measure approximately 0.010-inch in thickness. Wood veneer squares are typically made of maple or mahogany or glued combinations of these or similar woods. Cross-shaped elements 11 , 21 are typically brass pieces of approximately 0.010-inch thickness and two-ply maple or mahogany veneer. Timbre is changed when sound surface waves move across timbre squares 31 and cross-shaped elements 11 , 21 made of different materials.
[0039] In operation, the sound emitter is mounted within the instrument's sound chamber beneath the sound opening 41 ( FIG. 2 ). Aligned with the sound emitter along the string 20 , the bridge 35 , on the other hand, is mounted outside of the sound chamber.
[0040] Preferably formed as a wooden half-ball which has a generally flat bottom and defines a reverse-tapered hole 19 extending perpendicularly thereto, the bridge 35 is sized to straddle the sound opening 41 . The bridge 35 collects a portion of the sound surface waves which typically move to and travel along F-hole edges. There the inaudible sound surface waves create active vibration centers which add their sound to the air as air with sound leaves the instrument's sound chamber through sound openings 41 , 41 ′. Tests have shown that the amount of sound energy around F-hole edges varies considerably. As suggested in FIG. 6 , the device 10 is designed to facilitate searches, along the length of an F-hole 41 , for the best location to mount the bridge 35 .
[0041] In use, opposing edges of the sound opening are wedged between the bridge's flat bottom and the sound emitter. Holding them together in assembled relation is the waxed string 20 , a terminal retaining ring 33 , and a tapered pin 36 ( FIGS. 3 and 5 ). The pin 36 fits tightly in the smallest transverse cross-section of the reverse-tapered hole 19 . So fitted, the pin 36 does not protrude from the bridge's flat bottom. Doubled upon itself except where it contacts the ring 33 , the waxed string 20 , which preferably measures about 1/32-inch in thickness, passes through both the reverse-tapered hole 19 and the central holes 16 , 17 , 18 , as well as through openings in threadless brass nut spacers 32 . The brass fittings 32 , 33 help to reduce damping effects of the string 20 on the sound emitter.
[0042] Seated in the reverse-tapered hole 19 , the pin 36 is used to hold a length of the doubled waxed string 20 securely against the hole's upper edge at the top of the half-ball once the string 20 has been pulled tight, drawing the retaining ring 33 and the sound emitter together.
[0043] Under tension, the waxed string 20 , an unusual but efficient medium for sound waves, performs three functions in the device 10 : (1) it holds the sound emitter securely against the bottom surface of the instrument's top; (2) it serves as the medium for sound surface waves between the half-ball and the sound emitter; (3) it provides necessary flexibility so that the sound emitter can be inserted into the elongated sound opening 41 , one component at a time, and allows the sound emitter to be “self-constructed” as the various pieces of the sound emitter are drawn together when the string 20 is pulled taut.
[0044] The excellent acoustic efficiency of the waxed string 20 is also evident in the noticeable change in timbre which can be achieved by using different materials, such as rosewood, ebony, and plastic, for the pin 36 . Because of the remote location of the pin 36 relative to the sound emitter, this timbre effect, which is dependent upon the presence of high frequency sounds passing over and/or through the pin 36 , most likely enters the instrument's sound through the string 20 and is then transferred to the sound emitter in the sound chamber. Conversely, sound also travels from the sound emitter to the pin 36 where the half-ball/pin combination detects these sounds and broadcasts them to the instrument's top.
[0045] Not only does sound move to and from the sound emitter through the string 20 but also directly through the timbre square 31 where it touches the bottom surface of the instrument's top and where the cross-shaped elements 11 , 21 and the timbre square 31 touch each other.
[0046] Because of the very short distance involved and the fast speed of sound through and over brass and hardwood materials, sound on the string 20 enters all wood and metal components strung thereon at almost the same time and is amplified, throughout surfaces in the sound emitter, where surface sound waves with similar frequencies meet.
[0047] The sound emitter not only amplifies the sound surface waves in the cross-shaped elements 11 , 21 and timbre square 31 by constructive interference but also adds timbre characteristics and transfers these waves into the air of the sound chamber. The amplified sound in air in the chamber further increases the sound surface waves at the sound hole edges which are again sent back to the sound emitter for amplification in the manner of positive feedback. Because the device 10 is made to respond efficiently to high frequencies, primarily through the use of thin geometries and very short distances, harmonics are amplified, improving sound quality. The positive feedback effect also increases sound duration unless the latter is reduced by using softer materials in the components, or alternately fewer components, in the sound emitter.
[0048] Much of the uniqueness of the F-hole embodiment revolves around the ease with which a player can construct and then modify the device 10 to achieve different timbres and volumes. The flexible string 20 allows the sound emitter is be easily inserted, withdrawn and also “self-constructed” in the sound chamber immediately beneath the F-hole opening 41 when the string 20 is pulled tight.
[0049] Illustrated in FIG. 7 is a simple tool 42 which can be used to facilitate insertion and removal of the device 10 through the F-hole 41 . The player first constructs the device 10 in loose form by threading desired components including cross-shaped elements 11 , 21 and timbre square 31 on the string 20 . Since the components are either small or almost flat, they can be placed sideways through the sound opening 41 , one component at a time.
[0050] When all the components, except for the bridge 30 , which are to be strung on the string 20 are hanging from it in the sound chamber, the player then presses the bridge half-ball down on the instrument's top and pulls the string taut (but not tight). Because the string 20 is, at this point, not very tight, the half-ball bridge 30 can be slid along the length of the F-hole 41 , while one intermittently picks the strings, to find the most responsive location for the device 10 . Once the best sounding location is found, the pin 36 is temporarily loosened, allowing the string 20 to be pulled very tight; and then the pin 36 is seated to secure it.
[0051] The tool 42 is next used to align the paired arms in an orthogonal array of the nested cross-shaped members 11 , 21 . The tool is also used to orient the timbre square 31 , which is mounted contiguous with the bottom surface of the instrument's top, relative to the cross-shaped elements 11 , 21 ( FIGS. 2 and 4 ). The relative angle between the timbre square 31 and the cross-shaped elements 11 , 21 determines the amount of sustained sound duration. As is done to find the best sounding location in the F-hole 41 , one can determine this relative angle by intermittent playing of the instrument 30 between changes in the angle. So that adjustments can be made without loosening the string 20 , the tool 42 includes a vinyl-coated hook for “pulling” a cross-shaped element to a different angle. And an indented portion or notch formed on the hook can be used to “push” either the timbre square 31 or the element 11 , 21 .
[0052] In addition, the tool 42 can be utilized to further adjust the sound quality of the instrument 30 , when the sound emitter is mounted in its sound chamber, by bending the paired arms 12 , 22 : 13 , 23 : 14 , 24 : 15 . 25 so as to change the angles A, C, D, B between them, respectively.
[0053] In the second embodiment, a sound enhancing device 51 is provided for use with a banjo 50 or similar instruments such as openable drums. The device 51 employs a bolt 52 instead of the string 20 to mount both the sound emitter and a bridge 53 within the banjo's sound chamber in such a way that the bridge physically contacts the instrument's wood rim.
[0054] Preferably, one of the original bolts for engaging one of the banjo's existing “shoes” 55 used to hold a hook 56 (for securing the banjo's top) is replaced. Made of either steel or brass, the replacement 52 has the same diameter and thread but is slightly greater in length, by about 3/16 inch, than the original bolt. Moreover, central mounting holes 56 , 57 , 58 in the cross-shaped elements 11 ′. 21 ′ and timbre square 31 ′ and the opening in the bridge 53 , which is preferably a brass (or alternately, steel) finishing washer, are sized to receive the bolt 52 .
[0055] The metallic finishing washer 53 serves as a highly efficient circular vibration transfer bridge, giving excellent sound quality, and is used in part to standoff the sound emitter from the inside wall of the banjo 50 . In operation, the bridge washer 53 brings “wooden” sounds from the inside surface of the banjo's wood rim to the back side of the sound emitter, while the head of the bolt 52 brings “metallic” sounds from the “shoe” 55 to the front side of the sound emitter.
[0056] In a third embodiment, an improved sound enhancing device 60 is provided to facilitate changing timbre in F-hole instruments 30 . Both the bridge 35 and nested cross-shaped elements 61 , 71 are mounted outside of the sound chamber. Very easily added without removing the timbre square 31 from the sound chamber, externally mounted cross-shaped elements 61 , 71 and their paired arms 62 , 72 ; 63 , 73 ; 64 , 74 ; 65 , 75 greatly increase the volume as well as affecting the timbre. Brightness and clarity are also increased if at least one set of paired arms is positioned over the F-hole. This brightness is further enhanced when a hole, preferably about ¼ inch in diameter, is formed in each of the two opposing square shaped arms 72 , 74 in the outermost cross-shaped element 71 ; and these opposing arms are then positioned so that their holes are disposed over the F-hole 41 in use.
[0057] Numerous modifications to and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. Details of the embodiment may be varied without departing from the spirit of the invention, and the exclusive use of all modifications which come within the scope of the appended claims is reserved.
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A sound enhancing device for F-hole stringed instruments, banjos, and drums. The device includes at least one cross-shaped element and a timbre square, which may be part of a larger, user-constructed sound emitter. Strung like beads along a fastener, one or more cross-shaped elements and timbre squares are arrayed between a bridge and terminal retainer. In one embodiment, the cross-shaped element and timbre square are juxtaposed, forming a sound emitter which is mounted within an F-hole instrument's sound chamber; the bridge, positioned above it and astraddle opposing F-hole side edges, collects inaudible sound surface waves and transmits them through the fastener—a knot-free, waxed string under tension—to the sound emitter. There sound waves are amplified by constructive interference, timbre characteristics added, and sound waves transferred into the sound chamber's air. The latter then increase the sound surface waves at the F-hole's edges, setting up a positive feedback loop.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pressure reducing valves, such as are used for reducing the pressure of hydraulic fluid supplied from a common high pressure source and delivered to low pressure components of a hydraulic circuit. More particularly, the invention relates to a pressure reducing valve assembly having a single, valved opening interposed between high and low pressure ports therefore providing for a simple, cost-effective, durable construction relative to more parts-intensive conventional valves.
2. Discussion of Prior Art
Pressure reducing valves are commonly used when it is desired to use a common high pressure fluid source (e.g., a pump) to supply multiple components of a hydraulic circuit wherein one or more of the components require low pressure fluid and one or more of the components require high pressure fluid. For example, in a hydraulic clamping system having a single pump and multiple clamps operating at various pressure levels, a pressure reducing valve may be interposed between the high pressure hydraulic pump and one or more low pressure clamps. The valve delivers low pressure fluid to the selected clamps while allowing the remaining clamps to operate at a higher fluid pressure, thus eliminating the need for a separate hydraulic pump for each required pressure level.
A problem with prior art pressure reducing valves is that they are typically bulky and therefore require a great deal of space. This is problematic in applications where space is limited such as in clamping operations where numerous clamps requiring different fluid pressure levels may be mounted to a single fixture.
Another problem with prior art pressure reducing valves is that they are not efficiently designed and therefore include a large number of parts. This not only increases the overall size of the valves, which contributes to the problems described above, but also increases the cost and the complexity of the valves.
SUMMARY OF THE INVENTION
The present invention solves the above-described problems and provides a distinct advance in the art of pressure reducing valves by providing a pressure reducing valve assembly having a single, valved opening and limited fluid communication with a body providing a compact and efficiently designed valve with a fewer number of parts.
One embodiment of the pressure reducing valve assembly of the present invention broadly includes an elongated tubular body, a pressure reducing valve including a single, valved opening interposed between high and low pressure ports, and a pressure reducing reservoir defined substantially between the body and the pressure reducing valve. The pressure reducing reservoir comprises the only substantial fluid communication between the body and the pressure reducing valve and fluidly communicates with the high pressure port by the single, valved opening.
In preferred forms, the pressure reducing valve includes an inner chamber housing a spring that, among other functions, serves as a reset valve to further reduce the space requirements and decreasing the cost and complexity of the valve assembly.
Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiment and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
A preferred embodiment of the invention is described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a side elevational view of a pressure reducing valve assembly constructed in accordance with a preferred embodiment of the present invention;
FIG. 2 is a plan view of the valve assembly;
FIG. 3 is a bottom view of the valve assembly;
FIG. 4 is a vertical sectional view of the valve assembly—with the spool and ball valve illustrated in elevation—shown mounted to the base and illustrating the pressure reducing valve out of its closed position;
FIG. 5 is a fragmentary vertical sectional view of the valve assembly—with the ball valve illustrated in elevation—shown mounted to the base and illustrating the pressure reducing valve in its closed position;
FIG. 6 is a fragmentary vertical sectional view of the valve assembly—with the ball valve illustrated in elevation—shown mounted to the base and illustrating the pressure reducing valve in a reset orientation; and
FIG. 7 is a horizontal cross-sectional view taken substantially along line 7 — 7 of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a pressure reducing valve assembly 10 constructed in accordance with a preferred embodiment of the present invention and configured for receiving fluid from a high pressure line and delivering the fluid to a low pressure line. The valve assembly 10 broadly includes an elongated tubular body 12 , a pressure reducing valve 14 having a single, valved opening, a pressure reducing reservoir 16 defined therebetween, and a base 18 which can be threadably coupled with the body 12 so that the valve 14 is disposed therebetween (see FIG. 4 ).
Turning initially to FIGS. 1 and 4, the body 12 is generally cylindrical and includes a hollow upper spring-housing section 20 that houses a spring assembly 22 and a spool 24 , and a relatively diametrically smaller lower valve-receiving section 26 . A cap assembly 28 is threadably coupled to the open upper end of the upper section 20 .
The upper body section 20 has a hexagonal shaped exterior sidewall defining a cylindrically shaped internal spool-receiving chamber 30 (see FIG. 4 ). The chamber 30 comprises an enlarged spring-receiving section 30 a at its upper end and a diametrically smaller stem-receiving section 30 b at its lower end. The spring-receiving section 30 a preferably includes a vent aperture 30 c bored through the sidewall providing air communication between the chamber 30 and the atmosphere so that no undesired motion-inhibiting air pressure buildup occurs in the otherwise sealed chamber 30 .
The spring assembly 22 is housed within the section 30 a and includes a spring guide 32 , a needle bearing 34 , a spring support 36 , and a compression spring 38 . The spring guide 32 has a disk shaped distal section 32 a having a smooth, flat top surface that abuts the protruding portion of a set screw (as will be subsequently described). The distal section 32 a is diametrically larger than the portion of the set screw that projects into the chamber 30 . The spring guide 32 has a cylindrical shaped proximate section 32 b configured to slidably engage the spring support 36 (see FIG. 4 ). The needle bearing 34 is received on the proximate section 32 b so that it is disposed between the bottom surface of the distal section 32 a and the top of the spring support 36 . The spring support 36 is generally cylindrical shaped having a center bore 36 a and a rimmed portion 36 b . The bore 36 a is configured to receive the proximate section 32 b of the guide 32 . The support 36 is configured so that the cylindrical portion is received within the upper throat of the spring 38 and the rimmed portion 36 b is engagingly disposed between the needle bearing 34 and the upper-most coil of the spring 38 . The upper end of the compression spring 38 is received on the spring support 36 and the lower end is received on the spool 24 .
The spool 24 includes a cylindrically shaped spring-receiving portion 24 a at its upper end, a diametrically smaller stem 24 b at its lower end, and a retention disk 24 c generally at its center (see FIG. 4 ). The spring-receiving portion 24 a is configured to be received within the lower end of the spring 38 so that the lower-most coil of the spring 38 abuts the top surface of the disk 24 c . The disk 24 c is configured to move freely within the spring-receiving section 30 a of the chamber 30 but is prevented from entering the stem-receiving section 30 b thereof. The stem 24 b is configured to be slidably and sealingly received in the stem-receiving section 30 b of the chamber 30 . The upper portion of the stem 24 b is cylindrically shaped and has exterior circumferential grooves 24 d . The grooves 24 d provide a means for any fluid that leaks into the chamber 30 to seal between the stem 24 b and the surface of the stem-receiving section 30 b . This provides a backup seal for the chamber 30 and facilitates the alignment and sliding of the stem 24 b relative to the stem-receiving section 30 b of the chamber 30 . The lower portion of the stem 24 b is bottle shaped and has a diametrically reduced neck 24 e configured to be received by the valve 14 . The lower portion of the stem 24 b is diametrically smaller than its upper portion so that a lip seal 40 can be couplably received thereon (see FIG. 5 ). The seal 40 provides a fluid-tight seal between the chamber 30 and the valve 14 so that substantially no fluid enters the chamber 30 . As previously discussed, small amounts of fluid are expected to leak around the moving seal 40 , however, this fluid will be captured in the grooves 24 d.
The lower valve-receiving section 26 is integrally formed with the upper body section 20 and includes a cylindrically shaped, externally threaded sidewall 42 defining a central bored valve-receiving chamber open at its lower end. The sidewall 42 includes a circumferential wire-receiving groove 42 a extending along the inside surface and an associated wire-receiving aperture 42 b opposite the groove 42 a and located on the outside surface of the sidewall 42 . The upper and lower body sections 20 , 26 share a common chamber-dividing wall 44 having a central stem-receiving aperture operable to slidably receive the stem 24 b.
The cap assembly 28 includes a hexagonal shaped cap 46 , a set screw 48 screwably received therein, and a lock washer 50 operable to lockingly couple the cap 46 and the screw 48 . The cap 46 includes external threading for mating it to the upper section 20 and the hexagonal shape is operable to receive a driving device (e.g., a wrench) for facilitating the mating. The cap 46 further includes an axial bore spanning the entire width of the cap 46 and having internal threading for receiving the set screw 48 . The set screw 48 has external, complemental threading for mating to the cap 46 and includes a center bored recess 48 a operable to receive a driving device (e.g., an allen wrench) for facilitating the mating. The set screw 48 has an axial length greater than the width of the cap 46 so that both ends of the screw 48 extend beyond the respective top and bottom surfaces of the cap 46 . The screw 48 is screwably received within the cap 46 so that the extent its proximate end extends into the upper section 20 is adjustable, for example, by using a driving device in the recess 48 a . Once the desired position is achieved, the lock washer 50 is threaded onto the screw 48 until it is flush with the top surface of the cap 46 so that the screw 48 is retained in the desired position.
The pressure educing valve 14 includes a valve body 52 , a single valved opening 54 , a valve seat 56 , ball valve 58 , a ball retainer 60 , a spring 62 , and a valve insert 64 . The valve body 5 is generally cylindrically shaped and has an upper end configured to sealably engage the valve-receiving chamber in the lower body section 26 and a lower end configured to sealably engage the base 18 . The valve body 52 includes circumferential grooves at each end for receiving 0 -ring type valve seals 52 a, 52 b, 52 c, 52 d that facilitate the fluid seal between the valve body 52 and the corresponding valve-receiving chamber and base 18 . The valve body 52 has a circumferential wire-receiving groove 66 and an associated aperture (not shown) located toward the center o its upper end that cooperate to receive wire (as will subsequently be described) o retain the position of the valve 14 relative to the lower body section 26 . The valve body 52 is diametrically smaller at its lower end (relative to its upper end) to facilitate mating to the base 18 .
The valve body 52 has an internal central bore defining a high pressure chamber 68 and a low pressure chamber 70 with the single valved opening 54 disposed therebetween. The high pressure chamber 68 has a stepped configuration with internal threading on its lower-most step. The low pressure chamber 70 has a generally conical shape complementing the bottle shaped portion of the stem neck 24 e . The valve body 52 includes a high pressure port comprising a plurality of fluid-receiving channels 72 located generally along the center circumferential surface and extending into the high pressure chamber 68 (see FIG. 7 ). The valve body 52 further includes a low pressure port comprising a plurality of fluid-discharging channels 74 along its top surface that are bored the entire axial length of the valve body 52 (see FIGS. 4 and 7 ). The fluid-discharging channels 74 must not intersect either the fluid-receiving channels 72 or the high and low pressure chambers 68 , 70 .
The single valved opening 54 is defined along the internal central bore of the valve body 52 disposed between the high pressure chamber 68 and the low pressure chamber 70 . Although there are other openings in the valve 14 (e.g., the channels 72 , 74 ), the opening 54 is the only opening that fluidly connects the high pressure side of the valve 14 (i.e., the high pressure line, the fluid-receiving channels 72 , and the high pressure chamber 68 ) with the low pressure side of the valve (i.e., the low pressure line, the fluid-discharging channels 74 , and the low pressure chamber 70 ). The opening 54 is also the only valved opening in the valve assembly 10 . The valve seat 56 is defined by shoulders formed in the lower end of the low pressure chamber 70 at the opening 54 (see FIG. 6 ).
The ball valve 58 rides in the ball retainer 6 O and is shiftable into and out of a closed position as shown in FIG. 5 wherein the ball valve 58 is in sealing engagement with the valve s at 56 . The ball valve is configured to completely close the opening 54 when in the closed position so that fluid communication between the high and low pressure chambers 68 , 70 is prevented. The ball retainer 60 is configured to be slidably received within the upper-most step of the high pressure chamber 68 . The retainer 60 is generally cylindrically shaped having a ball-receiving cup 60 a at its upper end configured to receive the ball valve 58 so that a sufficient portion of the ball valve 58 protrudes out of the pup 60 a to seal the opening 54 when the valve 14 is in the closed position. The upper end of the retainer 60 further includes a flange 60 b that both prevents the retainer 60 from retracting too far into the valve insert 64 and facilitates maintaining engagement of the ball valve 58 with either the stem 24 b or the valve seat 56 (e.g., high pressure fluid exerts a lifting force against the underside of the flange 60 b ). The retainer 60 includes a central spring-receiving bore in its lower end configured to receive the spring 62 and having a bleeder vent 60 c therein to prevent undesired hydraulic locking conditions. The spring 62 is received in this bore and is configured to exert a spring force between the retainer 60 and the insert 64 sufficient to maintain substantially constant engagement of the ball valve 58 with either the stem 24 b (i.e., when the valve 14 is pot in the closed position) or the valve seat 56 (i.e., when the valve 14 is in the closed position). The spring force of the spring 62 must be such that it never overcomes the spring force of the compression spring 38 (i.e., the spring 62 does not cause the spool 24 to move).
The valve insert 64 is configured to be sealingly received within the high pressure chamber 68 of the valve body 52 . The lower end of the insert 64 includes external circumferential threading, configured to threadably mate the insert 64 to the internal threading of the valve body 52 , and a center bored recess 76 operable to receive a driving device (e.g., an allen wrench) for facilitating the mating. The insert 64 includes a circumferential groove generally located at the center of the insert 64 (but in any event below the fluid receiving channels 72 of the valve body 52 ) and operable to receive O-ring type insert seals 64 a, 64 b. The upper end of the insert 64 includes a central bore operable to receive the spring 62 and the lower end of the ball retainer 60 (see FIG. 4 ). The upper end of the insert 64 has a triangular shaped perimeter that further defines the high pressure chamber 68 to provide clearance for high pressure fluid moving through the chamber 68 (see FIG. 7 ). The upper end of the insert 64 is further configured so that when it is fully received in the valve body 52 , it does not protrude into the upper-most step of the high pressure chamber 68 . This allows sufficient clearance for the ball valve 58 (and the retainer 60 ) to slide into and out of the closed position.
The pressure reducing reservoir 16 is defined in the lower body section 26 between the upper end of the valve 14 and the chamber-dividing wall 44 . The valve 14 is pressure fit into the lower body section 26 and a lock wire 78 is wound into the wire-receiving grooves 42 a , 66 to maintain a reservoir defining position (see FIGS. 4 and 6 ). Particularly, the wire 78 has a crimped end that fits through the wire-receiving aperture 42 b in the lower section sidewall 42 and is received in the aperture in the groove 66 on the valve body 52 . The valve body 52 is then rotated to wind the wire 78 into the grooves 42 a , 66 . The pressure reducing valve 14 and the body 12 are not designed to be uncoupled once they have been mated together (for manufacturing purposes they have been machined as separate components), therefore, the wire-receiving aperture 42 b in the sidewall 42 can be closed after the mating is completed to prevent uncoupling of the components, for example, by peening it closed. Fluid in the reservoir 16 is low pressure fluid and the reservoir 16 provides adequate clearance to allow the fluid passing through the opening 54 to enter the fluid-discharging channels 74 . As will subsequently be described in detail, the reservoir 16 provides the only fluid communication between the body 12 and the valve 14 .
As illustrated in FIGS. 4, 5 , and 6 , the valve assembly 10 is attached to the base 18 . The base 18 includes a recess 80 , inlet and outlet ports 82 , 84 , respectively, and corresponding fluid passageways 86 , 88 . The recess 80 is configured to sealingly receive the valve 14 mated to the body 12 . The recess 80 includes threading operable to threadably receive the external threading of the lower section 26 of the body 12 . An O-ring type base seal 18 a prevents fluid leakage between the body 12 and the base 18 . The inlet and outlet ports 82 , 84 include internal threading for connecting with externally threaded high and low pressure lines, respectively. The fluid passageways 86 , 88 provide fluid communication between the inlet and outlet ports 82 , 84 , respectively, and the corresponding fluid-receiving and fluid-discharging channels 72 , 74 .
OPERATION
High pressure fluid (e.g., 5000 psi) from the high pressure line (originating from a high pressure fluid source such as a pump) enters the pressure reducing valve assembly 10 through the inlet port 82 of the base 18 , where it passes through the fluid passageway 6 into the fluid-receiving channels 72 and enters the high pressure chamber 68 of the pressure reducing valve 14 . When fluid is initially delivered to the inlet port 82 the valve assembly 10 is in the state illustrated in FIG. 4 . Specifically, the compression spring 38 overcomes the spring force of the spring 62 and biases the pressure reducing valve 14 out of the closed position. The neck 24 e of the stem 24 b protrudes though the opening 54 displacing the ball valve 58 off of the valve seat 56 . The ball valve 58 is retained in the ball-receiving cup 60 a of the ball retainer 60 which is depressed into the central bore of the valve insert 64 . Fluid freely flows from the high pressure chamber 68 through the single valve opening 54 into the low pressure chamber 70 . Once in the low pressure chamber 70 , fluid is received in the pressure reducing reservoir 16 , passes through the fluid-discharging channels 74 through the fluid passageway 88 out the outlet port 84 and into the low pressure line where it is delivered to a low pressure component such as a clamp.
Fluid freely flow into the low pressure line until the fluid pressure reaches a pre-selected operating level (e.g., 750 to 4500 psi), wherein the valve assembly 10 shifts into the state illustrated in FIG. 5 . Specifically, fluid pressure in the reservoir 16 exerts a force against the stem 24 b that overcomes the spring force in the compression spring 38 causing the neck 24 e of the stem 24 b to recess out of the opening 54 and allowing the force of the spring 62 to simultaneously slide the ball valve 58 into sealing engagement with the valve seat 56 (corresponding to the valve 14 being in the closed position). When the valve 14 is in the closed position, fluid is prevented from flowing through the opening 54 between the high and low pressure chambers 68 , 70 . The pressure differentiation between the high and low pressure chambers 68 , 10 occurs at the single valved opening 54 . Fluid in the high pressure chamber 68 is under high pressure and fluid in the low pressure chamber 70 is under low pressure.
The pre-selected operating level pressure is selected in accordance with the needs of the low pressure component being controlled by the valve assembly 10 . The illustrated valve assembly 10 is capable of delivering low pressure fluid at a pressure between 500 psi and 4500 psi. The valve assembly 10 is set to control this level by adjusting the set screw 48 until the desired spring force in the compression spring 38 is achieved—i.e., a spring force that is completely overcome only by fluid pressure at or just above the operating level pressure. To increase the spring force exerted by the compression spring 38 , the screw 48 is turned in a clockwise direction when viewed from above as illustrated in FIG. 2 so that it protrudes further into the spool-receiving chamber 30 and further depresses the spring guide 32 . To decrease the spring force exerted by the compression spring 38 , the process just described is reversed. As the fluid pressure approaches the pre-selected operating level, it will begin to overcome the spring force of the compression spring 38 thereby causing the stem 24 b to retract out of the opening 54 . As the ball valve 58 slides toward the closed position, less fluid is allowed through the opening 54 ; however, until the spring force of the compression spring 38 is completely overcome and the stem 24 b fully retracts out of contact with the ball valve 58 , some fluid passes between the high and low pressure chambers 68 , 70 .
The valve assembly 10 provides and maintains low pressure fluid in the low pressure line at a constant and steady pressure. The valve assembly 10 reacts only to pressure changes in the low pressure line (except when performing its reset function as described below). The valve 14 is shifted into and out of the closed position based on the pressure level in the low pressure chamber 70 . The valve 14 does not react to pressure changes in the high pressure line with one exception: the valve 14 provides a reset function if the fluid pressure in the high pressure chamber 68 drops sufficiently below the fluid pressure in the low pressure chamber, for example if the fluid source is shut off and/or does not maintain static high pressure conditions. This pressure differential will overcome the spring force of the spring 62 causing the ball retainer 60 to retract into the valve insert 64 and shifting the ball valve 58 off of the valve seat 56 (corresponding to the valve assembly 10 being in the state illustrated in FIG. 6 ). Accordingly, the century spring 62 provides a reset function obviating the need for a separate reset valve. The state depicted in FIG. 6 is illustrated for descriptive purposes only. In application, depending on the conditions, the valve assembly construction, and the valve settings, the force of the compression spring 38 may instantaneously overcome the reduced pressure in the low pressure chamber 70 as the ball valve 58 shifts off of the valve seat 56 , thereby shifting the assembly 10 into the state illustrated in FIG. 4 .
The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiment, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
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A pressure reducing valve assembly ( 10 ) for receiving fluid from a high pressure line and delivering the fluid to a low pressure line includes an elongated tubular body ( 12 ), a pressure reducing valve (14) having a single, valved opening ( 54 ) interposed between high and low pressure ports ( 68 ),( 70 ), and a pressure reducing reservoir ( 16 ) defined substantially between the body ( 12 ) and the pressure reducing valve ( 14 ). The pressure reducing reservoir ( 16 ) comprises the only substantial fluid communication between the body ( 12 ) and the pressure reducing valve ( 14 ) and fluidly communicates with the high pressure port ( 68 ) by the single, valved opening ( 54 ). In preferred forms, the pressure reducing valve ( 14 ) includes a valve insert ( 64 ) housing a spring ( 62 ) that, among other functions, serves as a reset valve to further reduce the space requirements and decreasing the cost and complexity of the valve assembly ( 10 ).
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This is a continuation of application Ser. No. 07/759,477 filed Sep. 13, 1991 now abandoned.
THE FIELD OF THE INVENTION
The present invention relates to the field of fiber making and specifically to protecting refining discs from excessive mechanical wear.
BACKGROUND OF THE INVENTION
During the production of fibers for paper making, wood or another fiber source is ground into chips and chemically and/or mechanically treated such that the chips may be broken down further and refined into individual fibers.
The actual production of fibers generally takes place inside a refiner. In the refiner, chips and other pre-fiber material are brought into contact with one or more rotating discs, such as those described in U.S. Pat. No. 2,156,321. The interaction of the wood or other cellulosic material with the refining rings of the refining discs causes the individual fibers contained within the cellulosic material to separate from one another.
Refiners may include a single rotating disc in close opposition to a stationary disc, or may involve two counter rotating discs. In either circumstance, however, it is important that the material introduced between the various refining discs be uniform in size, water content, and most importantly composition. For example, the introduction of rocks or metal into the gap between refining rings of the refining discs, along with cellulosic material to be processed, could dramatically reduce the useful life of the refining segments which make up the refining ring. This is particularly true when the cellulosic material used for the production of fiber contains a great deal of contaminants such as rocks, metal fragments, or other debris which have not, or cannot, be pre-separated.
Depending upon the size and throughput of the refiner, unwanted contaminants can ruin a refining disc in a matter of seconds, or at very least, reduce the normal life thereof. The costs of replacing the refining disc can run into thousands of dollars in parts alone. The time taken in replacing the disc and the lost production time caused thereby can dramatically increase the overall costs.
The present invention relates to a device which is designed to be associated with a refiner, either originally or as a retrofit, to protect the refining discs from contaminants.
OBJECTS AND SUMMARY OF THE INVENTION
It is the object of the present invention to provide a device which may be used in conjunction with a conventional fiber refiner to protect the refining discs from damage caused by contaminants.
In accordance with one aspect of the present invention, there is provided a fiber refiner including a first and a second opposed refining disc, the first and second opposed refining discs being separated from one another and, at the periphery thereof, defining a refining zone. The refining zone has an entranceway through which material must pass before entering and while entering the refining zone and an exit, generally at the outermost periphery of the refining discs. At least one of the first and second refining discs has an inlet and at least one of the first and second refining discs is rotatable about its axis to thereby cause material to move outwardly from the inlet to and through the entranceway of the refining zone. Interposed between the inlet and the entranceway of the refining zone there is also provided guard means for urging material in a direction away from the entranceway of the refining zone.
The refiner may also include a means for receiving material deflected in a direction away from the entranceway by the guard means.
In a particular preferred embodiment, the guard means for urging material in a direction away from the entranceway of the refining zone includes at least a first deflecting ring attached to the first refining disc and at least one second deflecting ring attached to the second refining disc. The first and second deflecting rings being at least partially in opposition and are separated by a gap.
In conventional refiners, cellulosic feed material is introduced into a refiner near the axis of rotation of one or more rotating refining discs. Then, either through centrifugal force alone, or with the assistance of some additional structure, the material disperses outwardly towards the periphery of the refining discs. At the disc's periphery are the refining disc segments which make up a pair of opposed refining rings and which define a refining zone having an entranceway and an exit. Thus, the material moves outwardly from the inlet to and through the entranceway of the refining zone to be refined into fibers. In the refining zone, individual fibers are torn apart from chips and fiber bundles. Thereafter, the fibers are collected and, optionally, subsequently dewatered and further treated.
When contaminants enter a conventional refiner along with a slurry of cellulosic feed material, they too are fed into the gap between the refining discs and into the refining zone. However, because of their size and composition, these contaminants can gouge and/or destroy the refiner disc immediately reducing their effectiveness in providing homogeneous fibers and, eventually, destroying the usefulness of the disc entirely.
The present invention can aid in alleviating this problem thus extending the life of the refiner discs and lowering the down time of a refiner. This is accomplished by adding certain structures to the refiner which limits access to the refiner discs to only material intended to be refined or to contaminants which are too small to have a significant impact on the life of the refiner disc. This is accomplished by deflecting or urging contaminant material in a direction away from the entranceway to the refining zone and, in a preferred embodiment, into a convenient collecting or receiving area.
Furthermore, and in a preferred embodiment, the device of the present invention provides a gap in the guard means which may be oriented axially when compared to the normal "radial" flow of material between the inlet and the refining zone. By so orienting the gap, the pathway to the refining zone becomes complicated and contaminants may be excluded thereby. The gap is too small for dangerous contaminants to get through. Both the size and the relative orientation of the gap aid in preventing contaminants from reaching and traversing the entranceway of the refining zone.
Finally, the apparatus of the present invention is equipped with structure which will grind or destroy contaminants such that the contaminants will not pose as much of a danger to the refining discs as might otherwise occur, even if allowed to pass therethrough. The later structure also can assist in the prerefining of fiber material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a refiner in accordance with the present invention.
FIG. 2A is a cross-sectional side view of the first backing disc in accordance with the present invention.
FIG. 2B is a planar view of the first disc of FIG. 2A.
FIG. 3A is a cross-sectional view of the first deflecting ring.
FIG. 3B is a planar view of the first deflecting ring of FIG. 3A.
FIG. 4A is a cross-sectional side view of a second deflecting ring.
FIG. 4B is a planar view of the second deflecting ring of FIG. 4A.
FIG. 5 is a cross-sectional view of a refiner in accordance with the present invention illustrating a means for removing material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention involves the use of a device in conjunction with a refiner for purposes of aiding to deflect, exclude, and/or destroy unwanted contaminants carried into the refiner along with the cellulosic material to be refined. The apparatus of the present invention may be retrofitted into already existing refiners to provide additional contaminant removal or may be originally constructed into a specific refiner. For simplicity, the present invention will be described hereinafter in terms of a single rotating disc refiner wherein one disc rotates and another disc in opposition thereto remains fixed and stationary. However, the invention is not limited thereto.
The refiner of the present invention includes a housing 1, a shaft 2 which is connected at one end to a motor (not shown) and, at another end to one or more staging discs 3 and/or 4. These staging discs will hold the various refining segments of the first refining ring 5 and will translate the rotational energy of the shaft into rotational movement of the first refining ring 5. The first refining ring 5 is a ring made up of refining segments as is known, and is arranged and affixed toward the periphery of the staging discs 3 and/or 4. The first refining ring 5 and the various staging discs 3 and/or 4 make up the first refining disc.
Within the area defined by the inner most edge of the first refining ring 5 is attached a first backing disc 6. The first backing disc 6 may be attached to staging discs 3 and/or 4 by the use of screws, bolts or other conventional fastening devices. In a particular preferred embodiment the first backing disc 6 includes a recess 7 which is specifically adapted to receive, retain, and position a first deflecting ring 8. The recess 7 is preferably placed at the periphery of the first backing disc 6 such that the first deflecting ring 8 can be so placed. Of course, it is possible that the first deflecting ring 8 and the first backing disc 6 may be manufactured as a single piece.
The first deflecting ring 8 includes an inner-angled surface 9 which slopes away, relative to the plane of the first backing disc 6 and/or the imaginary center of the first deflecting ring 8. The first deflecting ring 8 further includes a first major surface 10 which may be parallel to the plane of the first backing disc 6 or may be angled such that the junction of the inner-angled surface 9 and the first major surface 10 forms the highest point of either surface. The slope of the inner-angled surface 9 may range from between about 30 degrees to about 60 degrees, but is preferably about 45 degrees.
In a particular preferred embodiment of the present invention, the first deflecting ring 8 further comprises a plurality of course grinding bars 11 which radiate from the inner edge of the first deflecting ring 8 to the outer edge thereof. Preferably, the course grinding bars 11 radiate from the lowest point of the inner-angled surface 4 to the furthest outer edge of the first major surface 10. The course grinding bars 11 may be of any size or shape. However, the present inventors have found that grinding bars having a trapezoidal cross-section and having a height above the inner-angled surface 9 and the first major surface 10 of between about 3 and about 6 millimeters are preferred. Particularly preferred is a height of approximately 6 millimeters.
It is of course possible for the height of the course grinding bars to be greater or less than between about 3 millimeters and about 6 millimeters depending upon the type of material to be refined, the throughput and size of the refiner and the material's consistency. However, it has been found that grinding bars greatly in excess of 6 millimeters tend to chip and break, and grinding bars of less than 3 millimeters are generally inefficient and ineffective. The size of the base of the trapezoidal cross-section grinding bar can vary widely. However, it is preferred that the width be between about 20 and about 30 millimeters and more preferably about 26 millimeters. Similarly, the width of the top of the trapezoidal cross-section of the grinding bar can vary widely in size but is preferably between about 5 and about 15 millimeters in width and most preferably about 12 millimeters in width when incorporated in the grinding bars as described herein. The number of grinding bars may also vary as necessary. The number of grinding bars may range from about 5 to about 30 but preferably varies from between about 10 to about 20.
The housing 1 also contains a plate 12 which has an orifice or inlet 13 through which material may be fed into the refiner. Attached to plate 12 is a staging disc 14 to which is further attached a second refining ring 15 which is similar in construction to the first refining ring 5 but in opposition thereto. The are between the refining ring 5 and the refining ring 15 is the refining zone 16, which has an entranceway 30 on the inlet side of the zone and an exit 31 at the refining discs outermost periphery. The dimensions of area 16 may taper and change with the dimensions of the first and second refining rings 5 and 15. The second refining ring 15 and staging disc 14 are collectively known herein as the second refining disc.
Located within the area defined by the inner most edge of the second refining ring 15 is a second deflecting disc 17 having a second major surface 18 which is opposed to the first major surface 10 of the first deflecting ring 8. The second deflecting ring 17 is attached to the staging disc 14 in any conventional manner. In refiners where the second refining disc is fixed, the second deflecting ring 17 may be attached to the staging disc 14 through a shim 19 or other means for adjusting the relative position of the second deflecting ring 17. By adjusting the position of the second deflecting ring 17 relative to the first deflecting ring 8, the gap 20 defined as the distance between the second major surface 18 of the second deflecting ring 17 and the first major surface 10 of the first deflecting ring 8 may be adjusted. The second major surface 18 of the second deflecting ring 17 may further include course grinding bars 21 which may be of identical size, composition, number and arrangement as the course grinding bars 11. They are not, however, necessarily identical thereto.
Gap 20 generally ranges from between about 12 and about 23 millimeters. However, it is more preferable that the distance between the first major surface 10 and the second major surface 18 be between about 18 millimeters and about 22 millimeters with about 22 millimeters being most preferred. Of course the distance of separation may be adjusted by the use of, for example, shims 19 such that the size of gap 20 may be increased or decreased. This is advantageously done to accommodate varying apparatus and conditions.
It is preferred that the gap 20 be oriented such that the direction of material flowing therethrough has a relatively axial component. This is accomplished by angling the first major surface 10 and the second major surface 18 such that they are parallel with respect to each other but in a plane which bisects the plane of the first and second refining rings. This is best illustrated in, for example, FIG. 1. By so orienting gap 20, material is forced to make a very sharp turn around the junction of the inner angled surface 9 and the first major surface 10 in order to gain access to and through gap 20. Such an orientation of gap 20 should not prevent cellulosic material from reaching the entranceway of refining zone 16 but should provide additional deterrent as far as contaminants are concerned. Refining gap 20 may also be oriented generally radially such that material flowing through the gap travels in a path very much like the otherwise uninterrupted pathway of cellulosic material travelling from inlet 13 to the refining zone 16.
Between the inlet 13 and the inner most edge of the second deflecting disc 17 is a recess 22 or other means for receiving material and into which rocks, metals and other contaminants may be deflected or urged by the guard means. As will be readily apparent, the guard means for urging material in a direction away from the entranceway of the refining zone, in one preferred embodiment, includes both the first deflecting ring 8 and the second deflecting ring 17 and the structure associated therewith. This recess 22 may be lined with magnetic material to aid in retaining metallic material. Optionally, the recess 22 may further comprise a means for removing the unwanted contaminants from both recess 22 and from the apparatus of the present invention in general. As illustrated in FIG. 5, this device 40 could be constructed from a conduit 41 which leads to a first valve 42. Valve 42 is also connected to chamber 43 into a second valve 44. Finally, valve 44 is also connected to a pipe 45. By opening valve 42, material will be allowed to flow from the recess 22 through conduit 41 into chamber 43. Valve 42 may then be closed to preserve the integrity, temperature and pressure within the refiner. Thereafter, valve 44 may be opened and the material removed from the recess 22 may exit from the chamber 43 through pipe 45. Thereafter, the valve 44 may be reclosed and the procedure started again as necessary.
In operation, cellulosic material is introduced into the refiner through inlet 13. The material is introduced in a generally axial direction, i.e., in the direction of the common axis of the first and the second refining disc. From there, the material must travel in a generally radial direction outwardly toward the entranceway 30 to the refining zone 16 and therethrough. Cellulosic material must, therefore, "turn a corner" from its generally axial introduction to a generally outward or transverse direction.
When the cellulosic material is inside the refiner, and as it makes its way outward, the cellulosic material is deflected by the first deflecting ring 8, and the material is urged in a direction away from the entranceway 30 to refining zone 16. In a particularly preferred embodiment, the material is deflected toward the means for receiving material which, in one embodiment, is an annular recess 22.
Because the guard means includes not only the first deflecting ring 8 and the second deflecting ring 17 but also gap 20, which is defined by the distance between the first deflecting ring 8 and the second deflecting ring 17, and because of the relative orientation of gap 20, material must also negotiate or "turn a corner" and enter gap 20 before being fed to the entranceway 30 of the refining zone 16. Once the cellulosic material reaches the entranceway 30 at refining zone 16, it is acted upon by first refining ring 5 and the second refining ring 15 as the former rotates relative to the position of the latter. Within the refining zone 16 and in the distance between the first refining ring 5 and the second refining ring 15, the cellulosic material is forced to separate into individual fibers. As the centrifugal force generated by the rotation of first the refining disc and the forces generated by the continual influx of cellulosic material through inlet 13 act upon the fibers in the refining zone 16, they are forced to the outermost periphery of the first and the second refining discs and, therefore, exit the refining zone through exit 31.
Metal, rocks, and other contaminants generally are relatively heavy by comparison to the cellulosic material entering the refiner through inlet 13. Because of their relative weight, these contaminants may be unable to change direction as quickly as the cellulosic material introduced into the refiner. They are, therefore, more likely to strike and be deflected by the first deflecting ring 8 up into recess 22 and thereby, in a direction away from the entranceway 30 of the refining zone 16. These contaminants may, at least for a time, remain in recess 22. However, they may also be swept up and fed back into the main flow of cellulosic material only to be redeflected by the first deflecting ring 8.
If a contaminant is able to escape the cycle of collection and redeflection just described, it still must make the sharp change in direction necessary to enter gap 20 and must be small enough to pass therethrough. Unable to "make the turn" or too large to enter the gap, the contaminants should eventually be swept back up into the cycle of collection and redeflection.
Of course, it is possible that stones, metal, or other contaminants may eventually be able to enter gap 20. However, upon doing so, the grinding bars 11 and 21 should serve to contact the contaminant crush or deform if such that the contaminant is less likely to have a significant impact on the useful life of the first refining ring 5 and the second refining ring 15.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular embodiments disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit and scope of the invention.
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The present invention relates to a device for protecting refining discs from excessive mechanical wear by preventing unwanted debris from coming between the discs.
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SUMMARY OF THE INVENTION
This invention relates to manufactured building structures and will have application to such a structure as equipped with a covered pool, spa, or similar structure.
The building structure of this invention is typically a transportable manufactured structure such as a mobile home, a vacation home, garden house, gazebo or the like. Such buildings can be moved and relocated via road travel. Heretofore, it has been impractical to construct such structures with a sunken tub or pool because of the road travel and the limited space in the structure.
This invention provides for a pool, hot tub or similar structure to be included in the manufactured building unit. The pool or hot tub liner is positioned inside the building unit and is supported atop the floor or the main frame of the building during road travel. When the building reaches its final destination, the supports are removed and the liner is lowered into an opening in the floor. Once secured, the liner can be supported either by the building floor or frame, or can rest directly on the ground beneath the building. An alternative construction has the liner bottom supported on a fixed frame support when the desired look is an indoor raised pool structure.
Accordingly, it is an object of this invention to provide for a transportable building structure which incorporates an interior pool or hot tub.
Another object is to provide a transportable building which has an indoor pool which can be rapidly shifted from a travel location inside the building to an operative location inside the building.
Another object is to provide for a pool or hot tub in a transportable building which does not detract from the living space of the building.
Other objects will become apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a manufactured building with the pool liner in the shipping or road travel position.
FIG. 2 is a cross-sectional view of the building of claim 1 with the pool liner in its lowered position and showing the removable floor.
FIG. 3 is a cross-sectional view of a manufactured building with a raised (or above floor) pool liner in the lowered position.
FIG. 4 is a cross-sectional view of a manufactured gazebo incorporating the pool of this invention in a lowered position.
FIG. 5 is a top floor plan view of the garden and swim house building.
FIG. 6 is a top floor plan view of the building of FIG. 5 incorporated into a preexisting building.
FIG. 7 is a perspective view of the pool.
FIG. 8 is a sectional view similar to FIG. 3 with an alternative pool support shown.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments herein described are not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described to explain the principles of the invention and their application and practical use to allow others skilled in the art to follow their teachings.
Referring first to FIGS. 1 and 2, reference numeral 10 generally designates a building structure of the type described. Structure 10 shown is a manufactured house which is capable of being transported from the factory to a living site via road travel in a common manner.
Structure 10 as is common includes a lower support frame 12, floor 14, walls 16 and a roof 18. These components are common to nearly all structures which fit the standard industry definition of manufactured housing and will not be further described in detail. The structure 10 shown also includes ceiling 20 which in the unit shown defines a loft area 22 also common in the industry. Structure 10 will normally have a wheeled carriage (not shown) detachably fixed to the underside of frame 12 to promote road travel.
FIG. 1 illustrates structure 10 after initial house setup. As is common, support pilings 24 are anchored in the ground 26 to both support structure 10 and to prevent shifting. After the carriage (not shown) has been removed, structure 10 is normally lowered onto pilings 24 as by a lift crane and is then fixed to the pilings by fasteners (not shown). In the embodiment shown, the ground is excavated to a predetermined depth below the position of the hot tub or pool 28.
Pool 28 includes a liner 30 which defines the dimensions of the pool and will necessarily include plumbing, heaters, filters and/or pumps (not shown) which may be shipped either with structure 10 or separately for connection and set up at the site. During shipping, liner 30 rests atop and is supported by a removable floor section 32. Shipping dunnage 34 may be used to ensure the stability of liner 30 during road travel.
Liner 30 includes an upper peripheral lip 36 which may be of the generally squared S-shape configuration shown. If dunnage 34 is used, lip 36 is supported atop the dunnage 34 as shown in FIG. 1.
When structure 10 has reached the destination and been secured to pilings 24, pool 28 may be installed. Floor section 32 is removed, and liner 30 is lowered usually by a mechanical lift shown in FIG. 3 as cables 38, pulleys 40 and winch 42. Any acceptable method of lowering liner 30 can be employed without departing from the spirit of this invention.
As shown in FIG. 2, liner 30 is lowered into the opening in frame 12 formed by removing floor section 32 until lip 36 contacts floor 14. Liner 30 may be supported directly on the ground 26 as shown in FIG. 2, by lip 36 bearing on floor 14, or a combination of the two. Floor section 32 may be raised or lowered as shown depending on the desired use or non-use of pool 28. After pool liner 30 has been lowered into the position of FIG. 2, the plumbing 44 and other accessories (not shown) may be installed as desired to allow normal pool or hot tub use.
FIG. 3 illustrates a modified structure 46. In this structure, frame 12 includes one or more fixed lower pool support 48 which support liner 30 if a raised pool or hot tub look is desired. Liner bottom 31 rests on and is supported by pool support 48. Lip 36 rests on peripheral support walls 50 which preferably surround the entire liner 30 and may be decorative to add a pleasing aesthetic appearance. In this embodiment, pool 28 is normally permanently secured in the position shown for both road travel and on-site use. Plumbing 52 and other accessories (not shown) can be installed at the factory or on-site.
FIG. 4 illustrates an alternative structure 54 for pool 55 which could be a gazebo, a swim house or similar structure. Structure 54 could be a stand alone unit such as with a gazebo or the garden-swim house 56 shown in FIG. 5, or can be incorporated into a common floor plan of a manufactured house 58 as shown in FIG. 6.
FIG. 4 illustrates pool 55 in the lowered position. Pool 55 includes liner 62 with a peripheral upper lip 64 and may be stored for road travel in much the same fashion as pool 28. When structure 54 reaches its intended destination, pool 55 is lowered in the same fashion as pool 28 with removable floor section 66 covering liner 62 when not in use. It should be noted that floor sections 32 and 66 could be of single piece or multiple piece construction.
The reference numerals used for the various other structural components of structures 10, 46 and structure 54 are identical to promote simplicity of description.
FIGS. 5 and 6 illustrate structure 54 in floor plan views. FIG. 5 illustrates structure 54 as a stand-alone unit independent of any other structure and includes a main room 68 which houses pool 55. Structure 54 may also include bathroom 70 and utility room 72 which may be used to house the pool heater 74 and filter/pump 76 shown and referenced in FIG. 6. FIG. 6 illustrates structure 54 as an attachment to a preexisting manufactured house 58. Numerals from FIG. 6 are the same as in FIG. 5 for simplicity of description.
In all of the embodiments shown and described, pool 28 or 55 may be stored in the manufactured structure 10 or 54 for road travel purposes, then lowered into its operating position and connected to the plumbing at the destination site. In all instances, the pool 28 or 55 may be covered by removable floor sections 32 or 66 to allow the structure to assume a dual use depending on individual needs and desires.
FIG. 8 illustrates an alternative means of supporting pool 28 in building 46. In this embodiment, pool 28 is supported by flexible straps 29 (one shown) which are connected to floor 14 and extend under pool bottom 31.
It is understood that the above description does not limit the invention to the above given details, but may be modified within the scope of the following claims.
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A manufactured building structure which can be transported via road travel. The structure includes a pool, spa, or the like which can be shifted between a travel position inside the structure to a lowered operative position when the structure reaches its destination.
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BACKGROUND OF THE INVENTION
[0001] Glass windows are the conventional means for illuminating rooms with daylight. However, ordinary windows have some disadvantages in respect to natural illumination of rooms. One disadvantage is that daylight does not penetrate very deeply into rooms from ordinary windows. The illumination provided through ordinary windows tends to fall almost exponentially with distance from the window. A second disadvantage of ordinary windows is that direct sunlight entering through the windows will produce areas of very intense illumination in areas close to the window that give rise to thermal discomfort and reflected glare.
[0002] Thus, an objective of this invention is a method for producing a thin panel, suited for installation in a window, that channels or redirects all, or a very high proportion of, the sunlight incident from the sky onto the panel, into an upwards direction and over the ceiling of the room being illuminated by the window. This channelling or redirection of all incident sunlight into an upwards direction providing for nearly complete shading from incident sunlight of areas of the room in the vicinity of the window which would otherwise receive intense direct sunlight and providing for natural illumination of areas deep inside the room by diffuse reflection of redirected light off the ceiling.
PRIOR ART
[0003] The light shelf is an effective and traditional means of reflecting light through a window deeper into a room and for shading areas near a window. However light shelves are an expensive architectural addition to a building and have a tendency to loose efficiency through the accumulation of dust. Therefore there have been many developments with the aim of providing the lighting and shading effect of a light shelf in a vertical panel form more suitable for installation in a window. Prismatic panels moulded from transparent material have been used for many years in windows to improve the natural illumination of buildings by refracting some light up toward the ceiling. A recent example is U.S. Pat. No. 4,557,565 to Ruck et al. However prismatic panels are deficient in refracting only a proportion of incident light upwards, deficient in refracting the light through a relatively small angle and deficient in dispersing the light which is refracted. The concept of deflecting light by total internal reflection at internal interfaces formed within a panel was invented by Wadsworth in 1903, U.S. Pat. No. 737,979. A method for producing such a panel by laser cutting is U.S. Pat. No. 4,989,952 to Edmonds in 1991.
[0004] Such panels are effective in deflecting a fraction of incident light strongly upwards. However such panels are deficient in allowing a significant fraction of incident sunlight to pass through the panel thereby producing reflected glare and thermal discomfort in work areas below the panel. When the internal interfaces in such panels are angled downwards into the room incident sunlight can be deflected into a lower elevation angle and much more deeply into a room. However, as the elevation of incident sunlight decreases the elevation of the deflected light can become negative, that is downward, and sunlight, when deflected, near horizontally and downward, into a room, presents an extremely serious glare problem to occupants.
[0005] Thus, a further objective of this invention is to provide a method for producing a thin transparent panel suited to installation in a window which channels all, or substantially all, incident sunlight into an upwards direction thereby providing effective shading to work areas below the panel and eliminating the possibility of sunlight being deflected near horizontally into occupants eyes.
[0006] Bartenbach et al U.S. Patent 4,699,467 describes a reflective light port formed from upper and lower metallic reflectors. A plurality of such ports arranged one above the other may be installed in a window to reflect sunlight into a room. The method of producing a light port of Bartenbach is deficient in that it is difficult and expensive to produce an array of complex metal reflectors fixed one above the other in a panel at the scale (10 mm thick) suited to installation in a window. Secondly the light ports of Bartenbach are deficient in requiring installation between two transparent panels to prevent accumulation of dust on the reflective surfaces.
[0007] Thus a further objective of this invention is to provide a method for producing a light-channelling panel, the reflecting surfaces of which do not accumulate dust.
[0008] Cowling, U.S. Pat. No. 5,295,051 (1994), describes a light channel formed from an element of transparent material with an upper and lower reflective surface. Each element being formed by extrusion or moulding, with an array of such light channelling elements to be fixed one above the other to form a thin panel for illuminating rooms.
[0009] The method of producing a light-channelling panel of Cowling is deficient in that, at the scale necessary to form a thin (10 mm) panel suited to installation in a window, each light channelling element is about 3 mm high and more than one hundred must be fixed one above the other to form a practical sized panel (about 0.5 m high). Fixing hundreds of small elements together is manually intensive or requires the development of specialised machinery. Alternatively, if a panel containing hundreds of precisely shaped elements is to be formed in one piece by extrusion, the extrusion die and infrastructure for extrusion are both highly specialised and expensive. By the method of Cowling, based on extrusion, it is difficult and expensive to make any variation in the design of a light-channelling panel as extensive and expensive variation of manufacturing tooling is required.
[0010] Thus it is a further objective of this invention to provide a method for producing a thin, large area, light channelling panel from readily available and inexpensive sheets of clear plastic by a relatively inexpensive and flexible method suited to the production of both small and large quantities of panel with the capability of quickly varying the light channel design so as to suit different applications; for example, high or low latitude locations, East or South facing windows.
SUMMARY OF THE INVENTION
[0011] The present invention provides a method to produce light channels within the body of a transparent panel by making a series of parallel cuts through both sides of a single sheet of clear plastic so as to form an array of light channels in the single sheet. In another embodiment the present invention provides a method for producing light channels within a panel by making cuts through one side of a first sheet of transparent plastic and through one side of a second sheet then transposing the second sheet relative to the first sheet and fixing the face of the transposed second sheet against the face of the first sheet thereby forming a combined panel containing an array of light channels. The light channels so formed channel light from the input face of the panel to the output face of the panel by a combination of refraction at the input face, by total internal reflection at the dielectric to air interfaces formed within the panel by the cuts and by refraction at the output face of the panel.
[0012] When installed in the upper part of a window to a room the light channelling panel of this invention channels substantially all sunlight incident on the panel, through the panel, and over the ceiling deep inside the room thereby illuminating, by diffuse reflection from the ceiling, the deep interior of the room while effectively shading areas near the window from intense sunlight.
[0013] Embodiments of the invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS.
[0014] [0014]FIG. 1 is a sectional view of a transparent solid sheets of plastic with cuts made right through the sheets at a small angle to the normal to the sheet.
[0015] [0015]FIG. 2 is a sectional view of a first sheet with angled cuts right through and a second sheet with similarly spaced angled cuts right through. The second sheet having being transposed and fixed in contact with the first sheet to produce light channels within the resulting panel.
[0016] [0016]FIG. 3 is a sectional view of a transparent solid sheets of plastic with cuts made partly through the sheets at a small angle to the normal to the sheet.
[0017] [0017]FIG. 4 is a sectional view of a first sheet with angled cuts partly through and 00 a second sheet with similarly spaced angled cuts partly through. The second sheet having being transposed and fixed in contact with the first sheet to produce light channels within the resulting panel.
[0018] [0018]FIG. 4 a is a schematic view of a first sheet with angled cuts partly through and a second sheet with similarly spaced angled cuts partly through. The second sheet having being transposed and fixed in contact with the first sheet to produce light channels within the resulting panel. For illustrative purposes this drawing shows the two sheets slightly separated.
[0019] [0019]FIG. 5 is a sectional view of a transparent sheet of plastic with angled cuts made partly through the first face of the sheet.
[0020] [0020]FIG. 6 is a sectional view of a transparent sheet of plastic with equally spaced angled cuts made through both faces of the sheet such that the cuts just meet thereby forming light channels within a transparent panel.
[0021] [0021]FIG. 7 is a schematic view of a light channelling panel showing the solid continuous border and solid narrow internal column that must be left to support the cut regions when the cuts extend right through the panel.
[0022] [0022]FIG. 8 is a sectional view of a light channelling panel illustrating the channelling of high elevation light through the panel.
[0023] [0023]FIG. 9 is a sectional view of a light channelling panel illustrating the wide angular range of elevation in which all incident light is channelled through the panel into an upwardly directed output.
[0024] [0024]FIG. 10 is a sectional view of a building showing the usual disposition of a light channelling panel in the window, the channelling of sunlight to the ceiling at the rear of the room and the shading of work surfaces near the window. It also illustrates the provision of an undistorted view through the panel in directions near horizontal.
DETAILED DESCRIPTION OF THE INVENTION
[0025] A first preferred method of producing a light channelling panel of this invention is described with reference to FIG. 1 and FIG. 2 as follows:
[0026] (1) By use of a laser cutting machine or a water cutting machine make a parallel array of thin cuts 1 through a first sheet of transparent plastic 2 , the cuts 1 to be made through the sheet 2 at a specified spacings and at a constant small angle from the normal to the sheet 2 so as to produce an array of cuts 1 in the sheet as shown in section in FIG. 1. When the cuts 1 extend right through the sheet 2 as in FIG. 1 borders and thin internal regions or columns in the sheet are left uncut and solid to support the cut regions, (see FIG. 7).
[0027] (2) Make a parallel array of thin cuts 3 through a second sheet of transparent acrylic plastic 4 with a cutting machine, the cuts 3 to be made through the sheet 4 at the same specified spacings as the cuts 1 made in said first sheet 2 and at a constant small angle from the normal to the sheet so as to produce an array of cuts 3 in the sheet 4 as shown in section in FIG. 1. The constant small angle from the normal of the cuts 3 made in the second sheet 4 may be equal to or different from the small angle from the normal of the cuts 1 in the first sheet 2 .
[0028] (3) Transpose, (that is, rotate through 180°, or flip), said second sheet 4 and fix the surface of the transposed second sheet 4 in contact with the surface of said first sheet 2 such that the edge of the cuts 3 in said second sheet are collinear with edge of the cuts 1 in said first sheet so as to form a combined panel 5 containing an array of light channels 6 as illustrated in FIG. 2.
[0029] A second preferred method of producing a light channelling panel of this invention is described with reference to FIG. 3 and FIG. 4 as follows:
[0030] (1)By use of a laser cutting machine or a water cutting machine make a parallel array of thin cuts 3 partly through a first sheet of transparent plastic 4 , the cuts 3 to be made through the sheet 4 at a specified spacings and at a constant small angle from the normal to the sheet 4 so as to produce an array of cuts 3 in the sheet as shown in section in FIG. 3.
[0031] (2)Make a parallel array of thin cuts 3 through a second sheet of transparent acrylic plastic 4 with a cutting machine, the cuts 3 to be made partly through the sheet 4 at the same specified spacings as the cuts 1 made in said first sheet 2 and at a constant small angle from the normal to the sheet so as to produce an array of cuts 3 in the sheet 4 as shown in section in FIG. 3. The constant small angle from the normal of the cuts 3 made in the second sheet 4 may be equal to or different from the small angle from the normal of the cuts 1 in the first sheet 2 .
[0032] (3) Transpose, (that is, rotate through 180°, or flip), said second sheet 4 and fix the surface of the transposed second sheet 4 in contact with the surface of said first sheet 2 such that the edge of the cuts 3 in said second sheet are collinear with edge of the cuts 1 in said first sheet so as to form a combined panel 5 containing an array of light channels 6 as illustrated in FIG. 4.
[0033] The light channelling panel of FIG. 4 is shown in a schematic view in FIG. 4 a . Sheet 2 with cuts 1 and transposed sheet 4 with cuts 3 would, in practice, be fixed together with the surfaces of each sheet in contact. However, in FIG. 4 a , sheet 2 and sheet 4 are shown with slight separation for the purposes of clarity of illustration. Two light rays are traced through the panel to illustrate how the light channels formed between cuts 1 and cuts 3 form a light channel 6 that channels light by refraction and total internal reflection from the input face of the panel through to the output face.
[0034] A third preferred method of producing a light channelling panel of this invention is described with reference to FIG. 5 and FIG. 6 as follows:
[0035] (1) Make a parallel array of thin cuts 1 through the first face 7 of a sheet of transparent plastic 8 with a laser cutting machine or a water cutting machine, the cuts 1 to be made partly through the sheet at a specified spacing and at a constant small angle from the normal to the sheet so as to produce an array of cuts 1 in the sheet as shown in section in FIG. 5.
[0036] (2) Transpose, (that is, rotate through 180° or flip), said sheet of transparent plastic 8 and by use of the cutting machine make a second parallel array of thin cuts 3 through the second face 9 of said sheet of transparent acrylic plastic 8 with the cutting machine, the cuts 3 to be made partly through the sheet 8 at the same specified spacing as the cuts 1 made through the first face 7 and at the same or a different constant small angle from the normal to the panel so as to produce an array of cuts 3 through the second face which just meet the bottom of the cuts 1 made through the first face 7 so as to produce a light channelling panel containing an array of light channels 6 as illustrated in FIG. 6 suited for the channelling of light from said first surface 7 through to said second surface 9 . As the cuts 1 and 3 meet inside the sheet 8 it is necessary to leave a border 10 and thin internal regions 11 uncut and solid to support the cut regions as illustrated schematically in FIG. 7.
[0037] As illustrated in FIG. 8 a typical configuration for a light channelling panel of this invention when fixed in vertical orientation in a window opening to a room will channel all, or substantially all, sunlight incident on the first face of said panel by the process of refraction and total internal reflection through to the second face of said panel so that the light emerging from said second face is directed upward into the room.
[0038] The typical practical dimensions of the light channelling panels illustrated in FIG. 2 or FIG. 6 would be as follows: overall panel width 12 mm, cut spacing 4 mm, cuts meeting at a depth of 6 mm, angle of cuts on the input side 12° to the normal, angle of cuts on the output side 12° to the normal to the panel face. The typical practical dimensions of the light channelling panel illustrated in FIG. 8 would be: overall panel width 12 mm, laser cut spacing 4 mm, laser cuts meeting at a depth of 6 mm in the panel, angle of laser cuts on the input side 6° to the normal and angle of laser cuts on the output side 12° to the normal to the panel. While these are typical dimensions and typical angles of cut of practical light channelling panels variations of these dimensions and angles fall within the scope of the invention and are to be considered part thereof.
[0039] To illustrate the illuminating and shading performance of the light channelling panel in more detail additional ray tracings through a typical example of the light channelling panel of this invention are shown in FIG. 9. The upper set of incident rays, ray group 12 in FIG. 9 show that high angle incident light is channelled through the panel and into a group of rays directed upward at low elevation. The second group of traced rays, ray group 13 , show that the minimum elevation angle at which all incident light is channelled into an upward direction is 18° for this particular configuration of light channelling panel. For light incident at angles below 18°, ray group 14 , some of the incident light passes directly through the panel thereby providing for an undistorted view through the panel in this direction but at reduced brightness. A fairly large proportion of light incident horizontally, ray group 15 , passes directly through the panel, thereby providing good viewing directly out through the panel. It is possible, within the scope of this invention, to alter the principal parameters of the light channelling panel, the cut spacing, the cut depth and the cut angle, to optimise desired performance characteristics. For example, maximising light penetration to the rear of the room by increasing the cut angle of the cuts through the input face, or, increasing the shading effect of the panel to include shading of lower angle light by decreasing the cut spacing.
[0040] [0040]FIG. 10 illustrates the usual positioning of the light-channelling panel of this invention in the window of a room. The panel is usually installed inside the window and in the upper part of the window. However, the embodiment of the light channelling panel illustrated in FIG. 4 may be installed in place of a glass window as this embodiment has solid external surfaces. As shown in FIG. 10, incident light, ray 16 , passes through window 17 and is channelled through panel 5 into the direction of ray 18 that penetrates upward and over the ceiling 19 deep in the interior of the room. From the ceiling 19 the light is diffusely reflected into rays 20 to provide illumination to work surfaces 21 deep inside the room. Light rays 22 that would otherwise have intensely illuminated work surfaces 23 close to the window are entirely redirected by the light channelling panel to the ceiling towards the rear of the room. Usually the light channelling panel 5 is installed in the window above eye level of occupants 24 in the room to avoid the possibility of sunlight being directed upwards into occupants view. Occupants 24 generally have a relatively undistorted view to the outside, ray 25 , through the light channelling panel provided the viewing direction is near horizontal.
[0041] The energy conservation advantages of the light-channelling panel of this invention are considerable. All sunlight incident on the panel is channelled through to the room. However the light channels redirect substantially all sunlight away from the floor and towards the ceiling from where it may be utilised to provide useful illumination in the room. Consider a panel similar to the designs in FIG. 1 through FIG. 9. The panel is 2 m wide and 0.5 m high and is installed in the upper part of a window as in FIG. 10. If sunlight of intensity 1000 W/m 2 is incident at 60° elevation on the panel the radiant power channelled through the panel is 2×0.5×1000×Cos 60°=500 W. Ignoring reflection loss, all of this radiant power is channelled into an upward elevation of about 30° and over the ceiling deep in the room. Ignoring reflection loss at the ceiling all of this radiant power is diffusely reflected downwards to provide useful illumination deep in the room. As the efficacy of sunlight is 105 lumens/W this radiant power is equivalent to 500×105=52,500 lumens of natural illumination. The efficacy of a fluorescent lamp is about 70 lumens/W and a 36 W fluorescent tube provides 36×70=2520 lumens of illumination. It follows from this example that 1 square metre of light channelling panel in a window channels incident sunlight to provide the equivalent illumination of 52500/2520=21 fluorescent lights in the room. If the light channelling panel were not present this 500 W of radiant power would be largely absorbed on the floor, converted to heat and not available for useful illumination. In overcast conditions the useful illumination provided by the panel is reduced to about ⅕ of the value calculated above for direct sunlight.
[0042] Those modifications and equivalents which fall within the spirit of the invention are to be considered a part thereof.
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A method for producing a light channelling panel by making an array of angled cuts in a first transparent plastic sheet, making a similarly spaced array of angled cuts in a second plastic sheet, transposing or flipping the second sheet and fixing it in contact with the first sheet to form a panel with an array of internal light channels. Alternatively, by making an array of angled cuts in the surface of a transparent plastic sheet and an array of similarly spaced angled cuts in the opposite surface of the transparent plastic sheet to form a panel with an array of internal light channels. Said light channelling panel when positioned in a window of a building channels substantially all sunlight incident on the panel through the panel and over the ceiling in the building thereby illuminating the building with daylight and shading work areas near the window.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits of U.S. Provisional Patent Application No. 60/679,344, filed May 9, 2005, the entire contents of which are expressly incorporated herein.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] The present invention relates to a method of installing a corner bead to a doorway, and also to an apparatus for installing the corner bead to the doorway.
[0004] Conventionally, a drywall corner bead is installed on a doorway by manually sawing a slot in a latch side jamb and a hinge side jamb of a doorframe for receiving the drywall corner bead. As will be further explained below, such conventional method of installing the drywall corner bead is unsatisfactory.
[0005] A door is installed in a wall by framing an opening in the wall such that the opening is sized and configured to fit a doorframe. The doorframe may be comprised of a latch side jamb, a hinge side jamb and a top jamb connected to upper distal ends of the latch and hinge side jambs. Before the doorframe is disposed within the opening of the wall, a slot may be manually sawed into edges of the jamb, as shown in FIG. 1 . After the slot is sawed into the jambs, the doorway is disposed within the opening of the wall. Shims may be disposed between the doorframe and an adjacent trimmer stud. The shims are adjusted until the doorframe is squared. Thereafter, the shims are nailed to the jambs and the trimmer studs. At this point, the jamb may fail due to the thin or reduced thickness of the jamb. In particular, when the slots were sawed into the edges of the jamb, it created stress concentrations or weak points at a base of the slot. As such when the nail is hammered into the doorframe, the weak point of the base of the slot may be fractured thereby damaging the doorframe. Also, the prior art method of attaching the corner bead to the doorway increases cost to manufacture or install the corner bead because the slot must be manually sawed in the factory or at the construction site. Another deficiency of the conventional method of installing the corner bead to the doorway is that an exposed edge of the jamb is reduced because the slot must be sawed at about a middle portion of the jamb edge, which increases the cost of radius millwork.
[0006] To mitigate against the reduction of the exposed edge of the jamb, prior art methods of installing the corner bead may include utilizing a jamb having a wider exposed edge such that when the slot is sawed into the jamb, the exposed edge of the jamb is approximately the same as typical jambs. Unfortunately, jambs having a wider exposed edge cost more due to the additional material, and further requires special oversized framing.
[0007] Accordingly, there is a need in the art for an improved method for installing a corner bead to a doorway and also for an apparatus for installing the corner bead to the doorway.
BRIEF SUMMARY
[0008] The present invention addresses the needs discussed above, below and those that are known in the art. While various applications of embodiments of the present invention are discussed herein as being utilized on a doorframe, it is also contemplated that embodiments of the present invention may be used with any millwork that may accept a drywall corner bead, including doorframes, windows, and/or other finished flat and radius millwork. Therefore, it shall be understood that use of terms referring to doors or doorframes, such as the term “doorframe,” as well as the teachings herein, may be applied for other millwork, such as windows. Thus, embodiments of the present invention may be applied to other forms of millwork that accept a drywall corner bead, and should not be considered to be limited to doorframe applications.
[0009] According to an embodiment of the present invention, a jamb strip is attached to the doorframe which collectively forms a receiving channel to receive the drywall corner bead to make installation of the corner bead less costly on radius millwork and maintain the structural integrity of the doorframe. In particular, the doorframe may comprise a latch side jamb and a hinge side jamb and a top jamb. These jambs define lateral side surfaces and an upper surface. The jamb strip may be secured to the lateral side surfaces and the upper surface by stapling an attachment base of the jamb strip to such surfaces. A flange of the jamb strip may also be directed to the exterior of the wall. The flange of the jamb strip may define a receiving surface which may be offset from an interface surface of the attachment base. Accordingly, when the jamb strip is secured to the jamb, the receiving surface does not contact the lateral side surfaces of the latch and hinge side jambs and the upper surface of the top jamb. The receiving surface of the jamb strip flange and the lateral side surface/top surface of the jamb defines a receiving channel which receives the corner bead.
[0010] After the jamb strip is secured to the doorframe, the doorframe is disposed within an opening of the wall and squared via shims. The shims are secured to the doorframe and the wall via a nail, and the shims are cut off flush to the doorframe. The corner bead is then attached to a drywall of the wall and inserted into the receiving channel.
[0011] The corner bead may comprise a corner portion, a first flange and a second flange. The first flange may have a plurality of apertures for receiving a shaft of a nail. The first flange of the corner bead is laid adjacent to the drywall, and simultaneously, the second flange may be inserted into the receiving channel. Nails are inserted into the apertures of the first flange to secure the corner bead to the drywall. Correspondingly, the receiving channel secures the second flange of the corner bead to the door frame. The exterior surfaces of the doorframe, corner bead and the drywall are then painted to make the doorway aesthetically beautiful.
[0012] In a first embodiment of the jamb strip, the attachment base may define an upper surface having a convex configuration. The junction between the flange and the attachment base may have an abrupt change in direction which may serve as a guide for a staple gun or a nail gun. More particularly, when the installer secures the jamb strip to the doorframe, the installer may bump a staple gun against the guide to align the staple of the staple gun to a fulcrum of the upper surface. In this manner, the installer does not have to manually align the staple to the attachment base. Also, since the staple is aligned to the fulcrum of the upper surface, it is less likely that the staple will penetrate through the attachment base and into the doorframe. The installer may quickly staple the attachment base to the doorframe by bumping the staple gun against the guide along a plurality of points of the attachment base.
[0013] In an aspect of the jamb strip, the jamb strip may have a cam surface and a lip formed on a flange of the jamb strip. The cam surface, lip and receiving surface of the flange of the jamb strip along with the lateral side surface of the jamb forms a receiving channel for receiving a second flange of the corner bead. Also, the second flange of the corner bead may be formed with a pawl for engaging the lip for holding the corner bead to the jamb.
[0014] In another aspect of the jamb strip, the same may be reversible such that a first width of a receiving channel may be formed between a receiving surface of a first portion of the jamb strip and the lateral side surface of the jamb when the jamb strip is attached to the jamb in a first orientation (i.e., second portion attached to the jamb). Also, the jamb strip may form a second width of a receiving channel defined by a receiving surface of a second portion of the jamb strip and the lateral side surface of the jamb when the jamb strip is attached to the jamb in a second orientation (i.e., first portion attached to the jamb). Moreover, the first width may be narrower compared to the second width of the receiving channels for receiving corner beads having different second flange thicknesses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
[0016] FIG. 1 is an illustration of a prior art method of installing a drywall corner bead to a doorway;
[0017] FIG. 2 is a perspective view of a doorway;
[0018] FIG. 3 is an exploded cross-sectional view of the doorframe and wall illustrating a corner bead installable to the doorway via a jamb strip;
[0019] FIG. 4 is a perspective view of a corner bead defining a first flange and second flange with a corner portion interposed therebetween;
[0020] FIG. 5 is a first embodiment of the jamb strip;
[0021] FIG. 6 is a second embodiment of the jamb strip;
[0022] FIG. 7 is a third embodiment of the jamb strip;
[0023] FIG. 8 is a cross-sectional view of a doorframe incorporating a fourth embodiment of the jamb strip;
[0024] FIG. 8A is a partial exploded view of FIG. 8 ;
[0025] FIG. 9A is a fifth embodiment of the jamb strip;
[0026] FIG. 9B is an illustration of the fifth embodiment of the jamb strip attached to the doorframe in a first orientation;
[0027] FIG. 9C is an illustration of the fifth embodiment of the jamb strip attached to the doorframe in a second reversed orientation;
[0028] FIG. 10 is a partial view of an arched doorframe with the jamb strip secured to an upper surface of a top jamb;
[0029] FIG. 10A is a top view of the doorframe and jamb strip of FIG. 10 ;
[0030] FIG. 10B is a side view of the doorframe and jamb strip of FIG. 10 ; and
[0031] FIG. 11 is a flow chart of a method of installing the corner bead to the doorway with the jamb strip.
DETAILED DESCRIPTION
[0032] Referring now to the drawings which are for the purpose of illustrating the preferred embodiments of the present invention and not for the purpose of limiting the same, FIG. 2 is a perspective view of a doorway 10 . Although the various aspects of the present invention are described in relation to a doorway 10 , the various aspects of the present invention may be variously embodied and employed in different situations. By way of example and not limitation, the various aspects of the present invention may be employed in windows, skylights, and the like. In particular, embodiments of the present invention may be used with any millwork that may accept a drywall corner bead 26 , including doorframes, windows, and/or other finished flat and radius millwork. Therefore, it shall be understood that use of terms referring to doors or doorframes, such as the term “doorframe,” as well as the teachings herein, may be applied for other millwork, such as windows. Thus, embodiments of the present invention may be applied to other forms of millwork that accept the drywall corner bead 26 , and should not be considered to be limited to doorframe applications.
[0033] The doorway 10 may comprise a wall 12 defining an opening. A doorframe 14 may be disposed within the opening and squared. Thereafter, a door 16 may be hung on the doorframe 14 which may be rotatable about hinges 18 and locked to the doorframe 14 via a latch 20 .
[0034] To make the doorway 10 more aesthetically beautiful, the wall 12 which may comprise a plurality of vertical and horizontal studs 22 may be overlaid or covered with drywall 24 and subsequently painted. Moreover, the drywall corner bead 26 may be attached to the wall 12 and the doorframe 14 which may hide (see FIG. 3 ) the shims 28 , studs 22 and other raw construction materials (e.g., nails, staples, etc.) to make the doorway 10 more aesthetically beautiful.
[0035] As shown in FIG. 3 , the corner bead 26 may be disposed adjacent to the drywall 24 and the doorframe 14 . More particularly, the corner bead 26 may define a first flange 30 and a second flange 32 with a bead or corner portion 34 interposed therebetween (see FIG. 4 ). The bead or corner portion 34 shown in FIG. 3 has a rounded configuration, but it is also contemplated that the bead or corner portion 34 may have other configurations such as square (i.e., 90°), oblique, shaped and the like. The first flange 30 may be disposed against the drywall 24 (see FIG. 3 ). The first flange 30 may have a plurality of apertures 36 (see FIG. 4 ) for receiving a nail 38 so as to secure the first flange 30 and the corner bead 26 to the drywall 24 . Nails 38 may proceed through the apertures 36 of the first flange 30 and into the drywall 24 and the stud underlying the drywall 24 . In this manner, the corner bead 26 may be securely fixed to the building structure. The second flange 32 of the corner bead 26 may be received into a receiving channel 40 formed by a jamb strip 42 and the doorframe 14 . As shown in FIG. 3 , both sides of the wall 12 and doorframe 14 may be connected to each other via the corner bead 26 . Although the structure shown in FIG. 3 is of a latch side jamb 44 of the doorframe 14 , it is also contemplated that the corner bead 26 may be attached to the hinge side jamb 46 , the top jamb 48 and/or a threshold 50 . After the corner bead 26 is attached to the doorway 10 , the exterior surfaces of the doorframe 14 , corner bead 26 and drywall 24 may be painted to make the doorway 10 more aesthetically pleasing to visitors, guests and owners of the building structure.
[0036] The jamb strip 42 may be attached to the doorframe 10 in the following manner. Initially, the doorframe 10 is not attached to or disposed in the opening of the wall 12 . With the doorframe 14 not attached to the wall 12 , the jamb strip 42 may be attached to lateral side surfaces 52 of the latch side jamb 44 and/or hinge side jamb 46 , and/or the top surface 54 of the top jamb 48 (see FIG. 10 ). The jamb strip 42 may be a flexible strip such that it may bend and flex in its lengthwise direction. The flex permits the jamb strip 42 to hug the lateral side surfaces 52 of the side jambs 44 , 46 when the jamb strip 42 is attached to the jamb 44 , 46 , 48 despite the shape of the lateral side surface 52 or top surface 54 of the jamb 44 , 46 , 48 . By way of example and not limitation, if the top jamb 48 was arched, then the jamb strip 42 may conform to the curved arch configuration of the top jamb 48 (see FIG. 10 ). When the jamb strip 42 is disposed on the lateral side surface 52 or top surface 54 of the jamb 44 , 46 , 48 , a flange 72 of the jamb strip 42 may be directed toward an exterior surface of the wall 12 . A distal edge 56 (see FIG. 3 ) of the jamb strip 42 may be aligned with an exposed edge 58 of the jamb 44 , 46 , 48 . The jamb strip 42 may be permanently attached to the jamb 44 , 46 , 48 via a staple 59 or nail 38 . For example, the installer may staple an attachment base 60 of the jamb strip 42 to the jamb 44 , 46 , 48 . Since the jamb strip 42 is attached to the door frame 14 as a long strip, the installer may staple the attachment base 60 at a plurality of points so as to securely attach the jamb strip 42 to the doorframe 14 . In particular, the installer may bump a staple gun or nail gun against a guide 62 to align the staple or nail 38 to the attachment base 60 .
[0037] Optionally, the jamb strip 42 may be interrupted such that the jamb strip 42 does not extend the entire length of the top jamb 48 , the latch side jamb 44 or hinge side jamb 46 . Rather, the jamb strip 42 may be interrupted to provide space such that shims 28 may be interposed between the doorframe 14 and the wall 12 to square the doorframe 14 .
[0038] After the jamb strip 42 is attached to the doorframe 14 , the installer disposes the doorframe 14 in the opening of the wall 12 . The installer then inserts shims 28 between the doorframe 14 and the wall 12 to square the doorframe 14 . In particular, the opening of the wall 12 may be defined by a header 64 , king studs 66 , a latch side trimmer stud 68 and a hinge side trimmer stud 70 . With the doorframe 14 disposed within the opening of the wall 12 , the installer may place a leveler against the latch side jamb 44 or the hinge side jamb 46 . The installer inserts shims 28 between the latch side jamb 44 and the latch side trimmer stud 68 , the hinge side jamb 46 and the hinge side trimmer stud 70 , and the top jamb 48 and the header 64 . The shims 28 are adjusted until the latch side jamb 44 or hinge side jamb 46 is level and the doorframe 14 is squared. A nail 38 is inserted through the doorframe 14 , shims 28 and the trimmer stud 68 , 70 to secure the shims 28 between the doorframe 14 and the trimmer stud 68 , 70 . After the shims 28 are secured via the nail 38 , the protruding portions of the shims 28 are sawed off flush with the exposed edge of the doorframe 14 .
[0039] The corner bead 26 which may comprise a first flange 30 and a second flange 32 interposed by a corner portion 34 (see FIG. 4 ) may be disposed about the outer periphery of the door 16 . In particular, a first flange 30 may be disposed adjacent the drywall 24 . The first flange 30 may have a plurality of apertures 36 through which a nail 38 may be inserted to secure the corner bead 26 to the wall 12 structure. In particular, as shown in FIG. 3 , after the first flange 30 is disposed adjacent the drywall 24 , a nail 38 may be inserted into the aperture 36 to secure the corner bead 26 to the wall structure. The second flange 32 may simultaneously be inserted into a receiving channel 40 formed by the jamb strip 42 and the latch side jamb 44 . Thereafter, the doorframe 14 , corner bead 26 and the drywall 24 may be painted to make the same more aesthetically pleasing.
[0040] The jamb strip 42 may be provided as a roll or as a long strip. The longitudinal length of the jamb strip 42 may be flexible such that the jamb strip 42 may conform to variously configured doorways 10 such as arched doorways. Additionally, the flexibility of the jamb strip 42 allows the jamb strip 42 to conform not only to a curvature of the doorway 10 , but also may allow the jamb strip 42 to conform to a curvature of a window or a curvature of given millwork.
[0041] FIGS. 5-9C illustrate variously configured jamb strips 42 . Although five embodiments of the jamb strip 42 are shown in FIGS. 5-9C , it is also contemplated that other configurations of the jamb strips 42 may be embodied and employed. As shown in FIG. 5 , a first embodiment of the jamb strip 42 a may have an attachment base 60 a and a flange 72 a . The attachment base 60 a and the flange 72 a may be fabricated from a unitary material. The attachment base 60 a may define an interface surface 74 a having a flat configuration. The interface surface 74 a contacts the lateral side surface 52 of the side jambs 44 , 46 or the top surface 54 of the top jamb 48 and aids in setting an offset distance between the flange 72 a and the jamb 44 , 46 , 48 , as discussed below. The attachment base 60 a may also define an upper surface 76 a . A thickness of the attachment base 60 a defined by a distance between the upper surface 76 a and the interface surface 74 a may be sufficiently thick so as to prevent a staple or nail 38 being inserted through the attachment base 60 a via a staple gun or nail gun to secure the jamb strip 42 a to the doorframe 14 from penetrating through the attachment base 60 a . By way of example and not limitation, the upper surface 76 a may have a convex configuration wherein an attachment means (e.g., staple, nail. etc. and the like) may proceed therethrough and into the doorframe 14 to attach the jamb strip 42 a to the doorframe 14 . More particularly, a distance between a fulcrum of the upper surface 76 a and the interface surface 74 a may be sufficient to prevent the nail 38 , staple 59 or other attachment means from penetrating through the attachment base 60 a . The junction of the upper surface 76 a and the flange 72 a may have an abrupt change in direction. More particularly, the abrupt change in direction may be a vertical surface perpendicular to the interface surface 74 a and/or a receiving surface 80 a . The abrupt change in direction provides a guide 62 a such that an installer may bump a staple gun or nail gun against the guide 62 a such that the staple or nail 38 is aligned to the fulcrum of the upper surface 76 a . In this manner, the installer may quickly staple a plurality of points along the attachment base 60 a wherein the staples 59 are aligned to the fulcrum of the upper surface 76 a by bumping the staple gun against the guide 62 a . Moreover, a distance between the receiving surface 80 a and the interface surface 74 a may be greater than or equal to a thickness of the second flange 32 of the corner bead 26 .
[0042] Referring now to FIG. 6 , a second embodiment of the jamb strip 42 b may also have an attachment base 60 b and a flange 72 b . The second embodiment of the jamb strip 42 b may be identical with the first embodiment of the jamb strip 42 a except that a nub 78 b is formed on the receiving surface 80 a of the flange 72 b . Moreover, a distance between the nub 78 b and the interface surface 74 b may be less than or equal to a thickness of the second flange 32 of the corner bead 26 . The jamb strip 42 b may also define an upper surface 76 b and a guide 62 b similar to the upper surface 76 a and guide 62 a of the first embodiment of the jamb strip 42 a.
[0043] Referring now to FIG. 7 , a third embodiment of the jamb strip 42 c may have an attachment base 60 c and a flange 72 c . The flange 72 c may be identical with the flange 72 b of the second embodiment of the jamb strip 42 b (see FIG. 6 ). In particular, a nub 78 c may be formed on a receiving surface 80 c of the flange 72 c . Alternatively, the flange 72 e of the third embodiment of the jamb strip 42 c may be formed in a similar fashion as the first embodiment of the jamb strip 42 a (see FIG. 5 ). In particular, the receiving surface 80 c does not incorporate a nub 78 c . The attachment base 60 c of the third embodiment of the jamb strip 42 c may have an inclined upper surface 76 c and a concave interface surface 74 c . The attachment base 60 may also have two foots 82 for engaging the lateral side surface 52 of the side jamb 44 , 46 or the top surface 54 of the top jamb 48 . To install the jamb strip 42 e on the jamb 44 , 46 , 48 , the feet 82 of the attachment base 60 c are laid on the lateral side surface 52 of the side jambs 44 , 46 or the top surface 54 of the top jamb 48 with the flange 72 c directed toward an exterior wall surface. A staple 59 or nail 38 is pierced through the attachment base 60 c and into the jamb 44 , 46 , 48 to secure the jamb strip 42 c to the jamb 44 , 46 , 48 . More particularly, the nail 38 or staple 59 penetrates the upper surface 76 and may urge the concave interface surface 74 c against the lateral side surface 52 of jamb 44 , 46 , 48 .
[0044] Referring now to FIGS. 8 and 8A , a fourth embodiment of the jamb strip 42 d may have a similar configuration as that shown in the first embodiment of the jamb strip 42 a (see FIG. 5 ). Moreover, the flange 72 d may have a cam surface 84 which extends from a distal end 56 d of the flange 72 d to a medial portion thereof. A cam lip 86 may be formed at a terminal end of the cam surface 84 . The flange 72 d may also have a receiving surface 80 d which together with the lip 86 and cam surface 84 and the lateral side surface 52 of the side jambs 44 , 46 or top surface 54 of the top jamb 48 forms the receiving channel 40 .
[0045] The receiving channel 40 may receive a second flange 32 of the corner bead 26 . More particularly, the second flange 32 of the corner bead 26 may have a pawl 88 formed at a distal end thereof. A thickness of the pawl 88 may be equal to or less than a distance between the interface surface 74 d of the attachment base 60 d and the receiving surface 80 d . Also, the distance or thickness of the pawl 88 may be greater than a distance between the lateral side surface 52 of the side jambs 44 , 46 or top surface 54 of the top jamb 48 and the edge 90 of the lip 86 . Moreover, a distance from the pawl 88 to an offset or an intersection 92 of the second flange 32 and the corner portion 34 of the corner bead 26 may be longer than or equal to a distance between the lip 86 and a distal edge 56 d of the flange 72 d . When the second flange 32 of the corner bead 26 is inserted into the receiving channel 40 , the pawl 88 is interposed between the lateral side surface 52 of the jamb 44 , 46 or top surface 54 of the top jamb 48 and the cam surface 84 . The pawl 88 being thicker than a distance between the cam surface 84 and the lateral side surface 52 of the jamb 44 , 46 or top surface 54 of the top jamb 48 deflects the flange 72 d away from the jamb 44 , 46 , 48 until the pawl 88 passes the lip 86 of the flange 72 . At about the same time, the offset junction 92 engages a corner 94 of the jamb 44 , 46 , 48 . The second flange 32 of the corner bead 26 may not be removed from the receiving channel 40 because the pawl 88 engages the lip 86 (see FIG. 8 ). If required, the second flange 32 of the corner bead 26 may be removed from the receiving channel 40 by lifting the flange 72 d away from the jamb 44 , 46 , 48 with a flathead screwdriver or the like.
[0046] FIGS. 9A-9C illustrates a reversible jamb strip 42 e which is referred to herein as the fifth embodiment of the jamb strip 42 e . The fifth embodiment of the jamb strip 42 e may have a lightening bolt configuration. In particular, the jamb strip 42 e may have a first portion 96 and a second portion 98 which integrally formed as a unitary piece. As shown in FIG. 9A , the first portion 96 and the second portion 98 may be generally parallel but offset with respect to each other. The jamb strip 42 e may be attached to the jamb 44 , 46 , 48 , as shown in FIG. 9B or in a reversed orientation, as shown in FIG. 9C . In FIG. 9B , the second portion 98 of the jamb strip 42 e functions as the attachment base 60 e and the first portion 96 of the jamb strip 42 e functions as the flange 72 e . Accordingly, the first portion 96 and the lateral side surface 52 of the iamb 44 , 46 or the top surface 54 of the top jamb 48 forms the receiving channel 40 . A distance between the receiving surface 80 e of the first portion 96 and the interface surface 74 e of the second portion 98 defines a first width 100 of the receiving channel 40 .
[0047] In FIG. 9C , the first portion 96 of the jamb strip 42 e may function as the attachment base 60 e and the second portion 98 of the jamb strip 42 e may function as the flange 72 e . Also, a distance between the receiving surface 80 e of the second portion 98 of the jamb strip 42 e and the interface surface 74 e of the first portion 96 of the jamb strip 42 e may define a second width 102 of the receiving channel 40 formed by the receiving surface 80 e of the second portion 98 and the jamb 44 , 46 , 48 . As shown by comparing FIGS. 9B and 9C , the first width 100 of the receiving channel 40 is narrower compared to the second width 102 of the receiving channel 40 (see FIG. 9C ). Although the first and second portions 98 , 98 of the fifth embodiment of the jamb strip 42 are shown as being generally flat, it is also contemplated that nubs 78 , lips 86 , cam surfaces 84 and curved upper surfaces 76 may be formed on the first and second portions 96 , 98 in varying combinations.
[0048] The flange 72 may be attached to the attachment base 60 , as shown in FIG. 5-9C . The flange 72 may define a receiving surface 80 which may be parallel with respect to the interface surface 74 . Although the receiving surface 80 is shown and described as being flat and parallel with the interface surface 74 , it is also contemplated that the receiving surface 80 may have other shapes and configurations such as concave, convex, skewed, etc. A distance between the receiving surface 80 and the interface surface 74 may be greater than or equal to a thickness of the second flange 32 of the corner bead 26 . In this manner, the second flange 32 may be slid into and out of the receiving channel 40 formed by the jamb strip 42 and the doorframe 14 (1 st , 2 nd , 3 rd and 5 th embodiments of the jamb strip). The flange 72 of the jamb strip 42 may be fabricated from a material such that the flange 72 is urged back toward its natural configuration when the second flange 32 of the corner bead 26 pushes against the receiving surface 80 . When the second flange 32 of the corner bead 26 is inserted into the receiving channel 40 , there may be an imperfect fit therebetween. The imperfect fit causes the second flange 32 to push against the receiving surface 80 to thereby open the receiving channel 40 and push the flange 72 away from the jamb 44 , 46 , 48 . Although the flange 72 is pushed away from the jamb 44 , 46 , 48 , the resilient and flexible nature of the jamb strip 42 prevents the flange 72 from breaking off of the attachment base 60 . Rather, the flange 72 pushes against the second flange 32 of the corner bead 26 to hold the corner bead 26 in place.
[0049] As shown in FIG. 3 , when the attachment base 60 is secured to the jamb 44 , 46 , 48 , the receiving surface 80 may be parallel with the lateral side surface 52 of the jamb 44 , 46 . To retain the second flange 32 in the receiving channel 40 , a nub 78 (see FIGS. 6 and 7 ; second and third embodiments of the jamb strips 42 b , 42 c ) may be formed on the receiving surface 80 which may urge the second flange 32 against the lateral side surface 52 of the jamb 44 , 46 . To this end, a distance between a distal end of the nub 78 and the interface surface 74 may be less than or equal to the thickness of the second flange 32 of the corner bead 26 . Accordingly, when the second flange 32 is inserted into the receiving channel 40 , the flange 72 may be deflected slightly away from the jamb 44 , 46 , 48 and the nub 78 urges the second flange 32 against the lateral side surface 52 of the jamb 44 , 46 , 48 to hold the corner bead 26 .
[0050] By way of example and not limitation, the jamb 44 , 46 , 48 may have a width of about 1.5 in.; a width of the flange 72 may be about 0.563 in.; a throat of the receiving channel 40 may be about 0.4375 in.; and a gap of the receiving channel 40 may be about 0.094 in.
[0051] As stated above, the jamb strip 42 may be applied to a top jamb 48 having an arched configuration which is shown in FIGS. 10 , 10 A and 10 B. Similar to the construction shown in FIGS. 2 and 3 , the jamb strip 42 may be used to install a corner bead 26 to the arched doorway 10 . FIG. 10 shows a curved top jamb 48 of an arched doorway 10 . The jamb strip 42 may be attached to the hinge side jamb 46 and the latch side jamb 44 in the same manner discussed above. The jamb strip 42 may also be attached to the top or upper surface 54 of the curved top jamb 48 . The jamb strip 42 may be attached to the entire outer periphery of the top jamb 48 because the jamb strip 42 is flexible in its longitudinal length. The jamb strip 42 may be secured to the top jamb 48 by stapling or nailing the attachment base 60 of the jamb strip 42 to the top jamb 48 , as shown in FIG. 10A . Installation of the doorframe 14 and door 16 to the opening or doorway 10 may be made in a similar fashion as discussed above.
[0052] Referring now to FIG. 11 , a flow chart of installing a jamb strip 42 to a doorframe 14 is as shown. In the method of installing the jamb strip 42 to the doorframe 14 , a jamb strip 42 may be aligned to the doorframe 110 . In particular, a distal edge 56 of the flange 72 may be flush with the exposed edge of the jamb 44 , 46 , 48 . Thereafter, the jamb strip 42 may be attached to the doorframe 112 . By way of example and not limitation, the jamb strip 42 may be stapled, nailed or the like to the jamb 44 , 46 , 48 via a staple gun or a nail gun. The staple or nail may be pierced through the attachment base 60 of the iamb strip 42 and into the jamb 44 , 46 , 48 . After the jamb strip 42 is attached 112 to the doorframe 14 , the doorframe 14 may be disposed within a doorway opening of a wall 12 and squared 114 . With the doorframe 14 squared 114 , a first flange 30 of a corner bead 26 may be attached 116 to a drywall 24 via a nail 38 or the like. Simultaneously or at about the same time, a second flange 32 of the corner bead 26 may be inserted 118 into a receiving channel 40 formed by the flange 72 of the jamb strip 42 and the lateral side surface 52 or top surface 54 of the jamb. At this point, the corner bead 26 is installed on the doorframe 14 and the exterior surfaces of the jamb 44 , 46 , 48 and drywall 24 may be painted 120 .
[0053] The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.
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An apparatus for installing a corner bead to a doorway is provided. The apparatus may comprise a flange and an attachment base which are integrally connected to each other. The attachment base is securable to a doorframe such that upon securement, the flange and the doorframe form a receiving channel for receiving the corner bead therein. Such configuration maintains the structural integrity of the doorframe, maintains the length of the exposed edge of the doorframe and reduces cost to install the corner bead to the doorway.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 61/284,450 filed on Dec. 18, 2009, the entirety of which is incorporated herein by reference.
BACKGROUND
1. Field of the Invention
This invention relates to the field of aeration and circulation systems for ponds, lakes, sounds, treatment basins and other bodies of water; and especially to the field of aeration and circulation systems for bodies of water which experience periods of thermal-density stratification and oxygen depletion.
2. Discussion
Deep dimictic lakes typically exhibit a well mixed surface layer (epilimnion), a mid-depth where temperature decreases rapidly with increasing depth (metalimnion), and a uniformly cold deep layer (hypolimnion). Oxygen is supplied to the surface of the body of water from the atmosphere. Oxygen is also produced by photosynthesis within the body of water. When light penetration is limited, oxygen production by photosynthesis only occurs in upper strata. In more shallow water bodies such as, for example, lakes, estuaries, sounds and treatment basins that exhibit very high oxygen demand over the bottom, a weak or intermittent thermal stratification can occur and can result in oxygen depletion in deeper strata. The deep strata oxygen consumption rate and oxygen demands at the sediment/water interface can exceed the oxygen replenishment rate from the atmosphere and photosynthetic production near the surface.
The loss of dissolved oxygen from waters at various depths can have serious water quality consequences including:
Loss of desirable habitat for fish and other aerobic aquatic organisms; Accumulation of nutrients and anaerobic respiration products such as iron, manganese, hydrogen sulfide, phosphorus, ammonia and other constituents; and Increased eutrophication and degradation of resource quality for recreation, habitat, and water supply.
The thermal density stratification and oxygen depletion is characterized by an index: relative thermal resistance to mixing (RTRM). Intervention may be required to increase and enhance circulation and aeration to improve and maintain water quality.
SUMMARY
Briefly stated, an apparatus for circulating water in a body of water employs a wind turbine. A shaft is driven by the turbine. At least one impeller is coupled to the shaft for rotation therewith. A buoyancy module is disposed adjacent the shaft to maintain the shaft in an upright vertical orientation when a substantial portion of the shaft and the at least one impeller is submerged in the body of water. Exposure of the wind turbine to environmental wind and disposition of the impeller in the body of water causes the impeller to rotate to thereby circulate water to and from selected depths.
The apparatus can be configured to produce a mixing or blending of a depth strata, a downdraft circulation, or an updraft circulation within the body of water. In one embodiment, the apparatus includes a conduit. The impeller unit, or plurality of impellers, is disposed in the conduit and produces either a downdraft or an updraft pumping within the conduit. For some embodiments, the apparatus produces both a downdraft and an updraft pumping.
The apparatus may also comprise a conduit chamber with an intake port and an output port. At least one impeller is disposed in the conduit chamber and operable to circulate water from the intake port to the output port for depth-selective circulation of any vertical depth strata range.
The apparatus may also comprise a plurality of impellers spaced along the shaft. The apparatus can be configured to produce a downdraft circulation path, an updraft circulation path or a combination of downdraft and updraft circulation paths.
The apparatus may employ a wind turbine, which comprises either a direct drive vertical axis wind turbine or a horizontal axis wind turbine which rotatably couples with the shaft. The apparatus in one embodiment comprises a pumping chamber. At least one impeller is disposed within the pumping chamber. A direct drive compressor is coupled to the wind turbine to produce compressed air. An alternator stator is coupled to the wind turbine to generate electricity in some embodiments. In addition, a battery bank, a controller and a motor is drivably couplable to the shaft wherein the electricity from the alternator stator is employed to power the motor.
A solar voltaic array may be employed. A battery bank in communication with the array and a motor powered by the battery bank drives the shaft or a compressor may be employed. In some embodiments, the wind turbine is a vertical axis wind turbine and a horizontal axis wind turbine is integrated with the vertical axis wind turbine. The vertical axis wind turbine is coupled to the shaft for pumping circulation and to produce compressed air for diffusion into the water.
For some embodiments, a surface flotation platform mooring system employs an anchor system. At least one pulley is connected to the flotation platform. A cable connects the anchor, extends around the pulley and connects with a weight. The vertical spacing between the anchor and the flotation platform varies according to the depth of the water.
The apparatus may also be anchored by a plurality of pilings mounted to the bottom of the body of water in a fixed, upright position. The apparatus further has a platform disposed about the shaft. Tubes extend from the underside of the platform and are telescopically connected with the pilings so that the position of the wind turbine relative to the surface of the water is substantially constant regardless of the change in depth of the water. For bodies of water in which the water level does not significantly fluctuate, it is preferred that the apparatus be anchored by a heavy weight and a submerged buoyancy system to maintain the upright vertical position.
A wind turbine apparatus or photovoltaic array and battery bank system may also be employed to compress air. The compressed air is supplied via a conduit to an aeration diffuser heads disposed below the surface of the water. In some embodiments, the compressor is powered by a solar array which is installed on the land. A plurality of aeration heads is employed to distribute compressed air and circulate and oxygenate the water below the surface of the water. The aeration heads have openings, flow-controlling orifices, which are dimensioned to maintain pressure throughout the compressed air supply conduit regardless of distance or depth of diffuser, to ensure equal airflow to all diffuser elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a body of water and its surrounding environment, partly in diagram form, further illustrating three embodiments of a wind turbine circulator/aerator installed in the body of water;
FIG. 2A is a schematic view, partly in diagram form, of a body of water and its surrounding environment further illustrating depth profiles of temperature, RTRM and dissolved oxygen for epilimnion, metalimnion, and hypolimnion layers of the body of water and FIGS. 2B-2E are four embodiments of a wind turbine circulator/aerator as installed and operational in connection with the depth profile for a deep lake-type body of water;
FIG. 3 is a schematic view, partly in diagram form, of a body of water and its surrounding environment further illustrating depth profiles of temperature, RTRM and dissolved oxygen for depth layers of the body of water together with three embodiments of a wind circulator/aerator as installed and operating with the depth profile for a shallow lake-type body of water;
FIG. 4 is a perspective elevational view of a wind turbine circulator;
FIG. 5A is an elevational schematic view, partly in diagram form, illustrating a submerged buoy erect piling mooring system for a wind turbine circulator and further illustrating a submerged buoyancy installation approach;
FIG. 5B is an elevational schematic view, partly in diagram form, illustrating another embodiment for a wind turbine circulator which also includes a solar voltaic array and associated equipment and further illustrating a submerged buoyancy installation approach;
FIG. 5C is an elevational schematic view, partly in diagram form, illustrating another embodiment for a wind turbine circulator and a wind powered electrical generator apparatus;
FIG. 6A is a schematic view, partly in diagram form, illustrating the effects of the wind which creates a cylindrical circulation pattern at the surface which can be observed by Langmuir streaks in the body of water, together with an installed wind turbine circulator which transmits wind-induced circulation energy deeper into the water body;
FIG. 6B is a schematic view, partly in diagram form, of another embodiment of a wind turbine circulator employing impellers for both updraft and downdraft pumping and mixing of selected depth strata;
FIG. 6C is a schematic view, partly in diagram form, further illustrating another embodiment of a wind turbine circulator to pump circulated aerated water downward through a conduit and blending into a deep, cold hypolimnion layer;
FIG. 6D is a schematic view, partly in diagram form, of another embodiment of a wind turbine circulator employing multiple impeller elements which can be deployed in any combination of updraft or downdraft direction;
FIGS. 7A , 7 B and 7 C are schematic elevational views of three submerged buoyancy modules with wind turbine circulators, partly in diagram form, as installed in a body of water, with or without a conduit chamber for vertical conveyance of pumped water;
FIGS. 8A , 8 B, 8 C, 8 D and 8 E and are elevational installed views, partly in schematic and partly in diagram form, illustrating various embodiments of a wind turbine circulator/aerator as installed in a body of water with combinations of wind and solar powered shaft circulation and diffused aeration by produced compressed air;
FIG. 9 is a schematic diagram of a wind turbine circulator illustrating possible propeller/impeller system configurations with respect to pitch, rotation and angle which can be employed in the various wind turbine circulators and circulator/aerators to accomplish updraft or downdraft pumping and horizontal mixing and circulation;
FIGS. 9A and 9B are each a schematic diagram of a single propeller/impeller;
FIGS. 9C-9F are two cooperative propellers/impellers sharing various pitches and rotations;
FIG. 12A is an elevational schematic view, partly in diagram form, of a representative wind-solar circulator/aerator as mounted on pipe pilings;
FIG. 12B is an elevational schematic view, partly in diagram form, of a hybrid wind-solar circulator/aerator as installed in a body of water to aerate and circulate several depth strata simultaneously;
FIG. 12C is an elevational schematic view, partly in diagram form, of a hybrid wind-solar circulator/aerator as installed in a body of water and further illustrating a telescopic mount to accommodate fluctuating water levels;
FIG. 13 is an elevational installation view, partly in schematic and partly in diagram form, illustrating a solar powered circulator as installed in a water body;
FIG. 14A is a side elevational view and an associated cross-sectional view, partly in schematic and partly in diagram form, illustrating a pneumatic diffuser which is employed in conjunction with the wind turbine circulator and aerator;
FIGS. 15A-15F illustrate various applications for employing a pneumatic diffuser;
FIG. 16 is a schematic view of a diffuser and diffusing system which may be employed in conjunction with various circulators and aerators;
FIG. 17 is a schematic view illustrating a flow restricting size control of the amount of air delivered to a diffuser limit of FIG. 16 ;
FIG. 18 is a chart illustrating how flow restricting orifices control the amount of air delivered to the diffuser units of FIG. 16 and various representative line pressures; and
FIG. 19 is a schematic view, partly in diagram form, illustrating a body of water and its surrounding environment and a hybrid wind solar power generator which is land based for a solar power system for three aeration and circulation techniques.
DETAILED DESCRIPTION
With reference to the drawings wherein like numerals represent like parts throughout the several figures, a wind turbine circulator is designated generally by the numeral 10 in FIG. 4 . The wind turbine circulator 10 is self-powered and functions to circulate water in bodies of water so as to achieve mixing between selected depth layers.
As described herein, various types of circulators and circulator/aerators can be deployed for enhancing the water quality for bodies of water, such as reservoirs and lakes. Wind turbine circulators and wind turbine circulator/aerators are specifically adapted and installed to provide several functions, such as mixing and circulation of a specified depth range to create an aerobic layer bounded by functional thermoclines above and below the layer; downward expansion of the epilimnic mixed layer and associated downward transport of oxygen; and the downward transport of oxygenated water to the deep hypolimnic strata to offset demand. The circulators and circulator/aerators preferably do not require auxiliary power, but are powered by wind and solar energy and a combination of wind powered drives and solar panel produced energy.
In a body of water to which the wind turbine circulators and circulator/aerators of the present disclosure have particular applicability, the body of water receives oxygen from the atmosphere as well as oxygen available at some depths from photosynthesis. As schematically illustrated in FIG. 1 , there is a potential source of nutrients, anaerobic respiration products and other bottom generated contaminants which are introduced from the bottom into the body of water when dissolved oxygen is depleted. For most applications which benefit from enhanced circulation or aeration of deep or shallow water bodies, it is preferred to enhance circulation in a downward direction or within a specified depth strata while maintaining a stratified condition. The latter is preferred in order to minimize the adverse impact of up-welling nutrients, and anaerobic respiration products, such as iron and manganese, and other bottom generated contaminants.
The heavy black arrows in FIGS. 1-3 and 19 represent general induced water flow direction.
Wind turbine circulator 10 illustrated in FIG. 4 is highly efficient and is self-powered from the surrounding environmental forces. A support tube 20 connects an impeller unit 22 and extends through a buoyancy module 24 to upwardly support a wind turbine 30 . Upon installation, the turbine 30 is rotatable about a vertical axis and is positioned above the surface of the body of water. The turbine 30 includes a plurality of wind sails 32 which are generally equidistantly mounted by a pair of axially (vertically) spaced mounting brackets 34 extending from a central hub 36 .
There is a variety of specific wind turbine engines which are suitable to spin the shaft, including a three wing design, Savonius “scoop-type” design, Giromill, Darrieus, Helical, Lenz Wing and turbines such as those used for roof ventilation. Alternatively, the turbine could be a horizontal turbine, like a windmill, using a 90° gearbox to turn the vertical shaft. A shaft 40 is connected to the wind turbine for rotation about a vertical axis. The shaft 40 extends through the support tube to fixedly couple with the impeller unit 22 to rotatably drive the impeller unit 22 . The impeller unit 22 includes a plurality of impeller prop blades 42 . The impeller unit is housed within a protective cage formed by a pair of spaced plates 44 and axial struts 46 .
Upon proper installation, the wind turbine circulator 10 is installed upright in the body of water so that the wind turbine 30 is positioned above the surface of the water, and the impeller unit 22 is positioned at a selected depth to provide for circulation of the water. The wind turbine circulator is stabilized by the buoyancy module 24 . The module 24 stabilizes the wind turbine circulator in an upright relatively stable position wherein the impeller unit 22 is positioned at a generally direct location below the surface of the water to generate the desired water circulation.
As schematically illustrated in FIGS. 1 and 2 , various wind turbine circulators are designated as 10 A, 10 B, 10 C and 10 D. Circulator 10 A includes an elongated shaft 40 A which mounts and rotatably drives a pair of axially spaced impeller units 21 and 23 . The impeller units are configured and mounted for providing concurrently a downward directional circulation and an upward circulation. It should be appreciated that as the wind turbines rotate due to the environmental wind currents above the surface of the water, the impellers also rotate due to the fixed rotational relationships between the impeller units 21 , 23 , 25 and 27 and the wind turbine.
Wind turbine circulator 10 B includes a single impeller unit 21 which essentially provides for a downward circulation. For the wind turbine circulator 10 B illustrated in FIG. 2 , the length of the shaft 40 B is longer and the impeller 21 is configured to provide a downward direction to circulate the water and transport ambient dissolved oxygen from more shallow aerobic strata to deeper depths.
Wind turbine circulator 10 C includes a cylindrical chamber 60 which is mounted to the support post and includes an upper intake port 62 and a lower output port 64 . The impeller unit 21 is housed within the chamber 60 and functions to provide a downward circulation through the lower output port 64 , as best illustrated in FIGS. 1 and 2 . Wind turbine circulator 10 C is employed to provide downward transport of oxygenated water to the deep hypolimnetic strata to offset the demand.
For the wind turbine circulator 10 D illustrated in FIG. 2 , a multiplicity of impeller units 21 , 23 , 25 and 27 are employed. Impeller unit 21 provides a downward circulation. Impeller units 25 and 27 cooperate to provide intermediate downward and upward circulations. Impeller unit 23 provides an upward circulation to mix in circulating water.
A preferred application of the wind turbine circulators 10 A, 10 B, 10 C and 10 D may be appreciated by reference to FIG. 2 . Wind turbine circulator 10 A is employed to provide mixing circulation at a specified depth range to create an aerobic layer bounded by the upper and lower functional thermoclines. Wind turbine circulator 10 B provides a downward expansion of the epilimnetic surface layer and associated downward transport of dissolved oxygen.
The wind turbine circulators 10 A, 10 B and 10 C can also be employed, as best illustrated in FIG. 3 , in shallow lakes and other water bodies which exhibit intermittent stratification and/or a very high demand for dissolved oxygen. It will be appreciated that in this type of water body, the oxygen consumption in deeper strata and oxygen demands at the sediment water interface can exceed the oxygen replenishment rate from the atmosphere and photosynthetic production near the surface. Consequently, wind turbine circulator 10 A can be employed to provide a mixing circulation at a specified depth to increase oxygen delivery to the bottom. Turbine 10 C is employed to produce a downward transport of oxygenated water to the bottom waters to offset the high sediment oxygen demand.
A wind turbine circulator and/or wind turbine circulator aerator may be subject to significant damage from wave action across the body of water, especially during major storms. Consequently, for some embodiments, it is required that the structures be sufficiently anchored and adapted to alleviate the adverse effects of wave action. As illustrated in FIG. 5A , the wind produces a representative wave height h and a wave length λ across the body of water.
Wind turbine circulator 100 employs a submerged buoyancy piling and mooring system 110 , as illustrated in FIG. 5A . The buoyancy module 124 is sufficiently submerged below the surface of the water so that it will not be exposed to significant wave-induced oscillations. A pair of impeller units 121 , 123 produces a cooperative downward and upward circulation below a platform 112 . The platform is anchored at the bottom of the body of water. The anchoring may be provided by vertical pipes 114 secured to an anchor base 116 as illustrated or by a cable/chain mooring-type system. Alternatively, the anchoring connection can be provided by ropes, cables, chains and other solid connectors.
A tubular support post 118 extends from the impeller module through the water surface where it mounts the wind turbine 130 . A rotatable drive shaft 140 is housed in the pipe 130 . The wind turbine rotates the shaft 140 which directly drives the impellers. The buoyancy module 124 which is mounted below the surface of the water maintains the pipe 130 and the shaft 140 in a substantially erect vertical position. The anchor weight of the anchor base 116 has a ballast counterweight that is significantly greater than the buoyancy of the buoyancy module 124 . For wind turbine circulator 100 , the module 124 principally functions to maintain the vertical position of the surface structures.
Alternatively, a hybrid solar wind powered circulator 100 B illustrated in FIG. 5B employs a solar/photovoltaic array and associated equipment disposed in a housing module 104 (schematically shown). The apparatus includes a charge controller 105 , a load controller 106 and a battery system 107 . The battery system drives a DC or, if inverted, an AC, motor 108 or compressor system. The motor rotates the shaft to provide both air lifting and pumping as well as aeration of the impeller units during calm intervals.
Another embodiment in the form of a hybrid wind generator powered apparatus 100 C is illustrated in FIG. 5C . This embodiment includes an alternator stator assembly 109 which generates electricity. A charge controller 105 , load controller 106 and battery system 107 drives a DC motor compressor 150 to again provide airlifting, pumping or aeration of the apparatus during calm intervals when the wind is not sufficient to otherwise rotate the impellers and provide sufficient aeration.
Wind across the body of water also does produce circulation and mixing in the form of horizontal cylindrical water columns. These columns result in observed Langmuir streaks on the surface, as illustrated in FIGS. 6A-6C . As illustrated, the convergence of these columns produce divergent upwelling currents and convergent downwelling currents. A wind turbine circulator 200 employs a plurality of impeller elements 221 , which may have either a clockwise or counterclockwise pumping direction, to capture the wind energy and transmit it vertically down into the water to extend the depth of the wind induced mixing.
As best illustrated in FIG. 6B , wind turbine 200 B employs impeller units 221 and 223 configured to provide opposing clockwise rotations so that a blended layer or circulated layer is formed. In addition, only downward impellers (not illustrated) may be located to provide downward mixing for conditions wherein the bottom surface serves as a barrier to the downward circulation.
The wind turbine circulator 200 C illustrated in FIG. 6C employs a conduit 260 with a lower, nozzle-like peripheral outlet 264 which is restricted. The circulated water in the conduit is pumped or downwardly forced from a relatively shallow depth through the conduit 260 to mix and be forced through outlet 264 into the deep cold hypolymnium. A Venturi-type eduction of the outflow induces blending with deep water.
The wind turbine circulator 200 D illustrated in FIG. 6D employs multiple impeller units 221 , 223 , 225 and 227 to achieve the desired mixing and layering.
The vertical axis wind turbine circulator for a submerged buoyancy module may be configured in a number of circulation configurations with respect to the water level was illustrated in FIGS. 7A-7C . Wind turbine circulator 110 employs a pair of impeller units 121 A, 123 A which provide concurrent upward and downward pumping or circulation. The circulator is anchored to a base 116 A at the bottom of the water body.
Wind turbine circulator 110 B employs a cylindrical chamber 160 B which surrounds the impeller units 121 A, 123 A and has an upper and a lower inlet port 161 B, 163 B, respectively, and an intermediate outlet port 164 B. The impellers are configured concurrently to provide a downward and an upward circulation.
Wind turbine circulator 110 C employs a single impeller 121 C which provides a downward circulation path within a chamber 160 C. An upper inlet port 162 C is provided so that the circulator pumps water downwardly into a lower depth for release through outlet port 164 C to provide circulation.
A series of schematic representations illustrating how the capabilities of a circulator 300 may be enhanced by various wind and solar dependent modules for conditions wherein the wind is greater than five miles per hour and the sun is greater than five hours direct is illustrated in FIGS. 8A-8E . The circulator configurations are illustrated in relation to water level w. A compressor 350 may be added to provide, for example, 3-4.5 CFM at 30 PSI. In addition, a windmill 370 may be added to provide additional power so that, for example, 6-9 CFM may be produced. In addition, it is possible to provide a supplement of solar direct drive 380 for any of the various configurations.
The propellers for the impeller systems for circulator 300 (and other circulators) can be selectively configured to provide various circulation qualities as required for a given application. This is best illustrated by the charts of FIG. 9 . The propeller pitch, e.g., the displacement that the propeller makes in a 360° rotation about the shaft, can be selected to provide for desired torque and vertical axis wind turbine windspeed (VAWTRPM). The rotation of the propeller can be clockwise (CW) or counterclockwise (CCW) rotation. The angle of the propeller (P) can be varied and fixed to focus on more horizontal mixing or more vertical mixing and pumping. Naturally, with multiple propellers, various combinations can be employed to accomplish the desired horizontal and vertical functions.
Another problem that is encountered upon installation of wind turbine circulators in water bodies is that the water bodies themselves may experience significant water level fluctuations (Δw). The water level fluctuations may be compensated by the schematic illustration of FIG. 10 . An anchor 402 is fixedly positioned at the bottom of the body of water. Connecting pulleys 404 are mounted to a flotation platform 406 positioned at the surface of the water 406 . A wind turbine circulator 400 is mounted to the flotation platform. A cable 408 connects at one end with the anchor 402 and extends around a pulley 404 at opposed sides of the flotation platform 406 . A counterweight 410 is placed on the other end of the cable. Multiple pulleys 404 , cables 408 and counterweights 410 are preferably employed.
Consequently, as the level of the water changes from w to w′, as illustrated in FIG. 10 , the pulley system and counterweights function to maintain the proper position of the wind turbine circulator 400 relative to the upper surface of the water.
With reference to FIG. 11 , wind turbine circulator/aerator 500 employs a direct drive air compressor 550 on the drive shaft 540 . The circulator/aerator thus not only circulates the water, but provides for a diffused aeration enhancement through the drive of the wind turbine 530 . In addition, the circulator 500 employs a photo voltaic array of solar panels 502 which generate power. A controller 504 and battery pack 506 are employed to power a motor 508 . The motor 508 connects to the shaft 540 for driving the shaft and the compressor 550 to provide diffused air enhancement of the wind turbine when the wind velocity is relatively low or insufficient to provide suitable circulation and aeration.
Alternatively, any of the foregoing described wind solar circulation/aerators can be mounted onto pipe piling installations 570 as illustrated in FIG. 12A . Pipes 572 are anchored into the bottom of the water body and extend upwardly. A platform 574 includes downwardly extending parallel tubes 576 which are slidably received over the pipes 572 . The tubes 576 telescopically change position as indicated by the arrow A to accommodate the depth changes in surface of the water w. In addition, the pipe/tube assembly provides a very efficient way of removing and installing the circulator or circulator/aerator installations when required for seasonal purposes.
With respect to the anchoring system illustrated in FIG. 12B , the platform 584 is the top of a cylindrical chamber 586 . The platform 584 is mounted below a tandem impeller unit 521 , 523 and above a third impeller unit 525 . Impeller unit 525 is disposed in the chamber 586 which has an input port 587 and an output port 589 . Aerated water is preferably forced downwardly out of the output port 589 at the lower portion of the circulator/aerator unit. The chamber may rest on the bottom of the body of water or may be anchored to the bottom.
As best illustrated in FIG. 12C , the platform 594 may also be disposed below the buoyancy module 524 . A pair of telescopically received chambers 596 , 598 houses a dual impeller unit 522 which forces the water downwardly. The relative position of the lower chamber 598 vis-à-vis the upper chamber 596 which houses the impellers varies is indicated by arrow C. An input port 597 at the upper portion below the platform 594 provides the input opening so that the water is forced to circulate downwardly through chambers 596 , 598 and out of the bottom at the outlet port 599 . The compressor 550 also provides for oxygenation of the water which is typically warmer as it is circulated through the output port 599 into the generally cooler water level.
As additionally illustrated in FIG. 13 , the power for water circulator 600 may also be solely provided by a solar array 602 . The solar array 602 provides power for a motor disposed in housing 604 . The motor drives the shaft 640 . In the illustrated embodiment, impeller units 621 and 623 are disposed below a platform 650 which is anchored to the bottom floor of the body of water. The buoyancy module 624 functions to keep the circulator in a generally upright orientation.
A pneumatic impeller diffuser 700 can be driven by compressed air to induce a circulation current and solute phase oxygen input from diffused air, as best illustrated in FIGS. 14 and 14A . A housing 710 has a pair of bearings 712 , 714 for mounting about a central rotatable shaft 740 having a communication channel 742 . The housing 710 forms a chamber 730 with an inlet 732 and an outlet 734 . Inner pump rotor 750 rotatable in the chamber 730 has reciprocating vanes 752 , 754 , 756 , 758 which utilizes the expansion of compressed air to rotate the shaft and impeller. Release of exhausted air is jetted directionally to enhance impeller spin.
The air flows in the path as indicated by the arrows through the channel 742 to the impellers 720 and radially from the impellers for exit through ports 722 , 724 in the impellers. As the drive shaft 740 rotates, the air is forced axially and then radially from the impellers into the water as the impellers also rotate. As further illustrated, the pneumatic diffuser 700 can be deployed for rotation in any direction and is easily coupled to the wind driven shaft of the wind turbine circulator.
The pneumatic diffuser 700 can be employed in a number of ways, as best illustrated in FIGS. 15A-15F . In FIG. 15B , the diffuser is employed in a pump chamber 760 for pumping while dissolving gas and aerating. In FIG. 15D , the diffuser 700 is inverted in the pump chamber 760 .
As illustrated in FIG. 15C , a pair of diffusers are employed in a mixing chamber 765 for circulating while dissolving the gas. Either directional rotation may be employed. The diffuser is deployed at the inside of the mixing chamber 765 for downward pumping while dissolving gas, namely, oxygenation contactors. In FIG. 15E , the diffuser 700 is directionally employed as a means of propulsion inside a generally horizontally disposed housing 780 . As further illustrated in FIG. 15F , the diffuser 700 may be employed inside an aeration chamber 770 using high pressure/low volume to enhance efficiency of diffused aeration using low pressure/high volume blowers 772 .
As illustrated in FIGS. 16 and 17 , compressed air can be delivered in equal proportions to a plurality of diffuser elements 810 regardless of distance from compressed air source or water depth and pressure. A flow restricting orifice 830 controls the air volume to each diffuser assembly 810 . The flow limiting orifice 830 maintains pressure throughout the main feed line 820 so that diffusers can operate with an even airflow in terms of CFM distribution regardless of the pipe length and depth. By controlling airflow in this manner, the entire length of the feed line from the compressor is maintained at a pressure that feeds an equal amount of airflow to each diffuser, regardless of the depth/pressure of distance from the compressor as illustrated in FIG. 19 . The diffuser heads may be configured for various internal flow paths as schematically illustrated for heads 812 and 814 in FIG. 19 . The multi-diffuser approaches can be deployed with any of the described apparatus and methods that are driven by a diffuser and air-lift pumping, for example, hypolimnetic aerator units, layer aeration units, and design depth circulators.
As indicated by the graphical representations FIG. 18 , the orifice diameters may be dimensioned to maintain a substantially constant air pressure. It should be noted that the flow restricting orifice sizes are dimensioned so that the amount of air delivered to each diffuser element under pressure is substantially equalized. The orifice sizes are selected based on the total CFM and the required line pressure.
It should be appreciated that a hybrid wind solar panel generator 900 can essentially also be land based. Generator 900 drives an air compressor diffuser for diffused air circulation for hypolimnetic aeration, circulation, or layer aeration schematically illustrated in FIG. 19 .
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Circulation and aeration systems for ponds, lakes, sounds, treatment basins, and other bodies of water. In one set of embodiments, water is pumped in a downward direction to circulate ambient oxygen from the atmosphere and produced by plant photosynthesis to deeper strata. In other embodiments, water is circulated within predetermined depth strata. Each system preferably includes a wind turbine, a drive shaft, and an impeller array. Some systems include conduits for conveying and mixing water from and to selected depth strata, or configured as an open impeller-mixing apparatus. Alternative embodiments include systems which incorporate electrical power generation by the wind turbine, solar power generation and use hybrid wind-solar apparatus, and combinations of land-based and in-water based apparatus. A pneumatic pump diffuser and a control flow centered orifice diffuser line are employed in some embodiments.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a heat dissipation module, and in particular to a heat dissipation module incorporating a clip for mounting the heat dissipation module on a circuit board to effectively dissipate heat generated by an electronic device on the circuit board. The clip has such a configuration that a steady pressure generated by the clip on the electronic device can be easily obtained.
DESCRIPTION OF RELATED ART
[0002] With the advance of large scale integrated circuit technology, high speed processors have become faster and faster, which causes the processors to generate more redundant heat. Redundant heat if not quickly removed will have tremendous influence on the system stability and performance. Usually, people install a heat sink on the central processor to assist its heat dissipation, whilst a clip is required for mounting the heat sink to the processor.
[0003] FIG. 5 shows a clip in accordance with related art for mounting a heat sink (not shown) to a processor (not shown) in accordance with related art. The clip is T-shaped, including a locking portion 42 c and a securing portion 44 c. The securing portion 44 c is elongated and with two ends. The locking portion 42 c extends transversely from a middle of the securing portion 44 c. The locking portion 42 c defines two locking holes 421 c therein. Screws (not shown) extend through the locking holes 421 c to lock the clip to the heat sink. The securing portion 44 c defines two securing holes 441 c in the two ends thereof. When the heat sink with the clip fixed thereon is mounted to a circuit board (not shown) on which the processor is arranged, rivets or screws extend through the securing holes 441 c into corresponding holes defined in the circuit board to lock the heat sink to the circuit board. Thus the heat sink with the clip is fixedly mounted on the circuit board by riveting or screwing. The pressure exerted on the processor is generated by the downward deflection of the clip. However, for the requirement of compactness of the electronic device, the size of the clip is limited. A distance between each securing hole 441 c of the securing portion 44 c and the locking portion 42 c is limited. Such a limitation causes that when the deflection of the clip has a little variation, the pressure exerted by the clip on the processor changes enormously, which results in that the pressure exerted on the processor can not be easily controlled.
[0004] What is needed, therefore, is a heat dissipation module incorporating a clip for mounting the heat dissipation module to a circuit board, wherein the clip is so configured that the clip can exert a steady pressure to the processor even when the deflection of the clip has a large variation.
SUMMARY OF THE INVENTION
[0005] According to a preferred embodiment of the present invention, a heat dissipation module includes a base and a clip for securing the base to a heat-generating electronic component. The clip includes a connecting arm engaging with the base and at least one securing arm for securing the base to the heat-generating electronic component. The at least one securing arm bends curvedly from the connecting arm and has an end remote from the connecting arm. The remote end is securely fixed to a circuit board on which the heat-generating electronic component is mounted.
[0006] Other advantages and novel features of the present invention will be drawn from the following detailed description of the preferred embodiment of the present invention with attached drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of the present heat dissipation module can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present heat dissipation module. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views:
[0008] FIG. 1 is an exploded, isometric view of a heat dissipation module in accordance with a preferred embodiment of the present invention;
[0009] FIG. 2 is an assembled, isometric view of the heat dissipation module of FIG. 1 ;
[0010] FIG. 3 is a top view of a clip of the heat dissipation module of FIG. 1 ;
[0011] FIG. 4 is a top view of a clip in accordance with a second embodiment of the present invention; and
[0012] FIG. 5 is a top view of the clip in accordance with related art.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring to FIGS. 1-2 , a heat dissipation module includes a fan 10 , a base 106 extending from the fan 10 , a heat sink (not labeled) attached to the base 106 , and a pair of clips 40 for securing the base 106 to a printed circuit board 100 on which a heat-generating electronic device, such as a CPU 200 , is mounted.
[0014] The fan 10 includes a housing 11 defining a space (not labeled) therein, and a motor 50 received in the space of the housing 11 . A plurality of fan blades 52 extends radially and outwardly from an outer-periphery of the motor 50 for generating forced airflow during rotation of the motor 50 . The housing 11 defines an air inlet 54 in a top wall 12 thereof. An air outlet 60 perpendicular to the air inlet 54 is defined in a sidewall 14 of the housing 11 .
[0015] The base 106 is integrally formed with the housing 11 and extends from an outer periphery of the top wall 12 of the housing 11 . The base 106 is located at a side of the fan 10 opposite the air outlet 60 of the housing 11 . A pair of flanges 107 extends outwardly from two opposite sides of a distal end 104 of the base 106 , respectively. Three pins 109 extend upwardly from each of the flanges 107 . The pins 109 of the flanges 107 are arranged symmetric to each other. A through hole 108 is defined in the distal end 104 of the base 106 .
[0016] The heat sink includes a heat spreader 70 , a heat pipe 30 thermally attached to the heat spreader 70 , and a fin unit 20 thermally attached to the heat pipe 30 . The heat spreader 70 is made of material having relatively high heat conductivity, such as copper or aluminum. The heat spreader 70 has a shape and size the same as that of the through hole 108 and is received in the through hole 108 of the base 106 .
[0017] The heat pipe 30 is arranged on the base 106 . The heat pipe 30 includes an evaporating section 302 and a condensing section 304 at two opposite ends thereof. The evaporating section 302 is arranged on the distal end 104 of the base 106 and attaches to an upper surface 72 of the heat spreader 70 directly. Alternatively, for improving heat conductivity between the heat spreader 70 and the heat pipe 30 , thermal interface material such as thermal grease can be filled between the upper surface 72 of the heat spreader 70 and the heat pipe 30 . The condensing section 304 of the heat pipe 30 extends from the evaporating section 302 and across the top wall 12 to of the housing 11 .
[0018] The fin unit 20 is arranged at the air outlet 60 of the housing 11 , including a plurality of fins 22 stacked together. Each fin 22 has a main body 28 and a pair of hems 26 bent from top and bottom sides of the main body 28 . The hems 26 of each fin 22 abut the main body 28 of an adjacent fin 22 . Cooperatively the top hems 26 form a top surface 29 of the fin unit 20 . The condensing section 304 of the heat pipe 30 contacts with the top surface 29 of the fin unit 20 to dissipate heat to the fin unit 20 . A flow channel 24 is defined between the main bodies 28 of any two neighboring fins 22 for the airflow generated by the fan 10 to flow therethrough.
[0019] Also referring to FIG. 3 , the clips 40 are connected to the flanges 107 of the base 106 . Each clip 40 includes a connecting arm 42 at a middle portion thereof and two securing arms 44 at two opposite ends thereof. The connecting arm 42 is elongated and has a rectangular shape. Three locking holes 421 are defined in the connecting arm 42 of each clip 40 corresponding to the pins 109 of each flange 107 . Each securing arm 44 of the clip 40 bends reversely from a corresponding end of the connecting arm 42 and extends toward the other end of the connecting arm 42 . In other words, free ends (not labeled) of the securing arms 44 face to each other. A securing hole 441 is defined in the free end of each of the securing arms 44 . The two securing holes 441 of the clip 40 have shapes different from each other. One of the two securing holes 441 is circular, whilst the other securing hole 441 is oblong. Alternatively, the two securing holes 441 can have the same shape with each other.
[0020] When the heat dissipation module is assembled, the fin unit 20 is received in the air outlet 60 of the housing 11 . The condensing section 304 of the heat pipe 30 attaches to the top surface 29 of the fin unit 20 , and the evaporating section 302 is arranged on the base 106 . The heat spreader 70 is received in the through hole 108 of the base 106 with an upper surface 72 thermally connected with the evaporating section 302 of the heat pipe 30 . The clips 40 are connected to the flanges 107 of the base 106 . The two clips 40 are arranged opposite to each other. The connecting arms 42 of the two clips 40 are mounted on the flanges 107 , whilst the securing arms 44 of the two clips 40 are located beyond the base 106 . The connecting arms 42 are located closer to each other than the securing arms 44 of the two clips 40 . The pins 109 of the flanges 107 of the base 106 extend through the locking holes 421 of the connecting arms 42 of the clips 40 to lock the clips 40 to the heat dissipation module. The pins 109 of the flanges 107 can be fixedly engaged with the locking holes 421 of the clips 40 by riveting or interference fit. The four securing holes 441 of the securing arms 44 of the clips 40 are located around four corners (not labeled) of the base 106 . When the heat dissipation module is mounted to the CPU 200 , a lower surface (not shown) of the heat spreader 70 opposite to the upper surface 72 is thermally attached to the CPU 200 . Screws (not shown) extend through the securing holes 441 of the clips 40 into corresponding mounting holes (not labeled) of the circuit board 100 to secure the heat dissipation module to the circuit board 100 , whereby the heat spreader 70 can have an intimate contact with the CPU 200 mounted on the printed circuit board 100 .
[0021] When the clips 40 engage with the flanges 107 , each securing arm 44 of the clips 40 acts as a cantilever which has one end fixed and the other end free. A portion of the connecting arm 42 corresponding to the locking holes 421 acts as the fixed end of the cantilever, whilst a portion of each securing arm 44 corresponding to the securing hole 441 act as the free end of the cantilever. Each screw provides a downward load P to a corresponding securing arm 44 . The securing arms 44 of the clips 40 under the downward load P deflect. When the securing arms 44 of the clips 40 undergo a deflection which is in the linearly elastic range, the following equation can be applied to the securing arms 44 of the clips 40 : P=E*Y*W*T3/(4*L3), wherein E is the elastic modulus of the cantilever; Y is the displacement of the free end of the cantilever under the load P; W is the width of the cantilever; T is the thickness of the cantilever; and L is the length of the cantilever.
[0022] As shown in the above equation, the load P is directly proportional to the displacement Y, whilst is inversely proportional to the cube of the length L. Thus, when the length L between the locking holes 421 and each securing hole 441 of the clips 40 is increased, the load P is approximately constant (i.e., having a small variation) even if the displacement Y of the securing arm 44 has a variation. As the securing arms 44 bend backward from the connecting arm 42 , the length L is thus increased. Thus, when the deflection of each of the clips 40 has a variation, the pressure exerted by the clips 40 on the CPU 200 is approximately constant. Therefore, the heat dissipation module is mounted on the CPU 200 with steady pressure. The heat dissipation module can be more reliably attached to the CPU 200 , and the heat generated by the CPU 200 can be more reliably absorbed by the heat sink of the heat dissipation module. During operation of the heat dissipation module, the heat generated by the CPU 200 is transferred firstly to the heat spreader 70 . Working fluid received in the evaporating section 302 of the heat pipe 30 , which thermally attaches the upper surface 72 of the heat spreader 70 absorbs the heat therefrom and evaporates into vapor. The vapor moves from the evaporating section 302 to the condensing section 304 which thermally attaches to the fin unit 20 to dissipate the heat, whereby the vapor cools and condenses at the condensing section 304 . The condensed working fluid returns to the evaporating section 302 and evaporates again to thereby repeat the heat transfer from the evaporating section 302 to the condensing section 304 . By this way, the heat generated by the CPU 200 is transferred from the heat pipe 30 to the fin unit 20 almost immediately. When the forced airflow generated by the fan 10 flows through the flow channels 24 of the fin unit 20 , the heat can be efficiently carried away by the airflow. Therefore, the heat of the CPU 200 can be dissipated immediately.
[0023] FIG. 4 shows a top view of a clip 40 a in accordance with a second embodiment of the present invention. Also the clip 40 a has a connecting arm 42 a to lock with the heat dissipation module, and a pair of securing arms 44 a extending from two opposite ends of the connecting arm 42 a. The connecting arm 42 a is T-shaped, and includes a first portion 43 a and a second portion 45 a extending transversely from a middle of the first section 43 a . The connecting arm 42 a defines two locking holes 421 a therein. The locking holes 421 a are respectively located in the first and second portions 43 a, 45 a. To lock the clip 40 a to the heat dissipation module, the positions and sizes of the pins 109 of the heat dissipation module can be changed according to the locking holes 421 a of the clip 40 a. The two securing arms 44 a bent from opposite ends of the first portion 43 a of the connecting arm 42 a, respectively. Each securing arm 44 a is U-shaped. Also each securing arm 44 a defines a securing hole 441 a in a free end (not labeled) thereof, wherein the free ends face a same lateral side of the clip 40 a. The two securing holes 441 a and the locking hole 421 a in the first portion 43 a of the connecting arm 42 a are aligned with each other. As the securing arms 44 a are curve-shaped, the length between each securing hole 441 a and the locking holes 421 a is increased in comparison with the related art. Thus when a deflection of each of the clips 40 a has a variation during mounting of the heat dissipation module to the printed circuit board 100 , the pressure exerted by the clips 40 a on the CPU 200 remains approximately constant. Accordingly, the heat dissipation module can be reliably mounted on the CPU 200 to have an intimate contact therewith. In both embodiments as shown in FIGS. 3 and 4 , the securing arms 44 , 44 a are in a same horizontal plane with the connecting arms 42 , 42 a before the free ends of the securing arms 44 , 44 a are depressed.
[0024] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to accommodate various modifications and equivalent arrangements. The clips 40 , 40 a in accordance with the preferred embodiments of the present invention comprise a connecting arm 42 , 42 a and a pair of securing arms 44 , 44 a extending from the connecting arm 42 , 42 a. It is can be understood that the size, and the shape of the connecting arm 42 , 42 a and the securing arms 44 , 44 a can change according to the heat dissipation module or the space in which the heat dissipation module is mounted. As the securing arms 44 , 44 a bending from the locking portion 42 , 42 a, the clips 40 , 40 a are curve-shaped. The length between the locking holes 421 , 421 a and the securing holes 441 , 441 a is thus increased. The influence of variation of the deflection of the clips 40 , 40 a to the pressure exerted on the CPU 200 by the clips 40 , 40 a is lessened. Thus, the heat dissipation module can be easily and reliably mounted on the CPU 200 .
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A heat dissipation module for removing heat from a heat-generating electronic component includes a base ( 106 ) and a clip ( 40, 40 a ). The clip includes a connecting arm ( 42, 42 a ) and a securing arm ( 44, 44 a ) for locking the base to the heat-generating electronic component. The connecting arm engages with the base. The securing arm extends from the contacting arm and is curve-shaped with a free end thereof being for being depressed whereby the securing arm exerts a downward force on the base so that the base and the electronic component can have an intimate contact with each other.
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BACKGROUND OF THE INVENTION
Donald H. Meclelland disclosed a Maintenance-free type Lead Acid Cell in his U.S. Pat. No. 3,862,861 which is characterized by structurally free, non-self-supporting plates separated from one another with highly absorbent flexible separators containing electrolyte and constrained within a container such that mechanical integrity is imparted to obtain a unitary self-supporting structure. However such a lead acid cell has the following defects:
1. Even such a cell provides a valve means 23, a yieldable cap of the central vent of the cell, to release any excessively high pressure in the cell and if such a cell is inferentially expected to be a rechargeable storage battery as subject to a overcharged condition, the electric terminals are still connected without being cut off, thereby resulting in much loss of entrained electrolyte droplets as laden in the venting gas and possibly causing unsafe situation.
2. One of its preferred embodiments disclosed a spiral configuration by spirally winding the positive and negative plates, and the separator material disposed between the two plates, which however may be squeezed to deform the electrodes or to break the separator to cause short-circuit drawback between the electrodes to thereby reduce the output electricity of the plates and decrease the overall efficiency of the cell.
The present inventor has found the defects of the prior Donald's cell and invented the present rechargeable storage battery and its making method.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a rechargeable storage battery including a container, a gas venting and circuit-breaker means and a concentric electrode assembly comprised of plural negative electrode plates, positive electrode plates and separators each disposed between every two adjacent, opposite plates, wherein the gas venting and circuit-breaker means may absorb the entrained electrolyte and may disconnect a positive terminal of the cell as biased by the excessive gas pressure during overcharged operation for safety purpose; and the concentric electrode plates may overcome the breaking or deformation drawbacks since the plates are concentrically wrapped up in one-fold, instead of a conventional spiral-winding electrode configuration which is continuously rolled up by many turns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional drawing of the present invention.
FIG. 2 is an illustration showing a gas venting and circuit-breaker means of the present invention.
FIG. 3 shows a wrapping operation for the plural electrodes and separators of the present invention.
FIG. 4 shows a wrapping operation for a double half-circle electrode in accordance with the present invention.
FIG. 5 shows the double half-circle electrode of the present invention.
DETAILED DESCRIPTION
As shown in FIGS. 1 and 2, the present invention comprises: a container 1, a gas venting and circuit-breaker means 2, and a concentric electrode assembly 3.
The container 1 includes: an outer cylindrical casing 11 preferably made of stainless steel plate having an upper crimped edge 111 and a lower crimped edge 112, an inner lining 12 encased in the outer casing 11 preferably made of insulating plastic materials and having an upper edge 121 packed between an upper crimped edge 111 and a top cover 21, a bottom portion 1 and a ring groove 120 formed on its upper inside wall, a bottom plate 13, secured under bottom portion 122, a side-portion electrolyte absorber 14, and a core-portion electrolyte absorber 15. The electrolyte absorbers may be made of chips, sliced parts, or mats of microporous materials, such as: polymers or composites of high molecular weight impregnated on paper having strong capability for absorbing liquid.
The gas venting and circuit-breaker means 2 includes: a top cover 21 having a positive terminal 22 formed as a cap on its central portion, a partition plate 23 having a cylindrical wall 231 secured under the top cover 21, having an extension ring 232 engaged with the ring groove 120 of the container 1 and having a neck portion 233 formed with a through hole and extending downwardly from the plate 23, a venting stack 24 extending upwardly from the plate 23 having a baffle 241 shaped as an inverse truncated cone formed on the stack top and having a neck portion with a through hole formed on a central portion of the baffle 241 and having a recess 243 circumferentially formed on an upper rim of the stack 24, an elastomer cap 25 yieldably sealing on the upper portion of the stack 24, a contactor bell 26 disposed around the stack 24 as packed by the elastomer cap 25 having a contactor plate 261 protruding transversely from its lower perimeter to normally touch a spring plate 351 of a positive-terminal connector 35 electrically connected with the positive electrode plates 33 and forming an aperture 262 between the stack 24 and the bell 26, a metallic tensioning spring 27 resiliently retaining the bell 26 downwardly as backed against the positive terminal 22, and a neutralizing absorber 28 filled in a degassing chamber 20 defined among the top cover 21, the partition plate 23 and the bell 26 and also made of microporous materials, such as resin impregnated paper, glass fibers, and foam, which are soaked with neutralizing agent such as lime water adapted for absorbing and neutralizing any entrained electrolyte spilt through the aperture 262.
The top cover 21 is formed with a venting hole 211 thereon for releasing a gas at excessively high pressure. The elastomer cap 25 should be able to retain an internal pressure as normally operated and may be biased upwardly to relieve the high-pressure gas. The spring 27 can be selected to conform with a preset working pressure of the battery.
The concentric electrode assembly 3 includes: a plurality of negative electrode plates 31, separators 32 and positive electrode plates 33, every two adjacent, opposite plates 31, 33 being sandwiched with each separator 32 such that each negative electrode plate 31, each separator 32 and each positive electrode plate 33 are concentrically wrapped up subsequently and cyclically from a core-portion electrolyte absorber 15 until finally being encased by a wrapping cloth 30 within the side-portion absorber 14; an upper electricity collector 34 welded and secured above the positive electrode plates 33 as spaced apart from each negative plate 11 with a void 311 having a length of 1-2 mm; a positive-terminal connector 35 protruding upwardly from the upper collector 34 through the partition plate 23 and extending transversely a spring plate 351 on its upper end in the degassing chamber 20; a lower electricity collector 36 welded and secured under the negative electrode plates 31 as spaced apart from each positive plate with a void 331; and a negative terminal 37 protruding downwardly from the lower collector 36 through the bottom plate 13.
The separator 32 may be made of microporous materials as aforementioned. The wrapping cloth 30 may be made of poly-propylene unwoven cloth. The separator 32 is provided for absorbing and retaining an electrolyte such as hydrosulfuric acid (specific gravity: 1.25), of which one gram of separator may absorb 18 grams of H 2 SO 4 . The collector 34 is drilled with plural perforations occupying about 40% of the collector area. Each perforation has a diameter less than 1 mm.
When making the electrode plate 31 or 33, a long strip of lead substrate plate having 0.06% calcium and tin 1% by weight is punched to form a grid having perforations occupying 80% of the whole area of the plate, and then coated with lead paste consisting of lead, litharge and graphite (poly-propylene short staples are added for positive plate and barium sulfate is added for negative plate) as mixed with dilute hydro-sulfuric acid. The paste coated plates are placed in dilute H 2 SO 4 bath for coagulating the paste and then electrolyzed to form electrode plates. The plates are washed in water by applying ultrasonic wave thereto and are drained to remove the excess water. The wet grid plates are then cut into the desired length and size.
The formed grid plates 31, 33 are stacked as shown in FIG. 3 in which an uppermost layer of negative electrode plate 31 is laid under a mandrel M. Then, a layer of separator 32 and a layer of positive electrode plate 33 are subsequently laid under the upper negative plate 31 until the lowest PP unwoven cloth 30. Each layer of plate or separator should have a length of 3.1416 times its diameter when concentrically wound. The plates 31, 33 and the sandwiched separators 32 are integratedly wrapped up around the central mandrel M as shown in dotted line. The outermost layer of cloth 30 is wound and sealed by a hot-melt adhesive or other bonding methods, to encase all said plates and separators.
If the electrode plate is made of slightly hard plate having 1.75% by weight of antimony of the lead plate, the electrode grid is first molded to form a corrugated strip having linear plural double half-circle units as shown in FIGS. 5 and 4, of which a recess 330 is formed between the two half circles of the unit for convenient winding operation. The multiple layers of plates 31, 33 and separator 32 are then concentrically wrapped up to form the electrode assembly of the present invention.
After assemblying all plates and separators, the central mandrel M is withdrawn and filled with the core-portion electrolyte absorber 15 as shown in FIG. 1. The illustration shown in FIG. 1 and the present invention merely discloses three negative electrode plates 31 and two positive electrode plates 33. However, the number of the plates 31, or 33 are not limited in this invention.
In using the present invention, the positive electricity is collected from upper collector 34 and then transmitted through positive-terminal connector 35, spring plate 351, contactor plate 261, bell 26, spring 27 and the positive terminal 22; while the negative electricity is transmitted from lower collector 36 and negative terminal 37, so that a direct current can be utilized by electrically coupling the positive terminal 22 and the negative terminal 37.
When the battery is charged and especially during the overcharge period, the electrolyte as laden in gas, when passing through the absorbers 14, 15, may be absorbed. Still, the gas if subject under excessive high pressure may bias the elastomer cap 25 and the bell 26 against the spring 27 to escape through aperture 262 and traces of electrolyte therein may be absorbed and neutralized by the neutralizing absorber 28 in the degassing chamber 20, to finally discharge through venting hole 211. In the battery of the present invention, any trace of entrained electrolyte may not spill over the neck portions 233, 242 respectively formed on the partition plate 23 and the baffle 241.
If the battery is under excessive high pressure as overcharged, the high gas pressure if being larger than the setting resilience force of the spring 27 may bias the cap 25, the bell 26 upwardly against the spring 27 to thereby disconnect the contactor plate 261 from the spring plate 351 to cut off the charging current for safety purpose.
Since the concentric electrode plates 31, 33 of the present invention as defined among the container 1, and the partition plate 23 are concentrically wrapped up in a one-fold step, the unexpected breakage or deformation of the electrodes as wound can therefore be prevented.
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A rechargeable storage battery includes a container, a gas venting and circuit-breaker device and a concentric electrode assembly comprised of plural negative electrode plates, positive electrode plates and separators each disposed between every two adjacent, opposite plates, wherein the gas venting and circuit-breaker device may absorb the entrained electrolyte and may disconnect a positive terminal of the cell as biased by the excessive gas pressure during overcharged operation for safety purpose; and the concentric electrode plates may overcome the breaking or deformation drawbacks since the plates are concentrically wrapped up in one-fold, instead of a conventional spiral-winding electrode configuration which is continuously rolled up by many turns.
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FIELD OF INVENTION
[0001] The present disclosure relates to cycles in heat pumps, particularly Vuilleumier heat pumps.
BACKGROUND
[0002] The displacers in most prior art Vuilleumier heat pumps are driven by a crank, such as shown in U.S. Pat. No. 1,275,507. A schematic of such a heat pump with crank driven displacers is shown in FIG. 1 . In the '507 patent, the displacers have a phase difference of 90 degrees as shown in FIG. 2 . A mechatronically-driven Vuilleumier heat pump, which is commonly assigned to the assignee of the present disclosure, has been disclosed in WO 2013/155258. In such a heat pump, the displacers are independently actuated allowing one displacer to remain stationary while the other displacer moves, which provides many additional degrees of freedom in controlling displacer motion. In the WO 2013/155258 A1 publication, a three-process cycle is also disclosed. A cycle that provides a high coefficient of performance is desired.
SUMMARY
[0003] A four-process cycle is disclosed that demonstrates a higher coefficient of performance than the previously disclosed three-process cycle based on modeling results.
[0004] A method to operate a heat pump is disclosed. The heat pump has a hot displacer adapted to reciprocate within a hot cylinder and a cold displacer adapted to reciprocate within a cold cylinder. The hot displacer has a remote position and a central position and the cold displacer has a central position and a remote position. The method includes: actuating the hot displacer to move from its central position to its remote position, actuating the cold displacer to move from its central position to its remote position, actuating the hot displacer to move from its remote position to its central position, and actuating the cold displacer to move from its remote position to its central position wherein the actuations occur in the given order.
[0005] At some operating conditions, the cold displacer remains stationary for at least a portion of the time during which the hot displacer moves between its central and remote positions and the hot displacer remains stationary for at least a portion of the time during which the cold displacer moves between it remote and central positions.
[0006] The actuating the hot displacer to move from its central position to its remote position comprises process one. The actuating the cold displacer to move from its central position to its remote position comprises process two. The actuating the hot displacer to move from its remote position to its central position comprises process three. The actuating the cold displacer to move from its remote position to its central position comprises process four. A cycle is made up of process one followed by process two followed by process three followed by process four.
[0007] The method may further include: commanding both displacers to remain stationary for a first predetermined time between process one and process two, commanding both displacers to remain stationary for a second predetermined time between process two and process three, commanding both displacers to remain stationary for a third predetermined time between process three and process four, and commanding both displacers to remain stationary for a fourth predetermined time between process four and process one.
[0008] A hot chamber is defined within the hot displacer cylinder with volume within the hot chamber related to the position of the hot displacer within the hot displacer cylinder. A cold chamber is defined within the cold displacer cylinder with volume within the cold chamber related to the position of the cold displacer within the cold displacer cylinder. When the hot displacer is in its remote position, the volume in the hot chamber is less than when the hot displacer is in its central position. When the cold displacer is in its remote position, the volume in the cold chamber is less than when the cold displacer is in its central position.
[0009] A heat pump is disclosed that has a hot displacer disposed in a hot displacer cylinder, a cold displacer disposed in a cold displacer cylinder, a hot displacer actuator which when actuated causes the hot displacer to reciprocate between remote and central positions within the hot displacer cylinder, a cold displacer actuator which when actuated causes the cold displacer to reciprocate between remote and central positions within the cold displacer cylinder, and an electronic control unit (ECU) coupled to the hot displacer actuator and the cold displacer actuator. The ECU commands the hot displacer and cold displacer to move through a series of arrangements: a first arrangement in which the hot displacer is at its central position within the hot displacer cylinder and the cold displacer is proximate its central position with the cold displacer cylinder, a second arrangement in which the hot displacer is at its remote position within the hot displacer cylinder and the cold displacer is proximate its central position with the cold displacer cylinder, a third arrangement in which the hot displacer within the hot displacer cylinder is at its remote position and the cold displacer is proximate its remote position within the cold displacer cylinder, and a fourth arrangement in which the hot displacer is at its central position within the hot displacer cylinder and the cold displacer is proximate its remote position within the cold displacer cylinder.
[0010] A cycle comprises moving from the first arrangement to the second arrangement to the third arrangement to the fourth arrangement to the first arrangement.
[0011] The cold displacer remains stationary in its central position for at least a portion of the time that it takes for the hot displacer to move from its central position to its remote position. The hot displacer remains stationary in its remote position for at least a portion of the time that it takes the cold displacer to move from its central position to its remote position. The cold displacer remains stationary in its remote position for at least a portion of the time that it takes the hot displacer to move from its remote position to its central position. The hot displacer remains stationary in its central position for at least a portion of the time that it takes the cold displacer to move from its remote position to its central position.
[0012] In some embodiments, the central axis of the cold displacer cylinder is collinear with a central axis of the hot displacer cylinder. In some embodiments, a diameter of the cold displacer cylinder is greater than a diameter of the hot displacer cylinder. In another embodiment, the diameter of the hot displacer cylinder is greater than a diameter of the cold displacer cylinder. In yet other embodiments, the heat pump of claim 6 wherein a diameter of the hot displacer cylinder is equal to a diameter of the cold displacer cylinder. In some embodiments, a distance that the hot displacer moves from its remote position to its central position is greater than a distance that the cold displacer moves from it remote position to its central position. In another embodiment, a distance that the hot displacer moves from its remote position to its central position is less than a distance that the cold displacer moves from it remote position to its central position. In some embodiments, a time that it takes for the hot displacer to move between its central and remote positions is different than a time that it takes for the cold displacer to move between its central and remote positions. In a heat pump in which the actuator includes springs, the springs acting on the displacers can be selected such that times for the displacers to move between their respective central and remote positions are unequal.
[0013] A heat pump is disclosed in which a hot displacer disposed in a hot displacer cylinder is adapted to reciprocate within the hot displacer cylinder and a cold displacer is disposed in a cold displacer cylinder and adapted to reciprocate within the cold displacer cylinder. The heat pump has a hot displacer actuator coupled to the hot displacer, the hot displacer actuator is adapted to cause the hot displacer to move between a central position and a remote position within the hot displacer cylinder, a cold displacer actuator coupled to the cold displacer, the cold displacer actuator is adapted to cause the cold displacer to move between a central position and a remote position within the cold displacer cylinder, and an electronic control unit (ECU) coupled to the hot displacer actuator and the cold displacer actuator. A cycle includes the following processes in the following order: the hot displacer actuator commands the hot displacer to move from the central position to the remote position within the hot displacer cylinder, the cold displacer actuator commands the cold displacer to move from central position to the remote position within the cold displacer cylinder, the hot displacer actuator commands the hot displacer to move from the remote position to the central position within the hot displacer cylinder, and the cold displacer actuator commands the cold displacer to move from remote position to the central position within the cold displacer cylinder.
[0014] The heat pump has a hot chamber at one end of the hot displacer cylinder, and a cold chamber at one end of the cold displacer cylinder. Volume in the hot chamber is greater when the hot displacer is in the central position than when the displacer is in the remote position. Volume in the cold chamber is greater when the cold displacer is in the central position than when the cold displacer is in the remote position. The heat pump includes a warm chamber which is a volume within the hot cylinder at the opposite end of the hot displacer from the hot chamber added to a volume within the cold cylinder at the opposite end of the cold displacer from the cold chamber.
[0015] In some embodiments, a central axis of the hot displacer cylinder is collinear with a central axis of the cold displacer. In other embodiments, a central axis of the hot displacer cylinder is substantially parallel to and offset from a central axis of the cold displacer. In some embodiments, the diameter of the hot displacer cylinder is greater than the diameter of the cold displacer cylinder.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a schematic of a prior art Vuilleumier heat pump;
[0017] FIG. 2 is a graph of displacer movement in the Vuilleumier heat pump with crank-driven displacers;
[0018] FIG. 3 is a schematic representation of a Vuilleumier heat pump with mechatronically-controlled displacers;
[0019] FIG. 4 is a representation of a three-process cycle in the Vuilleumier heat pump;
[0020] FIG. 5 is a representation of a four-process cycle in the Vuilleumier heat pump;
[0021] FIG. 6 is a chart showing movement of the hot and cold displacers as a function of time for a three-process cycle;
[0022] FIG. 7 is a chart showing movement of the hot and cold displacers as a function of time for a four-process cycle;
[0023] FIG. 8 is a chart showing movement of the hot and cold displacers as a function of time for a four-process cycle in which movement of the displacers overlap;
[0024] FIG. 9 is a chart showing movement of the hot and cold displacers in which there are periods in which both displacers remain stationary;
[0025] FIG. 10 is a representation of a Vuilleumier heat pump in which the diameter of the hot displacer cylinder is greater than the diameter of the cold displacer cylinder; and
[0026] FIG. 11 is a representation of a Vuilleumier heat pump in which the stroke of the hot displacer is less than the stroke of the cold displacer.
DETAILED DESCRIPTION
[0027] As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations whether or not explicitly described or illustrated.
[0028] Before describing cycles that are facilitated by a mechatronically-actuated Vuilleumier heat pump, a non-limiting example of such a heat pump 50 is shown in FIG. 3 . Heat pump 50 has a housing 52 and a cylinder 54 into which hot displacer 62 and cold displacer 66 are disposed. Displacers 62 and 66 reciprocate within cylinder liner 54 moving along central axis 53 . An actuator for hot displacer 62 includes: ferromagnetic elements 102 and 112 , electromagnet 92 , springs 142 and 144 , and a support structure 143 . Support structure 143 , as shown in FIG. 6 is attached to the electromagnet 92 , which is coupled to a central post 88 that is coupled to a cold end 86 of housing 52 . Post 88 , electromagnet 92 , and support structure 143 are stationary. When hot displacer 62 reciprocates upward from the position shown in FIG. 6 , spring 142 is compressed to a greater degree than its equilibrium preload and 144 is under a lower compression. Electromagnet 92 is energized to pull ferromagnetic elements 102 or 112 toward it, against the spring forces of springs 142 and 144 . Analogously, cold displacer 66 has a cold actuator that includes: an electromagnet 96 coupled to post 88 , a support structure 147 coupled to electromagnet 96 , and springs 146 and 148 . Spring 146 is coupled between support structure 147 and a first cap 126 of cold displacer 66 . Spring 148 is coupled between support structure 147 and a second cap 136 of cold displacer 66 . Electromagnet 92 and 96 are controlled via an electronic control unit (ECU) 100 .
[0029] Ferromagnetic blocks 102 , 112 , 106 , and 116 are coupled to: a standoff associated with a first cap 122 of hot displacer 62 , a second cap 132 of hot displacer 62 , a standoff associated with first cap 126 of cold displacer 66 , and second cap 136 of cold displacer 66 , respectively. Openings are provided in second cap 132 of hot displacer 62 , and first and second caps 126 and 136 of cold displacer 66 to accommodate post 88 extending upwardly through cold displacer 66 and into hot displacer 62 .
[0030] An annular chamber is formed between a portion of the inner surface of housing 52 and the outer surface of cylinder 54 . A hot recuperator 152 , a warm heat exchanger 154 , a cold recuperator 156 , and a cold heat exchanger 158 are disposed within the annular chamber. Openings through cylinder 54 allow fluid to pass between the interior of cylinder 54 to the annular chamber. Openings 166 allow for flow between a cold chamber 76 and cold heat exchanger 158 in the annular chamber. Openings 164 allow flow between a warm chamber and the annular chamber. Heat pump 50 also has a hot heat exchanger 165 that is provided near a hot end of housing 52 . Openings 162 through cap 82 lead to heat exchanger 165 which has passages 163 which lead to the annular chamber. Hot heat exchanger 165 may be associated with a burner arrangement or other energy source. A fluid that is to be heated flows to warm heat exchanger 154 into opening 174 and out opening 172 , cross flow. Fluid that is to be cooled flows to cold heat exchanger 158 in at opening 176 and exits at opening 178 . The flow through the heat exchangers may be reversed, parallel flow.
[0031] The end positions of the displacers in a three-process cycle in the Vuilleumier heat pump are illustrated in FIG. 4 . At state ‘a’, both a hot displacer 12 and a cold displacer 14 are at their upper positions within a cylinder 10 . In state ‘b’ in FIG. 3 , cold displacer 14 moves to its lower position. A change from state ‘a’ to state ‘b’ is a first process. From state ‘b’ to state ‘c’, hot displacer 12 moves from its upper to its lower position, i.e., a second process. In moving from state ‘c’ back to state ‘a’, both hot displacer 12 and cold displacer 14 move upwards, which is a third process.
[0032] In the cycle illustrated in FIG. 4 , hot displacer 12 and cold displacer 14 are in a central space within cylinder 10 at different points in the cycle. That is, at state ‘a’, cold displacer 14 is in the central space in cylinder 10 and at state ‘c’, hot displacer 12 is in the central space in cylinder 10 . The heat pump in FIG. 3 is suitable for a three-process cycle. A heat pump that would allow a four-process cycle is similar to that in FIG. 3 , except that the cylinder is elongated, the reason for which will become clear from the discussion below.
[0033] A four-process cycle for use in a Vuilleumier heat pump is shown in FIG. 5 in which a hot displacer 22 reciprocates within a hot displacer cylinder 20 and a cold displacer 24 reciprocates with a cold displacer cylinder 21 . At state ‘d’, a hot displacer 22 is at its central position within cylinder 20 and a cold displacer 24 is at its central position within cylinder 21 . In going from state ‘d’ to state ‘e’, hot displacer 22 moves to its remote position within cylinder 20 . This is a first process or process one. In going from state ‘e’ to ‘f’, cold displacer 24 moves to its remote position within cylinder 21 . This is a second process or process two. From state T to ‘g’, hot displacer 22 moves to its central position within cylinder 20 ; a third process or process three. In moving from state ‘g’ to back to state ‘d’, cold displacer 24 moves to its central position within cylinder 21 , undergoing a fourth process or process four.
[0034] As discussed above, in the three-process cycle in FIG. 4 , hot displacer 12 and cold displacer 14 occupy the same space but, of course, at different times during the cycle. In the four-process cycle of FIG. 5 , hot displacer 22 and cold displacer 24 do not cross a center line 26 . Cylinders 20 and 21 are collinear and of the same diameter and are denoted by cylinder 20 being above center line 26 and cylinder 21 being below center line 26 .
[0035] The displacer movement end positions illustrated in FIG. 4 are shown as a function of time in FIG. 6 . The movement of the lower edge of the hot displacer is shown as curve 16 . The movement of the upper edge of the cold displacer is shown as curve 18 . The cold displacer moves downward in going from state ‘a’ to state ‘b’ while the hot displacer is stationary. From ‘b’ to ‘c’, the hot displacer moves downward while the cold displacer is stationary. And from ‘c’ to ‘a’, which completes the cycle, both displacers move upward.
[0036] The displacer movement end positions illustrated in FIG. 5 are shown as a function of time in FIG. 7 . The lower edge of the hot displacer is plotted as curve 28 and the upper edge of the cold displacer is plotted as curve 30 . At state ‘d’, the displacers are both in their central positions and proximate each other. From state ‘d’ to state ‘e’, the cold displacer remains stationary and the hot displacer moves upward. From ‘e’ to T, the hot displacer remains stationary and the cold displacer moves downward. From T to ‘g’, the hot displacer moves downward and the cold displacer remains stationary. From ‘g’ to return to the starting position ‘d’, the hot displacer remains stationary and the cold displacer moves upward. The cycle in FIG. 6 is completed in three processes and the cycle in FIG. 7 is completed in four processes. Thus, if the displacers move at the same speed in the cycle in FIG. 6 as in FIG. 7 , the cycle in FIG. 7 takes longer, about 1⅓ times longer to complete than the cycle in FIG. 6 when the displacers have the same dynamics.
[0037] An alternative to the cycle in FIG. 7 is a cycle shown in FIG. 8 in which the movements of the displacers overlap slightly. The upper edge of the hot displacer movement is illustrated by curve 32 ; the lower edge of the cold displacer is illustrated by curve 34 . At time 220 in FIG. 8 , the cold displacer is finishing its upward movement and the hot displacer is starting its upward movement. At time 222 , the cold displacer has attained its upper position (its remote position) and remains there until time 224 . At time 224 , the hot displacer has not yet arrived at the upper position (its remote position), which happens at time 226 . Meanwhile, the cold displacer finishes the upward travel during time 224 to 226 . The hot displacer is stationary at its upper position from 226 to 228 . The cold displacer completes the downward travel at time 230 and then stays at the lower position until time 232 . Meanwhile, the hot displacer moves downwardly from time 228 through time 234 . At time 232 , the cold displacer moves upwardly through time 234 , time 220 ′, and time 222 ′. The hot displacer remains stationary from time 234 through time 220 ′. At time 220 ′, a complete cycle has been completed; the positions of the displacers are the same at time 220 as at time 220 ′.
[0038] The rate at the displacers move is determined by the spring constants and other properties of the system. As the illustrations in FIGS. 7 and 8 refer to the same configuration, the displacers move at the same rate in FIGS. 7 and 8 . However, because movement in the hot displacer is initiated before the cold displacer attains its extreme position and vice versa in the cycle shown in FIG. 8 , the FIG. 8 cycle occurs in less time than that in FIG. 7 . Such a cycle provides a higher output.
[0039] The discussion of cycles in regards to FIGS. 6-8 describe the highest output cycles that are possible. To obtain a downturn in output, both displacers remain stationary for a period between portions of the cycle. An example of such displacer movement is shown in FIG. 9 . The hot displacer movement is shown as curve 260 and the cold displacer movement is shown as curve 262 . At time 240 , both displacers are in their central positions within their cylinders. The hot displacer moves upward between time 240 and time 242 . Both displacers are stationary between time 242 and time 244 . The duration can be shorter or longer than that shown in FIG. 9 . Other intervals during which both displacers are stationary are between time 246 and time 248 and between time 250 and time 252 . Again, these can be shorter or longer to meet demanded output. Furthermore, the interval during which the displacers may be different in different parts of the cycle. E.g., the interval between time 242 and time 244 when the hot displacer is at its remote position and the cold displacer is at its central position can be of a different length than either of the other intervals: time 246 to time 248 or time 250 to time 252 .
[0040] A Vuilleumier heat pump in which the diameters of the cylinders are different is shown in FIG. 10 . A hot displacer cylinder 28 has a greater diameter than cold displacer cylinder 30 . A hot displacer 32 that reciprocates within hot displacer cylinder 28 is also greater than cold displacer 34 that reciprocates within cold displacer cylinder 32 . A heat pump in which the strokes are different is shown in FIG. 11 . A hot displacer cylinder 40 has a hot displacer 42 ; and a cold displacer cylinder 41 has a cold displacer 44 . The stroke of hot displacer 42 is less than the stroke of cold displacer 44 .
[0041] While the best mode has been described in detail with respect to particular embodiments, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. While various embodiments may have been described as providing advantages or being preferred over other embodiments with respect to one or more desired characteristics, as one skilled in the art is aware, one or more characteristics may be compromised to achieve desired system attributes, which depend on the specific application and implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described herein that are characterized as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
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A four-process cycle is disclosed for a Vuilleumier heat pump that has mechatronically-controlled displacers. Vuilleumier heat pumps that use a crank to drive the displacers have been previously developed. However, mechatronic controls provides a greater degree of freedom to control the displacers. The four-process cycle provides a higher coefficient of performance than prior cycles in the crank-driven Vuilleumier heat pump and those previously disclosed for a mechatronically-driven Vuilleumier heat pump.
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BACKGROUND
1. Technical Field
The present disclosure relates to a Universal Serial Bus (USB) connector and a connecting device using a USB connector.
2. Description of Related Art
A plurality of USB connectors is used in a computer or a server. The plurality of USB connectors are received in a bracket, and the bracket is secured to a metallic housing. A protecting member receives the metallic housing and includes a plurality pairs of blocking pieces for electromagnetic interference (EMI) protection. Each pair of the blocking pieces corresponds to each of the USB connector. A length of the protecting member may need to be adjustable according to a number of the plurality of USB connectors. Therefore, protecting members of different lengths may need to be individually designed. Therefore, an improved USB connector and a connecting device with a USB connector may be desired within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the embodiments can be better understood with reference to the drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is an exploded, isometric view of one embodiment of a USB connector.
FIG. 2 is an assembled, isometric view of the USB connector of FIG. 1 .
FIG. 3 is an exploded, isometric view of one embodiment of a connecting device with the USB connector of FIG. 1 .
FIG. 4 is an isometric view of the connecting device with the USB connector of FIG. 3 partially assembled.
FIG. 5 is an isometric view of the connecting device with the USB connector of FIG. 4 partially assembled.
FIG. 6 is an assembled, isometric view of the connecting device with the USB connector of FIG. 3 .
DETAILED DESCRIPTION
The disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
FIG. 1 shows one of a plurality of USB connectors 100 in accordance with an embodiment including a body 10 and a shelter 20 .
The body 10 , adapted to secure a USB cable (not shown), includes a top panel 11 , a bottom panel 12 , a front panel 13 , and a rear panel 15 . In one embodiment, the top panel 11 is substantially parallel to the bottom panel 12 , the front panel 13 is substantially parallel to the rear panel 15 and perpendicular to the top panel 11 . Each of the top panel 11 , the bottom panel 12 , the front panel 13 and the rear panel 15 defines an installation hole 16 . A resilient piece 17 obliquely extends inwards from each of the top panel 11 , the bottom panel 12 , the front panel 13 and the rear panel 15 .
The shelter 20 includes a top plate 21 , a bottom plate 22 , a front plate 23 , and a rear plate 25 . In one embodiment, the top plate 21 is substantially parallel to the bottom plate 22 , the front plate 23 is substantially parallel to the rear plate 25 and perpendicular to the top plate 21 . The top plate 21 includes a first plate 211 and a second plate 212 . The first plate 211 is substantially perpendicularly connected to the front plate 23 . The second plate 212 is substantially perpendicularly connected to the rear plate 25 . A gap (not labeled) is defined between the first plate 211 and the second plate 212 . An extrusion 26 protrudes inwards from each of the first plate 211 , the second plate 212 , the bottom plate 22 , the front plate 23 , and the rear plate 25 . The top wall 21 defines a first cutout 213 . The first cutout 213 extends from the first plate 211 to the second plate 212 and communicates from the gap. The first cutout 213 receives the resilient piece 17 of the top panel 11 when the resilient piece 17 is elastically deformed downwards. A first blocking piece 215 extends from a side edge of each of the first plate 211 and the second plate 212 . A second blocking piece 221 extends from a side edge of the bottom plate 22 . The bottom plate 22 defines a second cutout 223 . The second cutout 223 receives the resilient piece 17 of the bottom panel 12 when the resilient piece 17 is elastically deformed upwards. Two third blocking pieces 231 extend outwards from a side edge of the front plate 23 . Two fourth blocking pieces 251 extend from rear plate 25 . Each of the two third blocking pieces 231 corresponds to each of the two fourth blocking pieces 251 .
Referring to FIG. 2 , in assembly of one of the plurality of USB connectors 100 , the shelter 20 is moved towards the body 10 . The front plate 23 and the rear plate 25 are driven to extend away from each other and extend the gap between the first plate 211 and the second plate 212 . The shelter 20 is moved to surround the body 10 . Each of the extrusion 26 is elastically deformed until each of the extrusion 26 is aligned with each of the installation hole 16 . Each of the extrusion 26 rebounds to engage in each of the installation hole 16 . Thus, the shelter 20 is secured to the body 10 .
Referring to FIGS. 3-6 , a connecting device includes a mounting assembly (not labeled), and the plurality of the USB connectors 100 secured to the mounting assembly. The mounting assembly includes a base 30 , a covering member 50 , and a protecting member 60 .
The base 30 includes a base plate 31 , and two side plates 33 extending from two opposite sides of the base plate 31 . In one embodiment, the base plate 31 is substantially perpendicular to the two side plates 33 . A plurality of installation portions 35 is located on the base plate 31 . The base plate 31 defines a plurality of cutouts 311 . Each of the installation portions 35 includes an installation piece 351 , a limiting piece 353 , and an installation post 355 . The installation post 355 is located between the installation piece 351 and the limiting piece 353 . In one embodiment, the limiting piece 353 is substantially parallel to the installation piece 351 . A first positioning piece 3511 and second positioning piece 3512 extend from the installation piece 351 . In one embodiment, each of the first positioning piece 3511 and the second positioning piece 3512 is substantially perpendicular to the installation piece 351 . A width of the first positioning piece 3511 is greater than a width of the second positioning piece 3512 . Each of the two side plates 33 defines a receiving slot 331 . A latching block 333 extends from an inner surface of the receiving slot 331 , and the latching block 333 is located in the receiving slot 331 . The installation post 355 defines a receiving hole 3551 .
The covering member 50 includes a cover 51 and two latching pieces 53 . The two latching pieces 53 extend from two opposite ends of the cover 51 . The cover 51 defines a plurality of holes 515 . A top surface of the cover 51 defines two recessions 511 . A plurality of positioning posts 513 protrude from a bottom surface of the cover 51 opposite to the top surface. Each of the two latching pieces 53 defines a latching hole 531 .
The protecting member 60 includes a top wall 61 , a bottom wall 63 , and two sidewalls 65 . In one embodiment, the top wall 61 is substantially parallel to the bottom wall 63 , and the two sidewalls 65 are substantially parallel to each other. Two first restricting pieces 611 extend from the top wall 61 . Two second restricting pieces 631 extend from the bottom wall 63 . A plurality of protecting pieces 66 are connected between the top wall 61 and the bottom wall 63 .
In assembly, each of the plurality of USB connectors 100 are placed between each of the two side plates 33 and one of the installation portions 35 , and between adjacent two of the installation portions 35 . The limiting piece 353 abuts the front plate 23 . The second positioning piece 3512 abuts the rear plate 25 . The first positioning piece 3511 abuts the rear panel 15 . The second blocking piece 221 is received in one of the cutouts 311 .
The covering member 50 is moved to above the base 30 , each of the plurality of positioning posts 513 is aligned with the receiving hole 3551 , and each of the two latching pieces 53 is aligned with the receiving slot 331 . The covering member 50 is moved towards the base 30 , each of the two latching pieces 53 is slid into the receiving slot 331 and elastically deformed by the latching block 333 . Each of the positioning posts 513 is inserted into the receiving hole 3551 . Each of the latching pieces 53 is slid over the latching block 333 and received in the receiving slot 331 . Each of the latching pieces 53 rebounds to receive the latching block 333 in the latching hole 531 . The first blocking piece 215 is received in the positioning hole 515 . Thus, the covering member 50 is secured to the base 30 and prevents each of the plurality of USB connectors 100 from moving away from the base plate 31 .
The protecting member 60 is moved to adjacent to the plurality of USB connectors 100 . Each of the plurality of USB connectors 100 is aligned with adjacent two of the plurality of protecting pieces 66 . Each of the two first restricting pieces 611 and each of the two second restricting pieces 631 are elastically deformed by the cover 51 and the base plate 31 , until Each of the two first restricting pieces 611 is aligned with each of the two recessions 511 and each of the plurality of USB connectors 100 is partially exposed out of the adjacent two of the plurality of protecting pieces 66 . Each of the two first restricting pieces 611 exerts an elastic force to the cover 51 . Each of the two second restricting pieces 631 exerts an elastic force to the base plate 31 . Each of the third blocking pieces 231 and the fourth blocking piece 251 abuts an inner surface of each of the protecting pieces 66 . The first blocking piece 215 , the second blocking piece 221 , the third blocking piece 231 , and the fourth blocking piece 251 prevent the connecting device from EMI.
It is to be understood, however, that even though numerous characteristics and advantages of the embodiments have been set forth in the foregoing description, together with details of the structure and function of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A connecting device includes a protecting member, a base, a USB connector, and a covering member. The USB connector is mounted in the base. The covering member is secured to the base and covers the base. The covering member and the base are received and mounted in the protecting member. The USB connector comprises a body for securing a USB cable and a shelter surrounding the body; the shelter comprises a plurality of blocking pieces, and each of the plurality of blocking pieces abuts the protecting member, to prevent EMI from the body.
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FIELD OF THE INVENTION
This invention relates to tricyclic compounds, compositions comprising them and uses thereof in the treatment of obesity and related disorders.
BACKGROUND OF THE INVENTION
Obesity is a leading preventable cause of death worldwide, with increasing prevalence in adults and children, considered as one of the most serious and widespread public health problem of the 21 st century.
Excessive body weight is associated with various physical and mental diseases and conditions, particularly cardiovascular diseases, diabetes mellitus type 2, obstructive sleep apnea, certain types of cancer, osteoarthritis and depression. As a result, obesity has been found to reduce life expectancy. Once considered a problem only of high-income countries, obesity rates are rising worldwide and affecting both the developed and developing world.
To date, there is an ongoing search for an effective and safe treatment for obesity, abnormal fat-distribution and all health threatening conditions associated therefrom.
Fat tissue or adipose tissue is the loose connective tissue composed of adipocytes. Adipose tissue is derived from lipoblasts. Its main role is to store energy in the form of lipids, although it also cushions and insulates the body. Adipose tissue includes all fat tissue in the body including abdominal fat, epicardial fat and subcutaneous fat.
Adipose tissue has been recognized to participate in endocrine processes, including the production of hormones such as leptin, estrogen, resistin, and cytokine TNFα. Moreover, adipose tissue can affect other organ systems of the body and may lead to disease.
Obesity in humans and most animals does not depend on body weight, but on the amount of adipose tissue.
There are two types of adipose tissue: white adipose tissue (WAT), which primarily stores fat, and brown adipose tissue (BAT), which functions in the process of fat burning for heat production (Farmer S R, Gene & Development 22, 1269-1275 (2008), Petrovic N, JBC 258, 7153-7164 (2010)). The feasibility of WAT to BAT conversion was demonstrated, for example, by application of PPARγ agonists (Ohno H. et al., Cell Metabolism 15: 395-404 (2012)). However, from the whole organism point of view, PPARγ activation has also other effects on other tissues with the end result of increase in body weight in PPARγ agonists treated patients.
One optional strategy for treating obesity and related conditions, diseases and disorders associated with abnormal WAT distribution is to induce the conversion of WAT to BAT. Previous treatment of obesity in such mechanism of action included the use of thiazolidazine compounds which increased the body's sensitivity to insulin. Such compounds showed many adverse effects, including liver toxicity, bone loss, and weight gain.
SUMMARY OF THE INVENTION
The present invention provides a compound of the general formula (I):
wherein
each of R 1 -R 8 is independently selected from the group consisting of H, OH, SH, halogen, nitro, amino, nitrilo, nitroso, acetyl, acetamido, acylamido, alkylamino, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkenyl, straight or branched C 1 -C 5 alkynyl, straight or branched C 1 -C 5 alkoxy, straight or branched C 1 -C 5 carboxyl, straight or branched C 1 -C 5 ester, straight or branched C 1 -C 5 thioxy, straight or branched C 1 -C 5 sulfinyl and straight or branched C 1 -C 5 thionyl;
R 9 and R 10 is independently selected from null, straight or branched C 1 -C 9 alkyl, straight or branched C 1 -C 9 alkenyl, straight or branched C 1 -C 9 alkynyl, piperazinyl, pyridinyl, piperidinyl, morpholinyl and thiomorpholinyl;
wherein each of said R 9 and R 10 are independently optionally substituted with at least one substituent selected from the group consisting of amino (including quarternary ammonium), phosphonium, straight or branched C 1 -C 5 alkoxy, straight or branched C 1 -C 5 carboxyl, straight or branched C 1 -C 5 ester, straight or branched C 1 -C 5 thioxy, straight or branched C 1 -C 5 sulfinyl, straight or branched C 1 -C 5 thionyl;
X is selected from CH, N and P;
Y is selected from null, CH, N, P, —CH 2 , —NH, O, S, —CH—CH 2 , —CH═CH 2 , —C═O and N—C═O.
In a further aspect the invention provides a compound of the general formula (I):
wherein
each of R 1 -R 8 is independently selected from the group consisting of H, OH, SH, halogen, nitro, amino, nitrilo, nitroso, acetyl, acetamido, acylamido, alkylamino, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkenyl, straight or branched C 1 -C 5 alkynyl, amine, straight or branched C 1 -C 5 alkoxy, straight or branched C 1 -C 5 carboxyl, straight or branched C 1 -C 5 ester, straight or branched C 1 -C 5 thioxy, straight or branched C 1 -C 5 sulfinyl, straight or branched C 1 -C 5 thionyl;
R 9 and R 10 is independently selected from null, straight or branched C 1 -C 9 alkyl, straight or branched C 1 -C 9 alkenyl, straight or branched C 1 -C 9 alkynyl, piperazinyl, pyridinyl, piperidinyl, morpholinyl and thiomorpholinyl;
wherein at least one of said R 9 and R 10 is substituted with at least one quaternary amino (ammonium) group or a phosphonium group;
X is selected from CH, N and P;
Y is selected from null, CH, N, P, CH 2 , NH, O, S, CH—CH 2 , CH═CH 2 , C═O and N—C═O.
In some embodiments, Y is null. Under these embodiments the central ring in the tricyclic ring system is a five-membered ring. Thus, under these embodiments, a compound of the invention has a general formula (II):
In other embodiments, X is N. Under these embodiments a compound of the invention has a general formula (III):
In further embodiments, X is N and Y is null. Under these embodiments a compound of the invention has a general formula (IV):
In further embodiments, R 9 is a straight or branched C 1 -C 9 alkyl. In other embodiments, said straight or branched C 1 -C 9 alkyl is substituted with at least one amino. In further embodiments, R 9 is a straight or branched C 1 -C 9 alkyl. In other embodiments, said straight or branched C 1 -C 9 alkyl is substituted with at least one quaternary amino group.
In other embodiments, said amino (ammonium) has a general formula (V):
wherein each of R′, R″ and R′″ is independently selected from a group consisting of straight or branched C 1 -C 9 alkyl, straight or branched C 1 -C 9 alkenyl, straight or branched C 1 -C 9 alkynyl. In some embodiments, each of R′, R″ and R′″ is independently a straight or branched C 1 -C 9 alkyl.
In further embodiments, R 9 is a straight or branched C 1 -C 9 alkyl. In other embodiments, said straight or branched C 1 -C 9 alkyl is substituted with at least one phosphonium group. In other embodiments, said phosphonium group has a general formula (VI):
wherein each of R′, R″ and R′″ is independently selected from a group consisting of straight or branched C 1 -C 9 alkyl, straight or branched C 1 -C 9 alkenyl, straight or branched C 1 -C 9 alkynyl. In some embodiments, each of R′, R″ and R′″ is independently a straight or branched C 1 -C 9 alkyl.
In other embodiments, at least one of R 1 -R 4 is a halogen. In further embodiments, at least one of R 5 -R 8 is a halogen. In yet other embodiments, at least one of R 1 -R 4 is a halogen and at least one of R 5 -R 8 is a halogen. In some embodiments said halogen is Br.
In other embodiments, at least one of R 1 -R 4 is OH. In further embodiments, at least one of R 5 -R 8 is OH.
In other embodiments, at least one of R 1 -R 4 is a nitro. In further embodiments, at least one of R 1 -R 4 is a nitro and at least one of R 5 -R 8 is a nitro.
The invention also provides a compound selected from the following:
The term “halogen” is meant to encompass any halogen moiety selected from F, Cl, Br and I.
The term “nitro” is a —NO 2 moiety.
The term “amino” refers to —NH 2 , —NHR, —NRR′, wherein R, R′ and R″ are each independently selected from straight or branched C 1 -C 10 alkyl (also termed “alkylamino”), straight or branched C 2 -C 10 alkenyl, straight or branched C 2 -C 10 alkynyl. The term amino also includes quaternary ammonium moiety of the form — + NRR′R″ wherein R, R′ and R″ are as defined herein above.
The term “nitrilo” refers to —CN,
The term “nitroso” refers to a NO moiety, including C-nitroso moieties (e.g., nitrosoalkanes —R—N═O, wherein R is selected from straight or branched C 1 -C 10 alkanyl, straight or branched C 2 -C 10 alkenylene, straight or branched C 2 -C 10 alkynylene), S-nitroso moieties (nitrosothiols; —S—N═O or —RS—N═O wherein R is selected from straight or branched C 1 -C 10 alkanyl, straight or branched C 2 -C 10 alkenylene, straight or branched C 2 -C 10 alkynylene), N-nitro so moieties (e.g., nitrosamines; —N═N═O, RN—N═O, —RR′N—N═O), and O-nitroso moieties (—O—N═O, —RO—N═O wherein R is selected from straight or branched C 1 -C 10 alkanyl, straight or branched C 2 -C 10 alkenylene, straight or branched C 2 -C 10 alkynylene).
The term “acetyl” refers to a —C(═O)CH 3 moiety.
The terms “acetamido” and “acylamido” refers to —CH 2 C(═O)NH 2 and CH 3 C(═O)NH— respectively.
The term “straight or branched C 1 -C 5 alkyl” and “straight or branched C 1 -C 9 alkyl” encompasses a saturated hydrocarbon chain having between 1 to 5 or 1 to 9 carbon atoms.
The term “straight or branched C 2 -C 5 alkenyl” and “straight or branched C 2 -C 9 alkenyl” encompasses a hydrocarbon chain having between 1 to 5 or 1 to 9 carbon atoms and at least one double bond.
The term “straight or branched C 2 -C 5 alkynyl” and “straight or branched C 2 -C 9 alkynyl” encompasses a hydrocarbon chain having between 1 to 5 or 1 to 9 carbon atoms and at least one triple bond.
The term “straight or branched C 1 -C 5 alkoxy” is meant to encompass an —OR moiety wherein R is selected from a straight or branched C 1 -C 10 alkyl, straight or branched C 2 -C 10 alkenyl and straight or branched C 2 -C 10 alkynyl.
The term “straight or branched C 1 -C 5 carboxyl” refers to a —R—C(═O)OH moiety wherein R is selected from a straight or branched C 1 -C 10 alkanyl, straight or branched C 2 -C 10 alkenylene and straight or branched C 2 -C 10 alkynylene.
The term “straight or branched C 1 -C 5 ester” refers to a RC(═O)O— moiety wherein R is selected from a straight or branched C 1 -C 10 alkyl, straight or branched C 2 -C 10 alkenyl and straight or branched C 2 -C 10 alkynyl.
The term “straight or branched C 1 -C 5 thioxy” refers to a RS— moiety wherein R is selected from a straight or branched C 1 -C 10 alkyl, straight or branched C 2 -C 10 alkenyl and straight or branched C 2 -C 10 alkynyl.
The term “straight or branched C 1 -C 5 sulfinyl” and “straight or branched C 1 -C 5 thionyl” refers to a RS(═O)— moiety wherein R is selected from a straight or branched C 1 -C 10 alkyl, straight or branched C 2 -C 10 alkenyl and straight or branched C 2 -C 10 alkynyl.
The term “phosphonium” refers to a —P + RR′R″ moiety wherein R, R′ and R″ are each selected from a straight or branched C 1 -C 10 alkyl, straight or branched C 2 -C 10 alkenyl and straight or branched C 2 -C 10 alkynyl.
The term “piperazinyl” encompasses a moiety selected from:
The term “pyridinyl” encompasses a moiety:
The term “piperidinyl” encompasses a moiety selected from:
The term “morpholinyl” encompasses a moiety selected from:
The term “thiomorpholinyl” encompasses a moiety selected from:
The compounds of the present invention, as defined above, may have the ability to crystallize in more than one form, a characteristic, which is known as polymorphism, and it is understood that such polymorphic forms (“polymorphs”) are within the scope of formulae (I). Polymorphism generally can occur as a response to changes in temperature or pressure or both and can also result from variations in the crystallization process. Polymorphs can be distinguished by various physical characteristics known in the art such as x-ray diffraction patterns, solubility, and melting point.
As used herein, the term “substituted” refers to substitution with the named substituent or substituents, multiple degrees of substitution being allowed unless otherwise stated.
Certain of the compounds described herein may contain one or more chiral atoms, or may otherwise be capable of existing as two enantiomers or as two or more diastereomers. Accordingly, the compounds of this invention include mixtures of enantiomers as well as purified enantiomers or enantiomerically enriched mixtures. Furthermore, the compounds of this invention include mixtures of diastereomers, as well as purified stereoisomers or diastereomerically enriched mixtures. Also included within the scope of the invention are the individual isomers of the compounds of the invention, as defined above, as well as any wholly or partially mixtures thereof. The present invention also covers the individual isomers of the compounds represented by the formulas above as mixtures with isomers thereof in which one or more chiral centers are inverted.
It is also noted that the compounds of the present invention may form tautomers. It is understood that all tautomers and mixtures of tautomers of the compounds of the present invention, are included within the scope of the compounds of the present invention.
In a further aspect, the invention provides a composition comprising a compound of general formula (I), as defined herein above, or any salt thereof.
In some embodiments, said composition is a pharmaceutical composition, wherein said salt is a pharmaceutically acceptable salt.
Pharmaceutical compositions of the invention may additionally comprise any other suitable substances such as other therapeutically useful substances, diagnostically useful substances, pharmaceutically acceptable carriers or the like.
In some embodiments a compound or composition of the invention is administered (suitable to be administered) into an adipose tissue of a subject. In some embodiments said compound or composition of the invention is administered directly into an adipose tissue of a subject. In other embodiments said administration is via injection. In other embodiments, said administration is a transdermal administration. Under such embodiments, transdermal admonition can be achieved by any transdermal formulation known in the art and/or via a transdermal delivery device (for example a patch containing a compound or composition of the invention) at a close proximity to the adipose tissue location of said subject (for example the direct skin or mucosal tissue in contact with said adipose tissue).
Pharmaceutical compositions of the invention comprise a compound of the subject invention in admixture with pharmaceutically acceptable auxiliaries, and optionally other therapeutic agents. The auxiliaries must be “acceptable” in the sense of being compatible with the other ingredients of the composition and not deleterious to the recipients thereof.
Pharmaceutical compositions include those suitable for oral, rectal, nasal, topical (including transdermal, buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous, intra-adipose tissue and intradermal) administration or administration via an implant. The compositions may be prepared by any method well known in the art of pharmacy. Such methods include the step of bringing in association compounds used in the invention or combinations thereof with any auxiliary agent. The auxiliary agent(s), also named accessory ingredient(s), include those conventional in the art, such as carriers, fillers, binders, diluents, disintegrants, lubricants, colorants, flavouring agents, anti-oxidants, and wetting agents.
Pharmaceutical compositions suitable for oral administration may be presented as discrete dosage units such as pills, tablets, dragées or capsules (including softgel capsules), or as a powder or granules, or as a solution or suspension. The active ingredient may also be presented as a bolus, liquid formulation or paste. The compositions can further be processed into a suppository or enema for rectal administration.
The invention further includes a pharmaceutical composition, as hereinbefore described, in combination with packaging material, including instructions for the use of the composition for a use as hereinbefore described.
For parenteral administration, suitable compositions include aqueous and non-aqueous sterile injection. The compositions may be presented in unit-dose or multi-dose containers, for example sealed vials and ampoules, and may be stored in a freeze-dried (lyophilised) condition requiring only the addition of sterile liquid carrier, for example water, prior to use. For transdermal administration, e.g. gels, patches or sprays can be contemplated. Compositions or formulations suitable for pulmonary administration e.g. by nasal inhalation include fine dusts or mists which may be generated by means of metered dose pressurized aerosols, nebulisers or insufflators.
In some embodiments, compositions of the invention include also compositions where the compound of the invention is formulated in a fat emulsion formulation (i.e. formulated in conventional formulation processes to produce an emulation comprising at least one fat component, either from a natural or synthetic source), such as for example Intralipid formulation (in any concentration).
The exact dose and regimen of administration of the composition will necessarily be dependent upon the therapeutic or nutritional effect to be achieved and may vary with the particular formula, the route of administration, and the age and condition of the individual subject to whom the composition is to be administered.
The invention also includes any salt of a compound of the invention, including any pharmaceutically acceptable salt, wherein a compound of the invention has a net charge (either positive or negative) and at least one counter ion (having a counter negative or positive charge) is added thereto to form said salt. The phrase “pharmaceutically acceptable salt(s)”, as used herein, means those salts of compounds of the invention that are safe and effective for pharmaceutical use in mammals and that possess the desired biological activity. Pharmaceutically acceptable salts include salts of acidic or basic groups present in compounds of the invention. Pharmaceutically acceptable acid addition salts include, but are not limited to, hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, iso nicotinate, acetate, lactate, salicylate, citrate, tartrate, pantothenate, bitartrate, ascorbate, succinate, maleate, gentisinate, fumarate, gluconate, glucaronate, saccharate, formate, benzoate, glutamate, methanesulfonate, ethanesulfonate, benzensulfonate, p-toluenesulfonate and pamoate (i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)) salts. Salts of the invention may also include a counter anion being a halogen anion such as for example chloride and bromide anions. Certain compounds of the invention can form pharmaceutically acceptable salts with various amino acids. Suitable base salts include, but are not limited to, aluminum, calcium, lithium, magnesium, potassium, sodium, zinc, and diethanolamine salts. For a review on pharmaceutically acceptable salts see BERGE ET AL., 66 J. PHARM. SCI. 1-19 (1977), incorporated herein by reference.
In another aspect the invention provides a compound of general formula (I), as defined herein above, for use as a medicament.
In a further aspect the invention provides a use of a compound of general formula (I), as defined herein above, for the preparation of a medicament.
In some embodiments, said medicament is for the treatment of obesity, and conditions or disease associated therewith.
The term “obesity” is meant to encompass is a condition in a subject having excess body fat. It is defined by body mass index (BMI) and further evaluated in terms of fat distribution via the waist-hip ratio and total cardiovascular risk factors. Additional parameters measuring extent of obesity are percentage body fat and total body fat. Subjects suffering from obesity have a BMI value of above 25. In some embodiments the term “obesity” includes subjects having BMI values of between about 25.0 to about 29.9 (overweight), in some further embodiments between about 30.0 to about 34.9 (class I obesity), in yet further embodiments between about 35.0 to about 39.9 (class II obesity), in further embodiments above 40.0 (class III obesity), in other embodiments between about 40 to about 49.9 (morbid obesity) and in other embodiments ≧50 (super obesity).
In other embodiments, said medicament is for the treatment of abnormal fat-distribution and conditions or disease associated therewith.
The term “abnormal fat-distribution” is meant to encompass any irregular fat tissue distribution in, near or on an organ of a subject or parts thereof. Fat or adipose tissue includes all fat tissue in the body including abdominal fat, epicardial fat and subcutaneous fat. The term is further meant to encompass any irregular fat tissue distribution as perceived by the affected person and thereby is associated with poor self-image and psychiatric disorders related to it.
In some embodiments, conditions or disease associated with obesity, or abnormal fat-distribution include, but are not limited to: diabetes, cardiovascular diseases, obstructive sleep apnea, lipoma, cancer, osteoarthritis, endocrinologic disease and disorders, reproductive disease and disorders, neurological diseases and disorders, psychiatric diseases and disorders, rheumatological diseases and disorders and orthopedic disease and disorders and any combinations thereof.
The invention further provides a use of a compound of general formula (I), as defined herein above, for the preparation of a composition for the remodeling of white adipose tissue (WAT) to brown-like adipose tissue (BAT).
WAT adipocytes, contain a single lipid droplet. BAT adipocytes contain numerous smaller lipid droplets and a higher number of mitochondria. BAT also contains more blood-capillaries than WAT.
The term “remodeling of white adipose tissue (WAT) to brown-like adipose tissue (BAT)” is meant to encompass any qualitative or quantitative difference or change in the histology of WAT between the initial WAT condition and the WAT condition after treatment. Said qualitative or quantitative difference may be manifested by a change in WAT adipocytes size, ablation thereof, including macrophage-associated liponecrosis, and in appearance of BAT-like adipocytes.
The invention further provides a use of a compound of general formula (I), as defined herein above, for the preparation of a composition for the treatment of a disease, disorder or condition associated with or benefiting from the remodeling of WAT to BAT.
The invention also provides a use of a compound of general formula (I), as defined herein above, for the preparation of a composition for reducing the white adipose tissue (WAT) of a subject in need thereof.
It is to be noted that a reduction of WAT may be measured in any way known to a person skilled in the art, such as for example the reduction of tissue thickness, change in tissue density and so forth. Such reduction in WAT in a subject administered with a compound of the invention may be for any known purposes, such as for example cosmetic, medical (i.e. the treatment of conditions and diseases associated with excess or abnormal levels of WAT), or both.
In a further aspect the invention provides a compound of general formula (I), as defined herein above, for use in the treatment of obesity, and conditions or disease associated therewith.
In a further aspect the invention provides a compound of general formula (I), as defined herein above, for use in the treatment of abnormal fat-distribution and conditions or disease associated therewith.
The invention further provides a compound of general formula (I), as defined herein above, for use in the remodeling of white adipose tissue to brown-like adipose tissue.
The invention further provides a compound of general formula (I), as defined herein above, for use in the treatment of a disease, disorder or condition associated with or benefiting from the remodeling of white adipose tissue to brown-like adipose tissue.
The invention also provides a compound of general formula (I), as defined herein above, for use in reducing the white adipose tissue of a subject in need thereof.
The invention further provides a compound as defined hereinabove for use in the inhibition of protein kinase CDC42-binding-protein-kinase-alpha (CDC42BPA or MRCKA).
It is noted that screening of compound of the invention 5-(3,6-dibromo-9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium (MTK-012) against 191 different protein kinases showed significantly selective inhibition of protein kinase CDC42-binding-protein-kinase-alpha (also known as CDC42BPA or MRCKA).
In some embodiments said inhibition is associated with the treatment of at least one disease, disorder or condition selected from obesity, overweight or abnormal fat-distribution and conditions or disease associated therewith.
In another one of its aspects the invention provides a method of treating obesity, and conditions or disease associated therewith in a subject in need thereof, wherein said method comprises the administration of an effective amount of a compound of general formula (I), as defined herein above.
In another one of its aspects the invention provides a method of treating abnormal fat-distribution and conditions or disease associated therewith in a subject in need thereof, wherein said method comprises the administration of an effective amount of a compound of general formula (I), as defined herein above.
In a further aspect the invention provides a method of activating the remodeling of white adipose tissue to brown-like adipose tissue in a subject, comprising administrating to said subject an effective amount of a compound of general formula (I), as defined herein above.
In a further aspect the invention provides a method of treating a disease, disorder or condition associated with or benefiting from the remodeling of white adipose tissue to brown-like adipose tissue in a subject, comprising administrating to said subject an effective amount of a compound of general formula (I), as defined herein above.
The term “treatment” as used herein refers to the administering of a therapeutic amount of a compound and/or a composition of the present invention which is effective to ameliorate undesired symptoms associated with a disease, to prevent the manifestation of such symptoms before they occur, to slow down the progression of the disease or condition, slow down the deterioration of symptoms, to enhance the onset of remission period, slow down the irreversible damage caused in the progressive chronic stage of the disease or condition, to delay the onset of said progressive stage, to lessen the severity or cure the disease or condition, to improve survival rate or more rapid recovery, or to prevent the disease or condition form occurring or a combination of two or more of the above.
The “effective amount” for purposes disclosed herein is determined by such considerations as may be known in the art. The amount must be effective to achieve the desired therapeutic effect as described above, depending, inter alia, on the type and severity of the disease to be treated and the treatment regime. The effective amount is typically determined in appropriately designed clinical trials (dose range studies) and the person versed in the art will know how to properly conduct such trials in order to determine the effective amount. As generally known, an effective amount depends on a variety of factors including the affinity of the compound to its target protein(s), its distribution profile within the body, a variety of pharmacological parameters such as half life in the body, on undesired side effects, if any, on factors such as body-weight, BMI, age and gender, etc.
It must be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents unless the content clearly dictates otherwise.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any integer or step or group of integers and steps.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
FIG. 1 demonstrates the change in body weight of 42 weeks old male mice following intraperitoneal injection of 5-(3,6-dibromo-9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium (MTK-012).
FIGS. 2A-2B provides a representative illustration of the reduction in abdominal fat-mass of the MTK-012 treated mice following the termination of the experiment (control ( FIG. 2A ) and treated animal ( FIG. 2B ), as described in Example 5).
FIGS. 3A-3D provides a representative illustration of the reduction in subcutaneous fat 3 weeks after a single s.c. administration of MTK-012 to rats. The reduction of s.c. fat is manifested by the clear visibility of the underlining blood vessels which are otherwise hindered under a fatty layer in the control rats (Intact— FIGS. 3A and 3C , as compared with treated animals in FIGS. 3B and 3D ).
DETAILED DESCRIPTION OF EMBODIMENTS
Example 1
Preparation of 5-(3,6-dibromo-9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium chloride (MTK-012)
1.00 g (3.0 mM) 3,6-dibromocarbazole was dissolved in 100 ml dimethylformamide (DMF). 0.57 g (3.0 mM). (5-bromopentyl)-trimethyl-ammonium bromide was added at once. After 10 min of magnetic stirring 1.40 g (10 mM) potassium carbonate was added. After additional 10 min of stirring the temperature was raised to 50° C. and the mixture was stirred at this temperature for 4 h. After cooling to RT the solution was transferred to a separatory funnel and 200 ml of H 2 O and 200 ml dichloromethane were added. The solvent mixture was shaken and the lower phase was collected. The upper aqueous phase was extracted four times with 50 ml 3:1 dichloromethane:methanol and the 5 lower phases were combined and washed with 100 ml saturated sodium chloride solution. Dried with MgSO 4 , filtered and evaporated to dryness. The residue was crystallized from H 2 O. Yield: 1.28 g. Proton NMR in CD 3 OD: 1.31 m 2H, 1.70 m 2H, 1.93 m 2H, 3.01 s 9H, 3.16 m 2H, 4.39 t 2H, J=0.6, 7.47 d 2H, J=2.0, 7.54 dd 2H, J1=2.0, J2=0.4, 8.21 d 2H, J=0.4. MS: 451, 453, 455 M + (symmetrical 2Br triplet) 452, 454, 456 (MH) + (symmetrical 2Br triplet).
Example 2
Preparation of 5-(3,6-dibromo-9H-carbazol-9-yl)-N,N,N-trimethyl-propan-1-aminium chloride
1.2 g (3.7 mM) 3,6-dibromocarbazole were dissolved in 150 ml dimethylformamide (DMF). 1.0 g (3.8 mM). (5-bromopentyl)-trimethyl-ammonium bromide was added at once. After 10 min of magnetic stirring 1.40 g (10 mM) potassium carbonate was added. After additional 10 min of stirring the temperature was raised to 50° C. and the mixture was stirred at this temperature for 4 h. After cooling to RT the solution was transferred to a separatory funnel and 200 ml of sodium hydroxide 0.5 N and 200 ml dichloromethane were added. The solvent mixture was shaken and the lower phase was collected. The upper aqueous phase was extracted four times with 50 ml 3:1 dichloromethane:methanol and the 5 lower phases were combined and washed with 100 ml saturated sodium chloride solution. Dried with MgSO 4 , filtered and evaporated to dryness. Yield: 1.1 g.
Example 3
Preparation of 5-(9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium chloride
335 mg (2.0 mM) carbazole were dissolved in 50 ml dimethylformamide (DMF). 0.4 g (2.1 mM). (5-bromopentyl)-trimethyl-ammonium bromide was added at once. After 10 min of magnetic stirring 8.4 g (6.0 mM) potassium carbonate was added. After additional 10 min of stirring the temperature was raised to 50° C. and the mixture was stirred at this temperature for 4 h. After cooling to RT the solution was transferred to a separatory funnel and 100 ml of H 2 O and 100 ml dichloromethane were added. The solvent mixture was shaken and the lower phase was collected. The upper aqueous phase was extracted four times with 30 ml 3:1 dichloromethane:methanol and the 5 lower phases were combined and washed with 60 ml saturated sodium chloride solution. Dried with MgSO 4 , filtered and evaporated to dryness. Yield: 0.75 g.
Example 4
Preparation of 5-(2-hydroxy-9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium chloride
458 mg (2.5 mM) 2-hydroxycarbazole were dissolved in 80 ml dimethylformamide (DMF). 0.51 g (2.5 mM). (5-bromopentyl)-trimethyl-ammonium bromide was added at once. After 10 min of magnetic stirring 1.1 g (7.5 mM) potassium carbonate was added. After additional 10 min of stirring the temperature was raised to 50° C. and the mixture was stirred at this temperature for 4 h. After cooling to RT the solution was transferred to a separatory funnel and 100 ml of H 2 O and 100 ml dichloromethane were added. The solvent mixture was shaken and the lower phase was collected. The upper aqueous phase was extracted four times with 40 ml 3:1 dichloromethane:methanol and the 5 lower phases were combined and washed with 60 ml saturated sodium chloride solution. Dried with MgSO 4 , filtered and evaporated to dryness. Yield: 0.6.
Example 5
Preparation of 5-(3,6-dibromo-9H-carbazol-9-yl)-N,N,N-trimethylpentan-1-aminium chloride
1.00 g (3.0 mmole) 3,6-dibromocarbazole was dissolved in 100 ml Acetonitrile (CH 3 CN). 0.63 g (3.3 mmole). (5-bromopentyl)-trimethyl-ammonium bromide was added at once. After 10 min of magnetic stirring at room temperature (RT), 1.55 g (11 mmole) potassium carbonate (anhydrous) was added. The temperature was raised to 75° C. and the mixture was stirred at this temperature for 5 h. After cooling to RT the solution was transferred to a round bottom flask and evaporated to dryness. Then 200 ml H 2 O and 200 ml n-butyl alcohol were added and the solution was transferred to a separatory funnel. The solvents mixture was shaken and the upper butanolic phase was collected. The lower aqueous phase was extracted with 150 ml n-butyl alcohol. The two butanolic phases were combined and then washed one time with 200 ml saturated sodium chloride containing 0.5N HCl and 4 times with 200 ml saturated sodium chloride solution. Water-dried with MgSO 4 , filtered and evaporated to dryness. The product was crystallized from H 2 O. Yield: 1.49 g. Proton NMR in CD 3 OD: 1.31 m 2H, 1.70 m 2H, 1.93 m 2H, 3.01 s 9H, 3.16 m 2H, 4.39 t 2H, J=0.6, 7.47 d 2H, J=2.0, 7.54 dd 2H, J1=2.0, J2=0.4, 8.21 d 2H, J=0.4. MS: 451, 453, 455 M + (symmetrical 2Br triplet) 452, 454, 456 (MH) + (symmetrical 2Br triplet).
Example 6
Intraperitoneal (i.p.) Injection of MTK-012 to Mice
42 wks old male mice (35-42 g body wt.) were i.p. injected with either vehicle (=Control, 10 mice) or with MTK-012 dissolved in that vehicle (10 mice).
Vehicle composition: aqueous solution of 4% Tween20 (Sigma, P7949) and 20% Propylene-Glycol (Sigma, P4347).
MTK-012 was dissolved in vehicle composition at a final concentration of 5 mg/ml.
The mice were initially (t=0) injected a dose of 20 mg/kg, or the equivalent volume of vehicle to the controls (solid arrow in FIG. 1 ). Three weeks later the mice were injected a double dose of 40 mg/kg of MTK-012 or 40 mg/kg of vehicle (broken arrow in FIG. 1 ).
Body weight was measured once a week; the results are shown in FIG. 1 and expressed as the % change in body weight relative to the body weight on day 0. The animals in the treated group were well and active, similar to the controls.
At t=6 wks the animals were sacrificed and dissected for gross pathology. No apparent change was noted except for the ablation of the abdominal adipose tissue in the MTK-012 treated mice, as illustrated in FIGS. 2A-2B , showing an apparent difference in abdominal adipose tissue between the untreated animal ( FIG. 2A ) and the treated one ( FIG. 2B ).
Example 7
Single Subcutaneous (s.c.) Injection of MTK-012 Resulted in Substantial Reduction in s.c. Fat
SD male rats of about 400 g body weight were s.c. injected once (t=0) following light anesthesia with Ketamine-Xylazine.
MTK-012, at a final concentration of 10 mg/ml, was dissolved in a vehicle containing: 2.3% sodium decanoate (C10, Sigma, C4151), 2.3% sodium dodecanoate (C12, Sigma, L9755), 10% Solutol HS 15 (BASF, cat#06466701), 40% Propylene-Glycol (Sigma, P4347) and 45% Triacetin (Aldrich, cat#525073).
The injection of 1 ml MTK-012 (=25 mg/kg) was performed as follows: the left side of the rats body was shaved and s.c. injections, 0.2 ml each, were administered at 5 sites, equally distributed along the left side of the rats. The rats were sacrificed after 3 weeks and inner part of their skin was examined. It is evident that the s.c. adipose tissue was reduced (visibly shown) in the treated rats ( FIGS. 3B and 3D ), as manifested by the exposure of the underneath blood vessels, as compared with the same anatomical area in FIGS. 3A and 3C . It should be noted that although the injection was performed unilaterally, the effect expand to the entire subcutis.
Example 8
Intra-Nap Fat-Pad Injection of MTK-012 and MTK-013 to Psammomys
Animals
Ten 2-month old female pasmmomys were subjected to high-fat diet for 5 weeks prior to commencement of experiment.
Treatment Groups
Group I:
0.1 ml vehicle (2.3% sodium decanoate (C10, Sigma, C4151), 2.3% sodium dodecanoate (C12, Sigma, L9755), 10% Solutol HS 15 (BASF, cat#06466701), 40% Propylene-Glycol (Sigma, P4347) and 45% Triacetin (Aldrich, cat#525073))
Group II:
0.1 ml MTK-012 (concentration of 4 mg/ml in above vehicle).
Group III:
0.1 ml MTK-013 (concentration of 4 mg/ml in above vehicle).
Administration
Intra nap fat-pad injections of each composition were administered to animals in each treatment groups (3, 3, and 4 animals in each treatment group respectively), twice a week for 2 weeks, while on high-fat diet. All animals were sacrificed after 4 days from last injection.
Results
Table 1 below provides the results of nap WAT weight after 4 days from treatment. It is clear that significant reduction in WAT was observed when treated with MTK-012 and MTK-013 (treatment groups II and III) as compared with vehicle (treatment group I).
Additionally, extensive fat necrosis without inflammation was observed for treatment groups II and III. Histological examination of WAT tissue showed giant adipocytes in the necrotic site and in the surrounding adipose tissue. Additionally, treated tissue showed smaller than normal adipocytes and increased vascularity in regions away from the site of necrosis, as compared to control group.
TABLE 1
Nap WAT weight after 4 days from end of treatment
Treatment Group
Nap WAT (g)
Average (g) ± SEM
Group I - Vehicle
5.7
5.30 ± 0.21
5.0
5.2
Group II - MTK-012
4.6
3.85 ± 0.34
3.0
(P~0.01)*
3.7
4.1
Group III - MTK-013
3.8
3.33 ± 0.23
3.1
(P < 0.01)*
3.1
*by student t-test
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Tricyclic compounds, compositions and uses thereof in the treatment of at least one disease, disorder or condition such as for example obesity, overweight, abnormal fat-distribution and any conditions or disease associated therewith.
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This application is a continuation-in-part of a U.S. application filed on Feb. 28, 2002 and having Ser. No. 60/360,456.
BACKGROUND
1. Field of the Invention
The present invention relates generally to lighting fixtures and, more specifically, to an improved in-ceiling lighting fixture.
2. Prior Art
Recessed lighting fixtures are well known in prior art. However, such fixtures have been visually obtrusive in that all or some portion of the fixture falls below the ceiling line and disrupts the plane of the ceiling. Recently, low voltage halogen lights have become more popular because they are brighter and consume less energy. This has led to a need for further improvements in recessed lighting fixture design.
For aesthetic reasons, an in-ceiling light fixture is normally at least partially recessed into the planar surface of the ceiling. An opening is cut into the ceiling to illuminate the area beneath the light fixture. The fixture is generally mounted into the ceiling such that the bottom of the fixture (that part closest to the floor when installed) does not extend beyond the plane of the ceiling. Because the opening in the ceiling does not generally have a finished appearance, a trim or bezel is generally installed in the opening to enhance its appearance and conceal the cut out. Historically, the trim piece has been below the planar surface of the ceiling, visually diminishing the aesthetics of the ceiling. The same situation exists with wall mounted recessed lighting.
Another problem arising from the fixtures of prior art is that they could not accommodate differing thickness in ceiling materials. Ceiling panels are constructed in varying thicknesses and the trim/bezel must accommodate the multiple sizes of the ceiling material that are currently available in the market. Formerly, this required the manufacture and use of multiple sized trim kits and increased the costs of storage, materials and labor in installing recessed lighting.
Additionally, the light within the fixture must be properly aimed to achieve the desired design and aesthetic effect. In prior art fixtures, this is difficult and time-consuming. In prior art fixtures, aiming the light typically requires the user to first turn on the light to see where it is initially aimed, then turn off the light to let it cool down (as is required with halogen lighting), then adjust the aim of the light and then turn it on again to see where it is aimed after the adjustment. The process must be repeated until the light is aimed at the desired location. Thus, in the prior art, lights have been difficult to aim without generally requiring several iterations of aiming and adjusting the light, with a cool-down period between each of the several iterations.
Additionally, light bulbs of prior art fixtures have been difficult to replace without removing at least part of the fixture. Moreover, after such light bulb replacement, the aim of the light is often altered and requires re-adjustment and re-aiming.
Therefore, what is needed is an in-ceiling or recessed lighting fixture that is easy to install and use, permits ready adjustment of the aim of the light, and facilitates light bulb replacement without requiring re-aiming of the light.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, an improved recessed lighting fixture allows aesthetically pleasing illumination when the fixture is placed within a cavity of a planar surface, such as a ceiling or wall. The fixture permits ready adjustment of the aim of the light by allowing the aim of the light to be adjusted while the fixture is in place and the light bulb is on. The aim of the light is controlled by two angles, namely, an azimuthal angle that lies in the horizontal plane and an elevational angle that lies in the vertical plane. The fixture also enables its light bulbs to be replaced without requiring re-aiming of the light. Additionally, the present invention may be used with ceiling materials of varying thickness without the need for a trim kit.
The basic elements of the fixture of the instant invention include: a housing designed to fit onto an inner surface of a ceiling or wall, a fixed mudding collar attached to the housing, an adjustable mudding ring that mates with the fixed mudding collar, and a trim unit mounted in the adjustable mudding ring. The trim unit comprises two versions, a round trim unit and a square trim unit, each of which comprises: means to retain the trim unit in the adjustable mudding ring, an elevational light aiming mechanism that controls the elevational angle of the light, a lamp support system attached to the elevational light aiming mechanism, and an opening through which light from the light bulb emanates and through which the elevational angle of the light can be adjusted with a screwdriver.
In the square trim unit, the azimuthal angle of the light is controlled by an azimuthal adjustment ring that resides in the square trim unit. In the round trim unit, the azimuthal angle of the light is controlled by a keyed azimuthal adjustment ring that resides in the housing. Both the square and round trim units have a setscrew that holds the adjustment ring in place after the adjustment ring has been rotated to the desired position.
Unlike prior art, the current invention contains means to adjust the elevational angle of the light while the light bulb is on, without the need to turn the light bulb off and to allow it to cool down. Additionally, the removability of the trim unit and the manner in which the trim unit is made removable allow rapid changing of the light bulb without altering the azimuthal or elevational angle settings of the light and without the need to disassemble the housing.
It is therefore an object of the invention to provide a lighting fixture designed to fit into a recessed space, such as in a ceiling. The light that emanates from the fixture must be strong enough to provide adequate illumination, but diffuse enough to prevent glare and avoid being harsh. Thus, the light must be aimable to allow for proper lighting for conditions within the area to be lit. As with any lighting fixture, light bulbs ultimately burn out and require replacement. In a recessed lighting fixture, replacing a burned out light bulb should not require readjusting the aim of the light.
It is a further object of the present invention to provide a recessed lighting fixture whose light can be easily aimed.
It is a further object of the present invention to incorporate a fixed mudding collar that mates with an adjustable mudding ring in such a way that the housing can be mounted onto surfaces having different thicknesses.
It is a further object of the present invention to provide a light fixture having a light that can be readily and repeatedly aimed with respect to azimuth and elevation.
It is a further object of the present invention to provide a method to quickly replace a light bulb without changing the aim of the light bulb.
Further features and advantages of the present invention will be appreciated by reviewing the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the objects and advantages of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numbers and wherein:
FIG. 1 is a perspective view of a square trim unit;
FIGS. 2A and 2B are exploded perspective views showing the housing and fixed mudding collar in relation to the adjustable mudding ring and the trim unit;
FIG. 3 is a side view of the elevational light aiming mechanism;
FIG. 4A is a top view of the lamp support system and elevational light aiming mechanism;
FIG. 4B is a side view of the light bulb holder and elevational light aiming mechanism;
FIG. 5 is a top view of a square version of the trim unit;
FIGS. 6A and 6B are, respectively, bottom and side views of a round adjustable mudding ring;
FIG. 7 is a bottom view of a square fixed mudding collar;
FIGS. 8A and 8B are, respectively, top and side views of the keyed azimuthal adjustment ring;
FIG. 9 is a side view of a round trim unit;
DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, specific component arrangements and constructions and other details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known manufacturing methods and structures have not been described in detail to avoid unnecessarily obscuring the present invention.
Referring first to FIG. 1 , a perspective view of a square trim unit 10 A of the present invention is shown. FIG. 2A is an exploded perspective view of the fixture 91 A for a square trim unit 10 A showing its square fixed mudding collar 12 A, the adjustable square mudding ring 11 A, and the square trim unit 10 A. Contained within the square trim unit 10 A is a lamp support system 14 (FIG. 1 )that includes an azimuthal ring 60 ( FIGS. 1 and 5 ), an elevational light aiming mechanism 19 ( FIGS. 1 , 3 , and 5 ) and a bulb mount 15 .
The housing 92 A, 92 B of the preferred embodiment is designed for installation in a cavity behind a planar surface, such as a wall or ceiling. Installation of the housing 92 A, 92 B requires an opening in the ceiling or wall on which the housing 92 A, 92 B will be mounted. The opening will initially have an unfinished appearance. The fixture 91 A, 91 B has a mounting surface 93 that rests flush upon the inner surface of the ceiling or wall on which the fixture 91 A, 91 B is being mounted. The fixed mudding collar 12 A, 12 B extends into the opening in the ceiling or wall so that the adjustable mudding ring 11 A, 11 B can be attached to it to provide a more finished appearance. The adjustable mudding ring 11 A, 11 B has steps 13 A, 13 B that mate with tabs 23 A, 23 B located on the fixed mudding collar 12 A, 12 B. The steps 13 A, 13 B and tabs 23 A, 23 B are configured so that by rotating the adjustable mudding ring 11 A, 11 B with respect to the fixed mudding collar 12 A, 12 B, the fixture 91 A, 91 B can be adjusted so that it fits surfaces of different thickness.
The adjustable mudding ring 11 A, 11 B also has a ring surface 17 , a mudding edge 21 , and a mudding line 22 . When the fixture 91 A, 91 B has been properly installed, the distance between the mounting surface 93 and the mudding line 22 is equal to or approximately equal to the thickness of the ceiling or wall on which the fixture 91 A, 91 B is being mounted. When the fixture 91 A, 91 B has been installed in this manner, the mudding edge 21 , the ring surface 17 , and the adjacent, unfinished edge of the ceiling or wall form a three-sided cavity that can be filled with mudding material and smoothed over so that none of the components of the fixture 91 A, 91 B extend beyond the ceiling or wall on which it is mounted. In this manner, once the adjustable mudding ring 11 A, 11 B has been adjusted to fit a particular ceiling or wall thickness, it is fixed in that position with mudding material.
The trim unit 10 A, 10 B is held in the adjustable mudding ring 11 A, 11 B by detents 9 A, 9 B that reside in the trim unit 10 A, 10 B and mate with the adjustable mudding ring 11 A, 11 B. This allows the trim unit 10 A, 10 B to be readily removed from, or installed in, the adjustable mudding ring 11 A, 11 B by simply using one's hand to pull the trim unit 10 A, 10 B out of the adjustable mudding ring 11 A, 11 B or push the trim unit 10 A, 10 B into the adjustable mudding ring 11 A, 11 B.
Referring to FIGS. 3 , and 4 , detailed views of the elevational light aiming mechanism 19 are shown. This elevational light aiming mechanism 19 is the same regardless of whether it is used in the square trim unit 10 A or the round trim unit 10 B. The elevational angle of illumination is adjustable, even while the light bulb 20 is on and/or hot, by means of a unique rack and pinion assembly 28 and adjustment screw 36 ( FIG. 1 )
FIG. 5 shows how the azimuthal aim of the light bulb 20 in the square trim unit 10 A can be adjusted through an arc of 0 to 90 degrees by rotating the circular track 60 . FIGS. 8A , 8 B, and 9 show the components that control the azimuthal aim of the light in the round trim unit 10 B.
The lamp support system 14 includes a bulb mount 15 , a bracket 32 a rack and pinion assembly 28 , and an adjustment screw 36 (best seen in FIG. 1 ). The bulb mount 15 further comprises a banana slide rivet 43 and a banana/rack plate rivet 16 . The bracket 32 further comprises two rack plate rivets 44 A, 44 B, a banana slide opening 34 , a bracket base 33 , a bracket vertical surface 35 , and a rectangular opening 42 in the bracket vertical surface 35 . The rack and pinion assembly 28 further comprises a rack plate 27 , a rack plate lip 45 , an elongated bulb mount attachment hole 31 located in the rack plate 27 , a rectangular rack plate opening 41 , a rack 29 , and a pinion gear 30 The bulb mount 15 is attached to the bracket 32 via the banana slide rivet 43 and is further attached to both the bracket 32 and the rack and pinion assembly 28 via a single banana/rack plate rivet 16 . Accordingly, when the rack plate 27 moves translationally, the banana slide opening 34 forces the banana slide rivet 43 to move in an arc which, in turn, forces the bulb mount 15 to rotate about its banana/rack plate rivet 16 . The elongated nature of the bulb mount attachment hole 31 allows the banana/rack plate rivet 16 to move up or down as needed to accommodate the curvature of the banana slide opening 34 . In this manner, even while the light bulb 20 is on and hot, its elevational aim is adjustable via an adjustment screw 36 that turns the pinion gear 30 which causes the rack plate 27 to move translationally. Translational movement of the rack plate is obtained by controlling movement of the rack plate 27 via engagement of the rack plate lip 45 with the rectangular opening 42 and engagement of the rectangular rack plate opening 41 with the rack plate rivets 44 A, 44 B.
Referring next to FIG. 5 , in addition to elevational aiming described above, the azimuthal angle of the light can be adjusted in the square trim unit 10 A. This azimuthal adjustment is made by removing the square trim unit 10 A from the adjustable mudding ring 11 A, loosening the setscrew 39 , rotating the azimuthal ring 60 to the desired setting, and then tightening the setscrew 39 . At this point, the square trim unit is ready to be re-installed in the adjustable mudding ring 11 A. The range of rotation of the azimuthal ring 60 is less than 360 degrees with respect to the square trim unit 10 A. However, this limitation is fully addressed by installing the square trim unit 10 A in any one of the four principal orientations available based on the four equal sides of a square.
In the round trim unit 10 B, the keyed azimuthal adjustment ring 76 controls the azimuthal angle of the light. The keyed azimuthal adjustment ring 76 resides in the housing 92 B and can be adjusted by rotating it by hand. To access the keyed azimuthal adjustment ring 76 , the round trim unit 10 B is removed from the adjustable mudding ring 11 B. The setscrew 39 in the keyed azimuthal adjustment ring 76 is then accessible, and can be loosened, by hand. After the setscrew 39 is loosened, the keyed azimuthal adjustment ring 76 can be rotated through 360 degrees while it resides in the housing 92 B. A straight edge 73 in the keyed azimuthal adjustment ring 76 acts as a key that allows the round trim unit 10 B to be inserted into the keyed azimuthal adjustment ring 76 in only one orientation, namely, in such a way that the bracket vertical surface 35 is aligned with the straight edge 73 . In any other orientation, the straight edge 73 would prevent the round trim unit 10 B from passing into the keyed azimuthal ring 76 because the bracket vertical surface 35 is relatively straight while the keyed azimuthal ring 76 , except for its straight edge 73 , is round. In this manner, the straight edge 73 allows the light bulb 20 to be aimed in only one azimuthal direction, namely, in the same azimuthal direction as the straight edge 73 . Once this direction has been selected by rotating the keyed azimuthal ring 76 , the setscrew 39 is then tightened and the round trim unit 10 B is re-installed in the adjustable mudding ring 11 B.
FIGS. 2A and 2B show the steps 13 A, 13 B of the adjustable mudding ring 11 A, 11 B that make it adjustable with respect to, and when mated with, the tabs 23 A, 23 B of the fixed mudding collar 12 A, 12 B. The steps 13 A, 13 B in both the square and round version of the adjustable mudding ring 11 A, 11 B typically have four different heights, each one of which corresponds to one of four nominal thicknesses for ceiling or wall materials. Such nominal thicknesses are typically ½″, ⅝″, ¾″ or 1″.
The tabs 23 A on the square fixed mudding collar 12 A are spaced uniformly apart from one another along each side of the fixed mudding collar 12 A. However, among the four sides of the square fixed mudding collar 12 A, the tabs 23 A are spaced differently so that each set of tabs 23 A along any one of the four sides corresponds to one of four nominal ceiling or wall thicknesses in which the fixture 91 A may be mounted. This different spacing of the tabs 23 A among the four sides of the square fixed mudding collar 12 A is best seen in FIG. 7 . The adjustable mudding ring 11 A is rotated to one of four positions so that its steps 13 A engage the tabs 23 A of the square fixed mudding collar 12 A. In this manner, the height of the steps 13 A allows the distance between the mounting surface 93 and the ring surface 17 to be adjusted to fit one of four nominal ceiling or wall thicknesses. Once the adjustable mudding ring 11 A has been installed on the fixed mudding collar 12 A, they can be secured to one another via screws inserted through screw holes 75 . After the fixed mudding collar 12 A and the adjustable mudding ring 11 A have been secured to one another, mudding material is applied to fill the cavity created by the mudding edge 21 , the ring surface 17 , and the opening in the ceiling or wall in which the fixture 91 A is being mounted. This provides a finished look to the installed fixture 91 A so that no portion of it extends beyond the outer surface of the ceiling or wall in which it is mounted. Once mudding material has been applied and installation is complete, only the trim unit 10 A can be readily installed and/or removed.
The tabs 23 B on the round mudding collar 12 B are typically spaced uniformly around the round mudding collar 12 B. The adjustable mudding ring 11 B is rotated to one of four positions so that its steps 13 B engage the tabs 23 B of the round fixed mudding collar 12 B. In this manner, the height of the steps 13 B allows the distance between the mounting surface 93 and the ring surface 17 to be adjusted to fit one of four nominal ceiling or wall thicknesses. Once the adjustable mudding ring 11 B has been installed on the round fixed mudding collar 12 B, they can be secured to one another via screws inserted through screw holes 75 . After the round fixed mudding collar 12 B and the adjustable mudding ring 11 B have been secured to one another, mudding material is applied to fill the cavity created by the mudding edge 21 , the ring surface 17 , and the opening in the ceiling or wall in which the fixture 91 B is being mounted. This provides a finished look to the installed fixture 91 B so that no portion of it extends beyond the outer surface of the ceiling or wall in which it is mounted. Once mudding material has been applied and installation is complete, only the trim unit 10 B can be readily installed and/or removed.
The description of the present invention has been made with respect to specific arrangements and constructions of a recessed, architectural lighting fixture. It will be apparent to those skilled in the art that the foregoing description is for illustrative purposes only, and that various changes and modifications can be made to the present invention without departing from the overall spirit and scope of the present invention. The full extent of the present invention is defined and limited only by the following claims.
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An improved recessed lighting fixture allowing illumination from a lighting unit placed within a cavity of a planar surface, such as a ceiling or wall. The invention facilitates the ability to properly aim illumination because the user can aim the fixture while it is in place and illuminated. The invention is additionally designed to allow the substitution of lamps/light bulbs without requiring re-aiming of the fixture and to be used without modification with ceiling materials of varying thickness. The invention also includes an azimuthal adjustment mechanism wherein the lamp is mounted on a gimbal having a rack and pinion coupling to rotate the gimbal under control of a screw accessible from the exterior of the fixture and a horizontal aiming system.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a gas-insulated switchgear tank.
[0002] JP-A-2002-199522 discloses a switchgear in which a vacuum circuit-breaker and silicone oil are used. Fujijihou Vol. 75 No. 11 2002 discloses in “24 kV-datsu-SF 6 -gata-gas-zetuenn switchgear”, a switchgear product in which a vacuum circuit-breaker and dry-air are used.
BRIEF SUMMARY OF THE INVENTION
[0003] An object of the present invention is to provide a gas-insulated switchgear tank suitable for environment-consciousness while maintaining an electrical insulating characteristic.
[0004] According to the invention, in a gas-insulated switchgear tank in which an electric insulating characteristic is improved by a gas, and which has a vacuum circuit-breaker, a disconnecting switch, and a container in which container the vacuum circuit-breaker and the disconnecting switch are arranged and an inside of which container is adapted to be hermetically sealed and filled with the gas in such a manner that the vacuum circuit-breaker and the disconnecting switch are at least partially surrounded by the gas, since the gas includes N 2 and O 2 , the electric insulating characteristic by the N 2 is further improved by O 2 .
[0005] It is preferable for maintaining a hermetic sealing of the vacuum circuit-breaker securely, particularly, improving an operable life time of a bellows of the vacuum circuit-breaker against a fatigue caused by repeated expansion and contraction of the bellows that the container includes a first compartment in which at least a part of the vacuum circuit-breaker is exposed to the gas, and a second compartment in which at least a part of the disconnecting switch is exposed to the gas, and a gaseous pressure in the first compartment is lower than a gaseous pressure in the second compartment.
[0006] It is preferable for keeping the electric insulating characteristic of the gas that the gas is prevented from including a vapor whose dew point is not less than a minimum value of an environment temperature in which environment temperature the gas-insulated switchgear tank is permitted to be used, and/or that the gas is prevented from including a vapor whose dew point is not less than a minimum value of a temperature in the container in which temperature at least one (or both) of the vacuum circuit-breaker and the disconnecting switch is permitted to be operated.
[0007] It is preferable for easily or securely finding a leakage of the gas that the gas further includes a smelly gas component.
[0008] It is preferable for effectively improving the electric insulating characteristic of the N 2 by O 2 that a partial pressure of O 2 is 5-60% of a total pressure of the gas.
[0009] It is preferable for maintaining the hermetic sealing of the vacuum circuit-breaker securely, particularly, improving the operable life time of the bellows of the vacuum circuit-breaker against the fatigue caused by repeated expansion and contraction of the bellows that a direction in which a movable contact of at least one of the vacuum circuit-breaker and the disconnecting switch is movable is vertical.
[0010] It is preferable for effectively improving the electric insulating characteristic of the gas that a pressure of the gas in the container is 0.2-0.8 MPa.abs. It is preferable for effectively utilizing the electric insulating characteristic of N 2 that the gas includes N 2 and O 2 as main components thereof. It is preferable for miniaturization of the gas-insulated switchgear tank that a maximum length of (the longest length measurable in) a part of the gas-insulated switchgear tank which part is prevented from including a driving mechanical force generator for generating a driving mechanical force absorbed in the gas-insulated switchgear tank extends along a direction along which a maximum length of (the longest length measurable in) the vacuum circuit-breaker extends, and/or that the maximum length of the part of the gas-insulated switchgear tank which part is prevented from including the driving mechanical force generator for generating the driving mechanical force absorbed in the gas-insulated switchgear tank extends along a direction in which a movable contact of at least one (or both) of the vacuum circuit-breaker and the disconnecting switch is movable. It is preferable for maintaining the hermetic sealing of the vacuum circuit-breaker securely, particularly, improving the operable life time of the bellows of the vacuum circuit-breaker against the fatigue caused by repeated expansion and contraction of the bellows that the direction is vertical. It is preferable that the container has one of cylindrical shape and box shape.
[0011] When the vacuum circuit-breaker has a bellows shape deformable to expand and contract so that a vacuumed chamber is formed in the bellows shape and a movable contact movable in the vacuumed chamber, it is preferable for improving the operable life time of the bellows against the fatigue caused by repeated expansion and contraction of the bellows that an outer periphery of the bellows shape is exposed to the gas in the first compartment, and/or that both ends of the bellows shape terminating respectively in an expansion and contraction direction of the bellows shape overlap each other at least partially as seen vertically. It is preferable for effectively improving the electric insulating characteristic of the N 2 by O 2 while keeping the operable life time of the bellows against the fatigue caused by repeated expansion and contraction of the bellows that a ratio of a partial pressure of O 2 in the gas to a total pressure of the gas is greater than a ratio of a partial pressure of O 2 in the atmosphere to a total pressure of the atmosphere.
[0012] Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is a diagram showing a relationship between a gas pressure and a break down voltage in each of an adaequalis electric field in dry air, a concentrated electric field in dry air and an adaequalis electric field in N 2 gas.
[0014] FIG. 2 is a diagram showing a relationship between a break down voltage and a mixing (content) ratio of O 2 .
[0015] FIG. 3 is a diagram showing a relationship between a gas pressure and a break down voltage in each of mixing ratios between N 2 and O 2 .
[0016] FIG. 4 is a diagram showing a relationship between a dry air gaseous pressure and an apparatus weight.
[0017] FIG. 5 is a diagram showing a relationship between a break down voltage and an electrode condition.
[0018] FIG. 6 is a schematic view showing a tank type gas insulated switchgear as an embodiment of the invention.
[0019] FIG. 7 is a schematic view showing another tank type gas insulated switchgear as another embodiment of the invention.
[0020] FIG. 8 is a schematic view showing a box type C gas insulated switchgear as another embodiment of the invention.
[0021] FIG. 9 is a schematic view showing a three-phase gas insulated switchgear as another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] At first, a principle as a basis of the invention is explained. N 2 is known as a gas of extremely low influence on environment load. Further, N 2 is not electrically negative gas and is known as a good insulating gas of typical electron retarding gas. The electron retarding gas decelerates high-speed electrons to decrease electron energy. But, dielectric strength of N 2 is about one third in comparison with SF 6 as a generally used electrically negative gas, and thereby an improvement of dielectric strength thereof is necessary.
[0023] Further, when the dielectric strength of N 2 is 1, it is generally known that of N 2 O is 1.1, that of CH 4 is 1.0, that of CO 2 is 0.9, and that of O 2 is 1.0, irrespective of change thereof in accordance with various conditions. Among these, N 2 satisfies all of less influence on environment load, high dielectric strength, and easiness on handling.
[0024] A mechanism on destroying the insulation of N 2 is as follows. When an acceleration more than electron retarding effect is applied to the electrons by an electric field, electron avalanche occurs to increase a number of the electrons so that the insulation is destroyed. Generally, it is known that the dielectric strength is improved to increase a break down voltage by mixing the negative gas with the electron retarding gas, but the negative gas increasing significantly the dielectric strength is designated as a global warming gas, or GWP thereof is more than 1, so that the influence on the global environment is concerned.
[0025] On the other hand, as the negative gas whose global warming coefficient is not more than 1 and which does not include atom of Chlorine, Fluorine, Sulfur or the like, CO 2 and O 2 exist. Particularly, O 2 is not the global warming gas, and can improve the dielectric strength when being mixed with N 2 .
[0026] In FIG. 1 , a gaseous pressure characteristic of break down voltage of each of pure N 2 and N 2 /O 2 mixture gas (dry air) is shown. As described in “SF 6 no chikyuh-kankyou-huka to SF 6 kongou.daitai-gas zetuenn” of no. 841 Denki-gakkai-gijutsu-houkoku, a gaseous pressure characteristic of break down voltage in dry gas under adaequalis electric field is indicated by a dot line, and a gaseous pressure characteristic of break down voltage in N 2 under adaequalis electric field is indicated by a dashed line. The dielectric strength of N 2 saturates in a high gaseous pressure region not less than 0.8-1 Mpa.abs. A reason of this is that since N 2 has a gradual ionization characteristic change in the vicinity of critical electric field under the gaseous pressure less than about 0.5 Mpa.abs, a local electric field dependence is small so that the gaseous pressure effect determines the dielectric strength. On the contrary, since the electron avalanche is magnified by ionization in short length and the electric field destroying the insulation is high, the dielectric strength is strongly affected by weak point breakdown.
[0027] On the other hand, the gaseous pressure at which the dielectric strength of the air saturates is higher than the gaseous pressure at which the dielectric strength of N 2 saturates, and about 3 Mpa.abs. A reason of this is that by mixing with O 2 , the local electric field dependence is lowered. But, the gaseous pressure characteristic of break down voltage in the air obtainable when the electric field is not constant or a high voltage electrode on which the electric field is concentrated locally is used, is not known.
[0028] The solid line in the drawing shows the gaseous pressure characteristic of break down voltage obtainable when the electric field is concentrated. When the electric field is concentrated, since the electric field locally becomes significantly high under the gaseous pressure of about 0.5 Mpa.abs, the dielectric field is strongly affected by the weak point breakdown and a dielectric strength saturation tendency is found from about 0.5 Mpa.abs. In the switchgear, it is difficult that the whole of high-voltage regions is designed as the adaequalis electric field, and is should be designed to have the gaseous pressure characteristic on which the electric field concentration is taken into consideration.
[0029] In a case of the dry air, while the break down voltage is increased by the effect of O 2 as the negative gas in comparison with N 2 , the gaseous pressure characteristic depends on the characteristic of N 2 included by the whole gas by 80%, and has a tendency of saturating at 0.8-1 Mpa.abs. Therefore, when miniaturizing with increasing the gaseous pressure, the maximum gaseous pressure becomes about 1 Mpa.abs.
[0030] In FIG. 2 , a relationship between a mixing rate and the break down voltage is shown. An ordinate corresponds to a relative ratio with respect to the break down voltage of N 2 gas. The mixing rate is an average of the break down voltage under a constant gaseous pressure. Generally speaking, an increase of the break down voltage caused by mixing O 2 with N 2 occurs within a range of the partial pressure 5-60% corresponding to the mixing rate of O 2 . An optimum mixing rate of O 2 depends on the gaseous pressure. As shown in FIG. 3 , the optimum mixing rate is the partial pressure rate of O 2 of 5-60% when the gaseous pressure is 0.2-0.4 Mpa.abs, and the optimum mixing rate is the partial pressure rate of O 2 of about 20% when the gaseous pressure is not less than 0.4 Mpa.abs. Therefore, the dry air can be deemed to be the mixture gas of N 2 and O 2 as the electron retarding gas, and the optimum gaseous pressure is not less than 0.4 Mpa.abs when the dry air is used.
[0031] On the other hand, a length of a bellows becomes great to deteriorate the miniaturization and weight saving when the gaseous pressure in a container receiving therein a vacuum switchgear becomes high. An operating life against repeated opening and closing operations of the bellows is evaluated from a stress applied to each of corners of the bellows, and the stress is calculated as a total amount of a stress caused by the pressure and a stress caused by a displacement. That is, the stress caused by the pressure increases in accordance with an increase of the gaseous pressure, but the stress applied to each of the corners can be decreased to not more than an acceptable level by increasing a number of the corners of the bellows.
[0032] Therefore, the length of the bellows is mainly determined on the basis of the stress caused by the displacement when the gaseous pressure is low, so that an increasing rate of the length of the bellows with respect to an increase of the gaseous pressure is small, and the length of the bellows is mainly determined on the basis of the stress caused by the pressure when the gaseous pressure is high, so that the length increases substantially in proportion to the gaseous pressure. Generally, when the gaseous pressure is not more than 0.2 Mpa.abs, the stress caused by the displacement is dominant, and when the gaseous pressure is not less than 0.5 Mpa.abs, the stress caused by the pressure is dominant.
[0033] Therefore, for miniaturization of the apparatus, a design flexibility needs to be maintained in a longitudinal direction of the bellows of the vacuum switch gear and so forth, and the miniaturization is obtainable by making a longitudinal direction of a container containing therein the vacuum switch gear and a longitudinal direction of the vacuum switchgear parallel to each other. Incidentally, since it is effective for minimizing an increase in volume of the switchgear that the length is increased in the longitudinal direction rather than a short length direction, it is effective for the miniaturization that the increase in length of the bellows in accordance with the increase of the gaseous pressure is absorbed in the longitudinal direction of the switchgear by making the longitudinal directions of the vacuum switchgear and the container parallel to each other.
[0034] Further, in the disconnecting switch, a small current interrupting performance is needed. Since the interrupting performance of the N 2 /O 2 mixture gas includes problems of thermal destruction as well as continued current, a distance between poles cannot be necessarily decreased in accordance with the increase of the gaseous pressure. Therefore, the length in a direction between the poles increases in accordance with the increase of the gaseous pressure, so that a movable contact moving direction and a longitudinal direction of the container as well as the vacuum switchgear needs to be made parallel to each other to decrease the size and weight of the apparatus.
[0035] A wall thickness t1 of the container of cylindrical shape containing the high pressure gas with hermetic sealing increases in accordance with the gaseous pressure as shown in formula (1).
t 1 =P×D /(2π) (1)
[0036] In this case, π: allowable stress in circumferential direction, P: gaseous pressure, D: inner diameter, t1: wall thickness of cylinder. On the other hand, a plate thickness t2 of a flange not cylindrical increases in proportion to a square root of the gaseous pressure as shown in formula (2).
t 2=2 d× ( Z×C×P /π) 0.5 (2)
[0037] In this case, d: fixing bolt pitch circle, Z: constant value determined in accordance with a shape of plate, C: constant value determined in accordance with mounting feature of a flat plate, P: gaseous pressure, and π: allowable stress. From the formulas (1) and (2), it is apparent that the weight of the apparatus increases in accordance with an increase of the plate thickness caused by the increase of the gaseous pressure. That is, the weight of the apparatus increases in accordance with the increase of the pressure of the used gas when the inner diameter is kept constant. Further, the miniaturization of the apparatus is restrained by an increase of driving force of the actuator caused by the increase of the gaseous pressure. On the other hand, from the relationship between the gaseous pressure and the break down voltage shown in FIG. 1 , the increase of the gaseous pressure causes the increase of the dielectric strength to enable the size of the apparatus to be decreased, so that the size and weight of the apparatus is decreased. Therefore, an optimum gaseous pressure for decreasing both of the size and weight exists.
[0038] The optimum gaseous pressure changes in accordance with a ratio in weight between the cylindrical portion and the flange, but, it is generally used for the miniaturization and cost down that a number of the flanges is made minimum, that is, a constant value. Further, a length of the cylindrical portion can be decreased by the increase of the dielectric strength with an affect onto the mechanical portion or the like, so that its rate is small and estimated at about one-third in comparison with the change of the inner diameter.
[0039] FIG. 4 shows an example in which a ratio in weight between the cylindrical portion and the flange is 4:1. The gaseous pressure for minimizing the weight of the apparatus is about 0.4 MPa.abs, and a design should be done to satisfy the gaseous pressure of 0.2-0.8 MPa.abs to obtain a design within a range of 20% from the minimum value. Further, when the gaseous pressure of the N 2 /O 2 mixture gas is not more than 0.2 MPa.abs, the weight increases abruptly. An optimum range of the gaseous pressure of the dry gas for decreasing the size and weight of the switchgear is between 0.2-0.8 MPa.abs.
[0040] That is, in the gas-insulated switchgear tank including the insulating gas of the mixture gas (a partial pressure ratio of O 2 is 5%-60%) or dry air with the main components of N 2 and O 2 , it is necessary for decreasing the size and weight that the minimum gaseous pressure or rated pressure is 0.2-0.8 MPa.abs.
[0041] FIG. 5 shows the break down voltage changing in accordance with a treatment condition of the electrode in the N 2 /O 2 mixture gas. Lowest and highest break down voltages of a bare electrode are indicated by bars, and an average break down voltage is indicated by O. By coating the electrode, an initial break down voltage is made not less than the average of the bare condition. Further, the insulating matter is molded on the electrode, the break down voltage is further increased, so that under the constant gaseous pressure, the initial break down voltage is made 1.5 times of the average of the bare condition, and the significant miniaturization is obtainable if using the mixture gas. Further, the gaseous pressure characteristic for the electrode with the insulating coat is in proportion to the gaseous pressure characteristic for the bare electrode, so that decreasing the weight and size is obtainable by incorporating the insulating coat or insulating molding under the constant optimum gaseous pressure.
[0042] As the insulating coat, epoxy type resin, polyethylene resin or the like is usable. Further, if the epoxy type insulating material including alumina, silica, titanium oxide or the like is used as the molding material, a specific inductive capacity can be adjusted somewhat freely in combination with the molded thickness to optimize the apparatus. Hereafter, a plurality of embodiments will be described.
EMBODIMENT 1
[0043] FIG. 6 shows an embodiment of a tank type gas insulated switchgear of the invention. Cylindrical pressure vessels 2 , 7 a and 7 b are filled with a N 2 /O 2 mixture gas or dry air of 0.2-0.8 MPa.abs. A vacuum circuit breaker 1 is contained in the cylindrical pressure vessel 2 , a longitudinal direction of the cylindrical pressure vessel 2 is arranged parallel to a vertical direction, and a longitudinal direction of the vacuum circuit breaker 1 is arranged parallel to the longitudinal direction of the cylindrical pressure vessel 2 . The vacuum circuit breaker 1 is connected to an operator 3 through an opening and closing operation rod below the vacuum circuit breaker 1 . Further, an arrestor 4 is arranged under the vacuum circuit breaker 1 to decrease a size of the apparatus.
[0044] Arranging the longitudinal direction of the vacuum circuit breaker parallel to the vertical direction causes the following effects. When a length of a bellows increases in accordance with an increase of a gaseous pressure, a problem of that the bellows is bent to a V shape in response to the opening and closing operation occurs. Therefore, when the length of the bellows increases, a ring for preventing the bend needs to be arranged between protruding corners of the bellows, so that the length of the bellows is further increased. A probability of that this bend occurs becomes maximum when the bellows extends perpendicularly to the vertical direction, but by arranging the bellows parallel to the vertical direction, a number of the rings for preventing the bellows bend can be decreased to decrease the length of the bellows and the size of the apparatus.
[0045] A bus bar disconnecting switch 5 a and a line disconnecting switch 5 b are connected to each other through a spacer 6 as a gas partition. A gas compartment containing the disconnecting switches 5 is gaseously separated from a gas compartment containing the vacuum circuit breaker 1 , so that an influence to the other electric lines can be minimized by opening the disconnecting switches 5 a and 5 b on a trouble of the vacuum circuit breaker 1 occurs or an inspection. Further, movable contacts of the disconnecting switches 5 are formed monolithically respectively with movable contacts 10 a and 10 b of a grounding disconnecting switch to combine the disconnecting switches 5 and the grounding disconnecting switch with each other, so that a size of the disconnecting switches and grounding disconnecting switch is decreased. Further, a longitudinal direction of cylindrical pressure vessels 7 a and 7 b containing the disconnecting switches is arranged parallel to a movable direction of the movable contacts of the disconnecting switches 5 . Further, the longitudinal direction of the cylindrical pressure vessels 7 a and 7 b containing the disconnecting switches 5 is arranged parallel to the longitudinal direction of the cylindrical pressure vessel 2 containing the vacuum circuit breaker 1 to decrease the size and weight of the whole of the switchgear. Further, a solid insulation such as cable head 9 is applied to the bus bar 8 and lines to decrease the size of the apparatus and keep a flexibility of layout.
[0046] Further, the gaseous pressure in the cylindrical pressure vessel 2 containing the vacuum circuit breaker 1 is made lower than the gaseous pressure in the cylindrical pressure vessels 7 containing the disconnecting switches 5 to satisfy both the optimum miniaturization of the disconnecting switches 5 and the optimum miniaturization of the vacuum circuit breaker 1 and decrease the size of the whole apparatus. Additionally, since the electric field is concentrated at a high voltage shield of the disconnecting switches 5 and upper and lower electrodes and so forth of the vacuum circuit breaker 1 , these area to be insulated are coated by molding with the insulating coat of the epoxy type resin or the polyethylene resin including filler so that the significant miniaturization is obtainable without changing the gaseous pressure.
[0047] Further, by adding a sulfur type smelling agent to the mixture gas or dry air so that the mixture gas or dry air inserted into the apparatus becomes smelly, a gas leakage can be detected rapidly through the smell. The sulfur type smelling agent may be, for example, diethyl-disulfide, tasha-leaf or dimethyl-sulfide.
EMBODIMENT 2
[0048] FIG. 7 shows another embodiment of a tank type gas insulated switchgear of the invention. The vacuum circuit breaker (VCB) is vertically arranged, and is connected to the disconnecting switch (DS) unit through the gas partition. The line side is connected to a power cable through a cable head, and a current therethrough is measured by a current transformer.
[0049] An operator of the VCB is arranged in a box at a right side of the drawing, and operators of the disconnecting switch (DS) and the earthed switch (ES) are arranged under the operator of the VCB. Each of the metallic vessels containing respectively the VCB, DS, ES and bus bar has a substantially cylindrical shape suitable for inner pressure. The vessels contain, for example, the dry air with the minimum pressure of 0.5 Mpa.abs to form a compact and light-weight gas insulated switch (GIS) including no global warming gas.
[0050] In this embodiment, the VCB and the line disconnecting switch (DS L ) are contained in a common gas compartment, and the insulating compartment for the bus bar disconnecting switch (DS B ) is gaseously isolated from the common gas compartment. In such structure, each line is great, and 2-4 gas compartments are arranged. The disconnecting switch DS is of blade type, and a fulcrum of the movable contact is arranged on the conductive member at the disconnecting switch side, to include the earthed switch ES.
[0051] Further, if the dry air is used as the insulating gas, the leakage thereof from the apparatus as a rare case do not affect the environment, but it is difficult for a gas leaking position to be found, so that on the worst case, all of the gas compartments need to be replaced. Therefore, if helium or CF 3 CH 2 F of partial pressure ratio of not more than 5% is mixed with the dry air, the gas leaking position can be found easily by use of a gas detector so that a recovery can be performed effectively.
EMBODIMENT 3
[0052] FIG. 8 shows an embodiment of a box type C-gas insulated switch (GIS) of the invention. When the box type vessel is used, a weight increase in accordance with the increase of the gaseous pressure is remarkable in comparison with the cylindrical vessel, and the optimum gaseous pressure is relatively lower in comparison with the cylindrical vessel, so that a range of the minimum or rated gaseous pressure optimum for decreasing the size and weight is between 0.2-0.7 Mpa.abs. When the vessel is of box shape, an effect for decreasing an amount of the used gas is lower in comparison with the cylindrical vessel, but an space efficiency for mounting the switchgear can be improved.
[0053] In this embodiment, the VCB and the line disconnecting switch (DS L ) are contained in a common gas compartment, and the insulating compartment for the bus bar disconnecting switch (DS B ) is gaseously isolated from the common gas compartment. In such structure, each line is great, and 2-4 gas compartments are arranged. A linear type is applied to the disconnecting switch DS, and the disconnecting switch DS L on the circuit breaker side and the earthed switch ES are arrange perpendicularly to the vertical direction, so that a height of the switch gear is decreased. Further, it is connected to an underearth power cable through a cable head CH. Bus bars as gas-insulated bus bars are arranged parallel to each other to form three phase combined type, and the mixture gas (including the dry air) is applied to the circuit breaker compartment and the bus bar disconnecting switch with the minimum kept gaseous pressure not less than 0.2 Mpa.abs and not more than 0.7 Mpa.abs, so that both the environment-accordance and the dielectric strength are obtainable.
[0054] In C-GIS, the box shape causes the increase of the vessel size and cost in accordance with the increase of the rated gaseous pressure, and thereby the gaseous pressure is preferably as low as possible. Therefore, if the dry gas is used as the insulating gas for example, the minimum kept gaseous pressure or rated gaseous pressure is made 0.3-0.5 Mpa.abs, and the insulating coat or molding is used. In this case, the apparatus can have the same or less size in comparison with the apparatus with SF 6 gas of the minimum kept gaseous pressure (0.17 Mpa.abs).
EMBODIMENT 4 GAS
[0055] FIG. 9 shows an embodiment of a GIS of three phase combined of the invention. The vacuum circuit breaker 1 is arranged vertically, and connected to the bus bar disconnecting switch 5 a and the line disconnecting switch 5 b . It is connected through the cable head 9 to the power cable, the breaker 1 is contained in the metallic vessel 2 , the disconnecting switch 5 a and the bus bar are contained in the metallic vessel 7 a , and the disconnecting switch 5 b is contained in the metallic vessel 7 b , so that the size is decreased. The mixture gas of N 2 and O 2 or the dry air is used and the rated gaseous pressure is not less than 0.2 Mpa.abs and not more than 0.8 Mpa.abs, so that the environment-accordance and the decrease of the weight and size are achieved in the GIS. Incidentally, 19 denotes an absorbing agent container, and 20 denotes a mounting table.
[0056] The vacuum circuit breakers 1 are arranged parallel to the vertical direction and form a triangle shape, so that an inner diameter of the cylindrical pressure vessel 2 containing the vacuum circuit breakers 1 is decreased. The vacuum circuit breakers 1 are connected to the operator 3 through the operating rods under the vacuum circuit breakers 1 , so that the vacuum circuit breakers 1 are operated to be opened and closed by converting horizontal movement of the operator 3 to vertical movement. Further, the arrestor 4 as well as an arrestor release device 18 are arranged under the line disconnecting switch 5 b connected to the cable head 9 so that the miniaturization is obtained and an efficiency of test with electrically energizing on setting the apparatus is significantly improved.
[0057] It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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In a gas-insulated switchgear tank in which an electric insulating characteristic is improved by a gas, and which has a vacuum circuit-breaker, a disconnecting switch, and a container in which container the vacuum circuit-breaker and the disconnecting switch are arranged and an inside of which container is adapted to be hermetically sealed and filled with the gas in such a manner that the vacuum circuit-breaker and the disconnecting switch are at least partially surrounded by the gas, the gas includes N 2 and O 2 .
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to devices relying on magnetic properties and, more particularly, those which in operation rely on magnetic properties to support single wall magnetic domains.
2. Art Background
An integral part of any magnetic bubble device is a layer of a material that has a magnetic anisotropy that is capable of supporting single wall magnetic domains. One general class of such domain supporting materials has a garnet crystal structure. Thus, the interest in magnetic devices has generated a corresponding interest in garnet materials exhibiting the necessary anisotrophy.
Generally, garnet based devices have a growth-induced magnetic anisotropy produced by ions located on the dodecahedral sites of the crystal. This growth-induced component results from the presence of a magnetic rare earth ion, such as samarium, in conjunction with a different, either magnetic or non-magnetic, rare earth ion. (For purposes of this disclosure, yttrium is considered a rare earth ion.)
The growth procedures necessary to produce such garnets are well established and are commercially viable. In using these procedures to obtain an acceptable growth-induced magnetic anisotropy, e.g., an anisotropy greater than approximately 7,000 ergs/cm 3 , a substantial percentage of the dodecahedral sites must be filled with the necessary growth-induced anisotropy producing rare earth ions. Thus, once a suitable anisotropy is achieved in a particular crystal--especially in a material supporting small diameter magnetic domains where large growth-induced anisotropies, e.g., greater than 80,000 ergs/cm 3 are required--relatively few dodecahedral sites remain available for substitution. Often it is desirable to increase anisotropy or change the properties of the garnets by further substitution on the dodecahedral sites. Obviously, it is desirable to perform this substitution by well established growth procedures. As discussed in the case of garnet materials, the possibility of significant substitution on the dodecahedral site using established techniques typically is not available. Thus, the opportunity for tailoring of garnet material properties by adjusting the composition of the dodecahedral site is significantly limited.
SUMMARY OF THE INVENTION
Devices based on garnet materials having a magnetic anisotropy produced by an appropriate choice of ions both on the dodecahedral and on the octahedral sites are producible by conventional, well established growth procedures. The garnet materials employed in these devices have an anisotropy produced by a typical combination of rare earth ions on the dodecahedral site in combination with ions on the octahedral site that include (1) Co 2+ and/or (2) ions which have either 1, 2, 4, or 5 electrons in the 4d or 5d electronic orbital on the octahedral site. Exemplary of magnetic anisotrophies that are produced is approximately 18,000 ergs/cm 3 and 37,000 ergs/cm 3 for the composition La 0 .80 Sm 0 .31 Lu 1 .89 Ga 0 .78 Fe 4 .22-x Ir x O 12 , where x is 0 and a small quantity on the order of 0.01 respectively. (For purposes of this application, yttrium is considered a rare earth ion.)
Most importantly, the contribution to growth-induced magnetic anisotrophy from the typical rare earth combination is essentially additive with the contribution to growth-induced anisotropy produced by iridium or the other requisite ions used on the octahedral site. Thus, a garnet having a desired anisotropy is producible using significantly fewer dodecahedral sites than previously necessary. Since the requisite ions on the octahedral site significantly contribute to magnetic anisotropy, it is not necessary to use an excessive amount of either the octahedral or dodecahedral sites for magnetic anisotropy control purposes.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE illustrates an apparatus useful in producing the devices of the subject invention.
DETAILED DESCRIPTION
The devices of the subject invention are typically fabricated on a supporting substrate. Any mismatch in lattice parameters between the substrate and the garnet epilayer is a source of stress. This stress induces a magnetic anisotropy in the subject garnet materials. Substantial stress and thus sustantial stress-induced uniaxial anisotropy is not desirable. For example, assuming a typical magnetostriction constant to maintain magnetic domains of useful size solely with stress-induced magnetic anisotropy requires a large lattice mismatch between the substrate and the epitaxial layer--greater than -0.015 Angstroms for garnet materials with negative magnetostriction and +0.02 for material with positive magnetostriction in films of approximately 3 μm thickness. These large mismatches usually result in cracking or dislocated growth.
It is thus advantageous that stress and the resulting stress-induced magnetic anisotropy be limited. Generally, the stress-induced component of the magnetic anisotropy should be less than 15,000 ergs/cm 3 , preferably less than10,000 ergs/cm 3 . (The extent of the stress-induced component of the epitaxial layer is measured by conventional techniques such as by annealing out the growth-induced anisotropy and measuring the remaining K u . See R. C. LeCraw et al, Journal of Applied Physics, 42, 1641 (1971).)
The composition of the garnet layer growth on the substrate in accordance with the subject invention is represented by the nominal formula {A} 3 [B] 2 (C) 3 O 12 . The { }, [ ],and (), respectively, represent the dodecahedral, the octahedral, and the tetrahedral site of the garnet crystal structure. (The formula is nominal. To insure charge neutrality or because of growth defects, it is possible some slight deviations from strict stoichiometric ratios occur.) The letters A, B, and C individually represent the average composition found in the designated crystal site. Since the crystal must have a magnetic moment, for compositions of general interest, both B and C should typically include iron ions although the requisite moment produced by iron solely on B or C is not precluded if another magnetic ion is present on the B or C site to produce the necessary magnetic moment.
As in other garnet structures, the composition of A includes a typical magnetic anisotropy producing combination, i.e., where X 3-y Z y represents the occupants of the dodecahedral site, A, and where X is the magnetic rare earth ion of highest mole percentage in A, and Z represents the remaining constituents of A, then 0.1<y<2.9. In addition to these constituents the number of rare earth ions necessary to produce a given anisotropy is reduced by employing on the octahedral site, either Co 2+ and/or an ion having 1, 2, 4, or 5 electrons in 4d or 5d electronic orbitals. Exemplary of ions having an appropriate number of electrons in a 4d or 5d orbital is Ir 4+ . (The Ru +3 ion falls into this category. This ion unlike the others such as Ir 4+ produces a garnet with in-plane anisotropy when the garnet film is grown on a (111) oriented substrate. Materials with in-plane anisotropy are useful, for example, as hard bubble suppressants when overlying or underlying a material with anisotropy out of plane. It should be noted that the Ru +3 contribution to in-plane anisotropy is useful for addition to a typical combination of rare earth ions that produce in-plane anisotropy.)
Charge neutrality must be maintained in the garnet. When an ion having a 3 + charge is introduced into the garnet on an octahedral site, it replaces a 3 + iron ion and charge neutrality is not disturbed. However, if an ion having a charge other than 3 + replaces an iron ion, a net charge change in the garnet occurs and compensation is necessary. In a preferred embodiment, a charge compensator is introduced on the octahedral site. Exemplary charge compensators (those having, for example, a charge of 4 + to compensate for a 2 + ion and a charge of 2 + to compensate for a 4 + ion) are Mg 2+ , Fe 2+ , and Ca 2+ , which compensate for 4 + ions such as Ir 4+ , and Zr 4+ which compensates for 2 + ions such as Co 2 .
Substitution in some octahedral and tetrahedral sites by ions other than those enumerated above to adjust the magnetic properties desired for a particular application is also possible. The limitation on this substitution is that sufficient ions having a magnetic moment, e.g. iron, remain in the octahedral and/or tetrahedral sites to produce a net magnetic moment. Similarly, enough of the requisite ion must be left on the octahedral sites to produce, in conjunction with the rare earth ions on the dodecahedral site, the desired anisotropy.
Since a significant portion of the requisite growth-induced anisotropy is producible by constituents on the octahedral site, it is possible to introduce a substantial quantity of property controlling entities on the dodecahedral site. The ions introduced onto the dodecahedral site if they have charge other than 3 + require the introduction of other constituents to maintain charge neutrality. If this is required, the neutrality is produced as discussed for substitution on the octahedral site.
Various means are available for growing the desired garnet structure. Epitaxial growth procedures employing a supercooled melt show good results. Indeed, substantially the same conditions are employed as used for the corresponding garnet without the necessary anisotropy producing octahedral ions. In a preferred embodiment, to deposit a garnet of a desired composition, the substrate, 7, is placed in a substrate holder, 10, of a conventional epitaxial growth apparatus as shown in the FIGURE. The basic deposition steps are conventional and are described in various publications such as S. L. Blank and J. W. Nielsen, Journal of Crystal Growth, 17, 302-11 (1972). Briefly, in the preferred embodiment the melt is heated for a sufficient period to allow equilibration of its components. The temperature of the melt is then lowered to supercool it. The substrate is introduced above the melt to preheat it and then is lowered into the melt. During growth, in a preferred embodiment, the substrate is rotated through rotaton of rod, 28.
The choice of the melt composition used in the deposition process relies on essentially the same considerations employed when conventional garnet layers are fabricated. (See S. L. Blank et al, Journal of the Electrochemical Society, 123, (6), 856 (1976) and S. L. Blank and J.W. Nielsen, Journal of Crystal Growth, 17, 302-11 (1972).) As with conventional garnets, the melt compositionis adjusted to produce the desired formulation for A, B, and C. For example, for a garnet useful in the inventive devices such as (YSmLu) 3 (FeIr) 5 O 12 iron to rare earth atomic ratios in the melt in the range 12 to 30 while garnet oxide to flux atomic ratios in the range 0.10 to 0.28 are utilized. For such compositional ranges deposition temperatures in the range 800 to 1000 degrees C. are advantageously employed. In the previous example, it is contemplated that Fe 2+ is the compensator for the Ir 4+ .
Thus, in this situation, althugh no extra component need be added to the melt the presence of Fe 2+ is required. Under atmospheric conditions, i.e., air at standard temperature and pressure, Fe 2+ is always present and is incorporated into the garnet as a compensator. However, it is possible to introduce other compensators, e.g., Zn 2+ and Mg 2+ , into the grown garnet by adding an appropriate oxide, e.g., MgO or ZnO, to the melt. Typically, added compensator-to-anisotropy-producing-entity ratios in the melt up to 100-to-1 are employed. For example, Mg to Ir ratios up to 100-to-1 are used to produce the necessary compensation for a composition such as (YSmLu) 3 (FeGaIrMg) 5 O 12 . It has been found that these added compensators increase the obtainable K u . A contemplated explanation is that they increase the amount of available compensator and thus increase the amount of anisotropy producng ion which it is possible to incorporate in the octahedral site of the crystal.
As previously discussed, it is also possible to introduce various ions both on the octahedral, tetrahedral, and dodecahedral sites into the melt to produce certain desired properties in the resulting garnet. For example, to adjust the lattice constant to closely match that of a Gd 3 Ga 5 O 12 garnet (GGG) or another desired substrate material, appropriate ions, e.g., lanthanum or lutetium is added to a melt containing yttrium, samarium iron and iridium. The optimum melt composition to yield the desired garnet composition is determined by employing the criteria of S. L. Blank and J. W. Nielsen et al, supra, as an initial guide and then by using a controlled sample to fix the precise melt composition.
Once the garnet layer is deposited, it is possible to provide a means for propagating magnetic bubbles in the garnet. Typically, this means is a permalloy pattern which is deposited on the garnet layer using conventional lithographic techniques. (See, for example, Bobeck et al, Proceedings of the IEEE, 63, 1176 (1975).) Additionally, a means of detecting single wall domains and of producing these domains is also required. Typically, the detector is fabricated using standard lithographic techniques to produce an appropriate permalloy pattern. Similarly, a single wall magnetic domain nucleator is produced by lithographic techniques. (See Bobeck et al, supra.) A means for maintaining the single wall magnetic domains after its nucleation is also required as a component of a bubble device. This means is generally a permanent magnet surrounding the garnet layer with its associated detecting, propagating, and nucleating means.
The following are examples of typical conditions utilized in the deposition of the garnet epitaxial layer and contrast the anisotropy attainable with and without appropriate substitution on the octahedral site:
EXAMPLE 1
A circular GGG (Gd 3 Ga 5 O 12 ) substrate measuring 3/4 inches in diameter and 20 mils thick was used as the deposition substrate. This substrate, 7, (in the FIGURE) was cleaned, dried, and then inserted in the substrate holder, 10, of an apparatus containing a previously prepared melt composition, 11. This melt composition was prepared by inserting a mixture of approximately 1.43 g Y 2 O 3 , 1.31 g Sm 2 O 3 , 3.62 g Lu 2 O 3 , 44.0 g Fe 2 O 3 , 10.85 g B 2 O 3 , and 500.0 g PbO in a platinum crucible, 14. The melt was heated using resistant heating coils, 18, to a temperature of approximately 1020 degrees C.
Once a temperature of 1020 degrees C. was established the melt, 11, was allowed to react for a period of approximately 16 hours. The temperature of the melt was then lowered to a growth temperature of approximately 930 degrees C. The substrate was lowered to within 1 cm of the melt surface by lowering rod, 28. The substrate was maintained in this position for approximately 6 minutes. The substrate was then immersed approximately 2 cm into the melt by again lowering rod, 28, and a rotation of 100 rpm was imparted to the substrate through rod, 28. This rotation was maintained for approximately 2 minutes and the substrate then removed from the melt to a position 1 cm above the melt while continuing the rotation. The rotation was then increased to 400 rpm for a period of 1/2 minute. The rotation was discontinued and the substrate removed from the deposition area by extracting rod, 28, at a rate of approximately 1/2 cm/min.
A continuous adherent garnet film was obtained. This film had a thickness of approximately 3 μm and exhibited a K u of approximately 86,600 ergs/cm 3 and a lattice constant within 0.002 Angstroms of the substrate lattice parameter.
EXAMPLE 2
The procedure of Example 1 was followed except before growth an addition of 0.525 g IrO 2 and 0.525 MgO was made to the melt at approximately 1020 degrees C. and the mixture was stirred for approximately 1 minute to insure homogeneity. The garnet film obtained was approximately 3.5 μm thich with a K u of 196,200 ergs/cm 3 and a lattic constant within 0.004 Angstroms of the substrate lattice parameter.
EXAMPLE 3
The procedure of Example 1 was followed except that the melt contained 3.03 g La 2 O 3 , 0.27 g Sm 2 O 3 , 2.68 g Lu 2 O 3 , 4.51 g Ga 2 O 3 , 45.15 g Fe 2 O 3 , 6.80 B 2 O 3 , and 379 g PbO. The growth temperature was approximately 900 degrees C. and the growth time was 6 minutes. The resulting film was 3.8 μm thick, had a magnetic moment of 676 Gauss, a K u of 17,800 ergs/cm 3 and a line width of 890 Oe.
EXAMPLE 4
The procedure of Example 3 was followed except an addition of 0.207 g IrO 2 and 0.102 g MgO was made at approximately 1020 degrees C. before growth. The thickness of the new film was 4.1 μm, the moment was 692 Gauss, the K u was 37,400 ergs/cm 3 and the line width was 880 Oe. The line width as compared to that obtained in Example 3 had not changed with the addition of Ir within the uncertainty of the measurement.
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Devices based on epitaxial garnet layers that exhibit a high magnetic anisotropy are disclosed. These garnet layers are produced by introducing a Co 2+ or a species with 1, 2, 4, or 5 electrons in a 4d or a 5d electron orbital in the octahedral site of the garnet in conjunction with a typical anisotropy producing combination on the dodecahedral site. The contribution to magnetic anisotropy due to the typical combination on the dodecahedral site and the appropriate ion in an octahedral site is complementary.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to containers having self-locking closures formed by flaps with corners tucked under or overlapping adjacent flaps.
2. Description of the Prior Art
One prior art closure in a regular slotted container of corrugated paperboard includes four trapezoidal closure flaps hinged at the longest of their respective two parallel edges to the top edges of the walls of the container. Each of the closure flaps has one side edge, i.e. one of the non-parallel edges, perpendicular to the parallel edges, and has the other side edge formed at a 45° angle to the longest parallel edge. The closure flaps are folded sequentially with a portion of each closure flap adjacent the 45° angled edge overlapping a portion or corner adjacent the perpendicular edge of the previously folded flap. One of the flaps, i.e., the last flap to be closed, has a slot extending from its perpendicular side edge about one fifth of the distance along its longest parallel edge in line with the scoreline joining such flap to the container together with a scoreline extending from the inside end of the slot at a 45° angle across the flap to the 45° angled edge of the flap. This slot and 45° score line permits the corner portion adjacent the perpendicular side edge of this last flap to be resiliently folded down and inserted into the containers under the 45° angled edge of the adjacent flap to complete the closure so that the flaps are locked together. However, it is difficult to use this type of closure when the container is full of non-compressible materials since the non-compressible materials prevent the fold-down corner portion from being inserted into the container sufficiently to make the proper closure. Also distortion or deformation of the flap portion being tucked under the adjacent flap often occurs rendering the container less suitable for further use.
SUMMARY OF THE INVENTION
The invention is summarized in a container blank including a plurality of side panels serially hinged together so that the side panels can be folded to form an enclosed wall for a container, a joint flap on one end panel of the side panels for being secured to the other end panel of the side panels to form the enclosed wall, bottom means attached to the bottom edges of the side panels for closing the bottom of the container, a plurality of trapezoidal closure flaps each having the longer of the two parallel edges thereof hinged to the top edge of the respective side panel, the closure flaps having dimensions for being sequentially folded together so that one side portion bordered by one of the non-parallel edges of each closure flap is overlapped by another side portion bordered by the other non-parallel edge of an adjacent flap, one of the closure flaps having a slit extending along a segment of the longer parallel edge thereof from the one non-parallel edge thereof to an inner end of the slit, the one closure flap also having a first scoreline extending across the one closure flap from the inner end of the slit at an acute angle relative to the longer parallel edge thereof toward the other non-parallel edge thereof to form a fold-down portion between the first scoreline and the one non-parallel edge thereof to permit the one side portion of the one closure flap to be inserted beneath the another side portion of the corresponding adjacent closure flap, and the one closure flap having a second scoreline extending from the slit across the fold-down portion intermediate the first scoreline and the one non-parallel edge of the one closure flap to define a reverse folding portion between the second scoreline and the one non-parallel edge for being reverse folded relative to the remaining portion of the fold-down portion to substantially reduce the extent of protrusion of the fold-down portion into the container during insertion of the one side portion of the one closure flap beneath the another side portion of the corresponding adjacent closure flap.
An object of the invention is to construct a container with a manually closeable secured top with easy opening and reclosure and having knock-down capability.
Another object of the invention is to construct an improved container with top closure flaps for being interlocked by overlapping corner portions thereof wherein the last overlapped portion can be easily inserted beneath the corresponding adjacent flap without substantial extension into the center of the container.
It is yet another object of the invention is to eliminate breaking or weakening of an overlapped portion of the last closure flap during insertion beneath the corresponding adjacent closure flap.
A further object of the invention is to construct a container having a locking top suitable for accommodating a variety of package contents including those resulting in slight bulging in the top and bottom.
A still further object of the invention is to provide an alternative self-locking container to the presently employed regular slotted container.
One advantage of the invention is that a corner portion can be inserted beneath the adjacent flap even when the container is full without breaking or bending the corner flap except along its existing scorelines.
Other objects, advantages and features of the invention will be apparent from the following description of the preferred embodiment, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a blank for forming a container in accordance with the invention.
FIG. 2 is a perspective view taken toward an upper corner of a partially assembled container from the container blank of FIG. 1.
FIG. 3 is a perspective view taken toward a bottom corner of a partially assembled container from the container blank of FIG. 1 after the bottom has been assembled.
FIG. 4 is a perspective view taken toward an upper corner of the partially assembled container of FIG. 3.
FIG. 5 is a view similar to FIG. 4 but after a first step of the assembly of the top closure of the container.
FIG. 6 is a view similar to FIGS. 4 and 5 but after a second step of the assembly of the top closure.
FIG. 7 is a view similar to FIGS. 4-6 but after a third step in the assembly of the top closure.
FIG. 8 is a prospective view similar to FIGS. 4-7 but after a fourth step in the assembly of the top closure.
FIG. 9 is a perspective view similar to FIGS. 4-8 but after a fifth step in the assembly of the top closure.
FIG. 10 is a perspective view similar to FIGS. 4-9 but taken during the final step in the assembly of the top closure.
FIG. 11 is a perspective view similar to FIGS. 4-10 but after completion of the assembly of the top closure.
FIG. 12 is a plan view of a modification of one closure flap of the blank of FIG. 1.
FIG. 13 is a plan view of a second modification of one closure flap of the blank of FIG. 1.
FIG. 14 is a plan view of a third modification of one closure flap of the blank of FIG. 1.
FIG. 15 is a plan view of a fourth modification of one closure flap of the blank of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
One embodiment of the invention is formed from a single blank of corrugated paperboard or the like illustrated in FIG. 1 for forming a container. The blank includes side wall panels 20, 22, 24 and 26 which are serially hinged together by a scoreline 28 between the panels 20 and 22, a scoreline 30 between the panels 22 and 24 and a scoreline 32 between the panels 24 and 26. A joint flap 34 is hinged at a scoreline 36 on the end panel 20 for being secured to the opposite end panel 26 to form an enclosed wall for the container. The container blank also includes conventional bottom means, such as trapezoidal bottom flaps 40, 42, 44 and 46 hinged at scorelines 50, 52, 54 and 56 on the bottom edges or ends of the respective side wall panels 20, 22, 24 and 26 for closing the bottom end of the container. A top closure for the container includes closure flaps 60, 62, 64 and 66 which are formed in a trapezoidal shape and which are hinged at scorelines 70, 72, 74 and 76 on the top edges or ends of the respective panels 20, 22, 24 and 26 for closing the top end of the container. It is noted that the scorelines 70, 72, 74 and 76 extend along the longer edge of the two opposite parallel edges of the respective trapezoidal flaps 60, 62, 64 and 66, and that one of the non-parallel edges of each of the flaps 60, 62, 64 and 66 is perpendicular to the parallel edges of the flaps 60, 62, 64 and 66; such perpendicular non-parallel edges being on the same side of the respective flaps 60, 62, 64 and 66 in the blank as shown in FIG. 1. Additionally, it is noted that the flap 64 includes a cut or slit 78 extending for a short distance along the longer parallel edge of the flap 64 in line with the scoreline 74 from the perpendicular non-parallel edge 80 of the flap 64. The slit 78 can be of various lengths proportionate to the container length and width dimensions. It is preferred that the slit 78 has a length approximately one-fifth the length of the longer parallel edge of the flap 64. Alternately it is preferred to make the length of the slit 78 in the range of 3.175 to 6.35 centimeters (1.25 to 2.5 inches) long. A scoreline 82 extends across the flap 64 from the inner end of the slit 78 at an acute angle to the scoreline 74 toward the non-perpendicular non-parallel edge 84 of the trapezoidal flap 64. The scoreline 82 is preferred to extend at an angle approximately 45° to the scoreline 74. The scoreline 82 and the cut 78 define a fold-down portion 86 of the flap 64 between the scoreline 82 and the perpendicular non-parallel edge 80. As described above in the description of the prior art, closures for containers including trapezoidal flaps wherein one flap has a slit similar to slit 78 and a scoreline similar to scoreline 82 for forming a fold-down portion similar in dimensions to the fold-down portion 86 are well known.
The present invention differs from the prior art in the inclusion of a scoreline 88 which extends from the slot 78 to the shorter parallel edge 90 across the fold-down portion 86 intermediate the scoreline 82 and the edge 80 so as to form a reverse folding portion 92 between the scoreline 88 and the edge 80. The scoreline 88 can be a regular score permitting reverse folding, a reverse score, or a perforated score. In the embodiment of FIG. 1, the scoreline 88 is shown to extend from the inner end of the cut 78 at the intersection of the cut 78 and scoreline 82 across the fold-down portion 86 perpendicular to scoreline 74. In a variation shown of FIG. 12, the scoreline 88 extends from an intermediate or center point of the cut 78 at an acute angle, for example 72°, relative to the scoreline 74; such acute angle being greater than the angle formed by the scoreline 82 relative to the scoreline 74. In FIG. 13, the angle of the scoreline 88 relative to score-line 74 is substantially closer to the angle of the scoreline 82 so that the scoreline 88 extends to the non-parallel edge 84 spaced from the scoreline 82. In variations of FIGS. 14 and 15, the angle of the scoreline 88 is obtuse relative to the scoreline 74; the line 88 in FIG. 14 extending to the perpendicular non-parallel side 80 while in FIG. 15 the scoreline 88 extends to the shorter parallel side 90 on the flap 64.
The top closure with the top flaps 60, 62, 64 and 66 wherein one top flap 64 includes the cut 78 and scorelines 82 and 88 is suitable for use on square or rectangular containers as well as other multipanel containers with three or more sides.
In FIGS. 2-11 there is illustrated a sequence of the steps used in assembling the container blank of FIG. 1 into a container. As shown in FIG. 2 the wall panels 20, 22, 24 and 26 are folded or bent about the scorelines 28, 30, and 32 to bring the wall panels 20, 22, 24 and 26 into a rectangular configuration. The joint flap 34 is bent about the score line 36 and overlapped with the wall panel 26 and secured thereto by suitable means, such as glue. Then the bottom flaps 42, 44, 46 and 40 are sequentially folded about the scorelines 52, 54, 56 and 50 over the bottom of the container and into the inside of the container so that the corner of the flap 40 on its non-parallel perpendicular edge maybe inserted underneath the flap 42 thus producing a locked bottom closure by means of the angled non-parallel sides of the bottom flaps overlapping the square corners of the adjoining flaps, FIG. 3.
With the flaps 60, 62, 64 and 66 initially extending vertically as shown in FIG. 4, the top closure of the container is assembled by folding the flaps 62, 60 and 66 sequentially in the named order, as shown in FIGS. 5, 6, and 7 so that portions 94 and 100 of the flaps 60 and 66 adjacent the non-perpendicular non-parallel edges 95 and 102 of the flaps 60 and 66 overlap portions 96 and 104 of the flaps 62 and 60 adjacent the perpendicular non-parallel edges 98 and 106 of the flaps 62 and 60. Then as shown in FIG. 8 the reverse-folding portion 92 is bent back along the scoreline 88 relative to the rest of the fold-down portion 86, and the fold-down portion 86 is bent down about the scoreline 82 as shown in FIG. 9. Subsequently as shown in FIG. 10, the flap 64 is bent about the scoreline 74 toward the top of the container while the edge 80 and the reverse-folding portion 92 are guided or tucked underneath the non-perpendicular non-parallel edge 116 of the panel 62. Continued downward folding of the flap 64 as shown in FIG. 11 results in the unfolding of the fold-down portion 86 as well as the unfolding of the reverse folded portion 92 until a portion 108 of the flap 64 adjacent to the edge 84 overlaps the square corner or portion 110 of the flap 66 adjacent to the perpendicular non-parallel edge 112 of the flap 66 and until a portion 114 of the flap 62 adjacent to its non-perpendicular non-parallel edge 116 overlaps the square corner or portion 118 of the flap 64 adjacent the perpendicular non-parallel edge 80 of the flap 64. Thus the flaps 60, 62, 64 and 66 are locked in a closed position due to the resilience of the hinges at the scorelines 82 and 88 maintaining the flap 64 in the straight or unfolded condition.
The scoreline 88 extending across the fold-down portion 86 intermediate the scoreline 82 and the perpendicular non-parallel edge 80 of the flap 64 transforms the fold-down portion 86 into an articulated insertion tab resulting in the container closure being suitable for closing containers which are full of non-compressible material. The reverse-folded portion 92 allows the fold-down portion 86 to be inserted underneath the non-perpendicular non-parallel edge of the flap 62 without requiring any substantial extension of the fold-down portion 86 into the center of the container. The prior art closures which did not include the scoreline 88 or the reverse folding portion 92 formed thereby could not readily be closed when filled with packed materials that are noncompressible since distortion of the portion of the flap adjacent the perpendicular non-parallel edge was necessary in order to insert such portion beneath the adjacent flap; this distortion increased the difficulty of making the insertion and often produced breaking of the corrugations or distortion of the closure flaps rendering the container less suitable for reuse.
Since the present invention is subject to many modifications, variations, or changes in detail, it is intended that all matter in the foregoing description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.
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A reverse folding portion of a fold-down portion of one flap is hinged for being bent reversibly relative to the fold-down portion during insertion of the fold-down portion under an adjacent flap to produce locking of the closure flaps with overlapping corners of adjacent closure flaps.
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CROSS-REFERENCE TO RELATED APPLICATIONS:
This application is a continuation-in-part of application Ser. No. 08/001,020, filed Jan. 6, 1993, which is a continuation of U.S. application Ser. No. 07/743,792, filed Aug. 12, 1991, now U.S. Pat. No. 5,180,016.
FIELD OF THE INVENTION
This invention relates generally to apparatus for completing downhole wells, and in particular to apparatus for setting hydraulic packers.
BACKGROUND OF THE INVENTION
In the course of completing an oil and/or gas well, it is common practice to run a string of protective casing into the well bore and then to run the production tubing inside the casing. At the well site, the casing is perforated across one or more production zones to allow production fluids to enter the casing bore. During production of the formation fluid, formation sand is also swept into the flow path. The formation sand is relatively fine sand that erodes production components in the flow path.
In some completions, however, the well bore is uncased, and an open face is established across the oil or gas bearing zone. Such open bore hole (uncased) arrangements are utilized, for example, in water wells, test wells, highly deviated and horizontal well completions. One or more sand screens are installed in the flow path between the production tubing and the open, uncased well bore face. The packer and sand screens are run in place while water is pumped under high pressure through a float shoe to wash the uncased bore and remove drill cuttings and clean well completion apparatus prior to placing the well into production. It is desirable that the wash job be performed as the completion apparatus is run into the well. After the annulus along the uncased well bore has been cleaned, the packer is customarily set to seal off the annulus in the zone where production fluids flow into the production tubing. Inflatable packers are preferred for use in sealing an uncased well bore.
DESCRIPTION OF THE PRIOR ART
The float shoe contains multiple ports through which fluids are jetted to wash drill cuttings from a well bore while a packer, screen or other set of well completion tools are run into the well bore. Because high differential pressures may be created by the jets at the end of the float shoe, it has been difficult to run hydraulically operated down hole well tools, such as hydraulic packers, in the same trip because of the potential for inadvertent set of the tools as a result of the back pressures generated in the annulus during the jet cleaning operation. Therefore, when such operations have been conducted previously, it has been necessary to first jet clean and clear the well bore, and then, in a separate trip, run the completion apparatus and production tubing into the well.
In the course of preparing the well for production, a well packer and screen along with a service tool and other well completion tools are run into the well on a work string, with the packer being releasably anchored against the well bore. When the well bore is cased, a hydraulically set packer having compressible seal elements and radially extendible anchor slips are utilized. When an uncased well bore is completed, an inflatable packer is utilized. Both types of packers may be set by the application of hydraulic pressure through setting ports.
Conventional hydraulic setting mechanisms have open ports which can allow the packer to be inadvertently set while running the packer and clearing drilling debris from the annulus with the float shoe. A build-up of hydraulic pressure might cause premature setting while pumping through the work string and circulating out through the annulus to remove debris. If the annulus or float shoe clogs up below the hydraulic setting mechanism, the pressure may build to a level which will cause the packer to set, allowing the elements to expand and engage the well bore. Some inflatable packers employ a check valve which prevents release of the pressure, and most hydraulically settable packers which include anchor slips have ratchet couplings that prevent retraction of the anchor slips. A prematurely set packer is typically required to be retrieved and then re-run.
OBJECTS OF THE INVENTION
The principal object of the present invention is to provide an improved hydraulic setting apparatus for use in combination with hydraulic settable completion equipment such as hydraulic packers which are run into a well simultaneously with the washing of the well bore without risk of causing the premature or unintentional operation of the hydraulically settable equipment.
A related object of the invention is to provide a hydraulic setting apparatus of the character described which maintains a hydraulic setting port in sealed condition during running operations, which may be selectively opened when it is desired to set the packer, and which automatically seals the hydraulic setting port after the tool has been set and/or the setting device is expended.
SUMMARY OF THE INVENTION
The foregoing objects are achieved according to the present invention in which a hydraulic setting apparatus has an isolation sleeve which covers setting ports and prevents entry of hydraulic setting pressure into a pressure settable tool such as an inflatable packer or a hydraulic packer. The setting apparatus has a production mandrel adapted for coupling and flow registration with the flow bore of the pressure settable completion tool. The setting apparatus mandrel is mechanically coupled to the mandrel of the pressure settable completion tool by a guide tube member which provides an enlarged counterbore chamber. The guide tube is intersected by radial setting ports which permit the entry of pressurized fluid for pressurizing a hydraulic pressure chamber in the completion tool.
In one embodiment, the hydraulic pressure chamber provides driving pressure for a piston actuated, hydraulically set packer. In an alternative embodiment, the pressure chamber is coupled in fluid communication with the pressure chamber of an inflatable packer. In both embodiments, a shiftable isolation sleeve opens the setting ports. A radially outwardly biased split C-ring is engaged against the bore of the isolation sleeve. Longitudinal travel of the split C-ring is limited by a shear collar which is releasably pinned to the isolation sleeve.
In one embodiment, the isolation sleeve is pinned to the guide tube by hollow shear pins. The packer is set by flowing a drop ball down the work string until it engages the seating surface provided by the C-ring. The hydraulic pressure is increased until the hollow shear pins shear and separate, and the isolation sleeve is shifted longitudinally through the bore to the open port position. After the packer has been set, the drop ball is still engaged against the C-ring seat. The hydraulic pressure is increased until the shear pins on the shear collar shear and separate, permitting the shear collar to shift toward an extended open position, with the outwardly biased split C-ring being shifted into the counterbore of the isolation sleeve. As this occurs, the isolation sleeve expands radially outwardly, thus permitting the drop ball to be shifted through the flow production bore to the next packer. At this point, the bore of the setting apparatus is no longer restricted which will allow passage of a tool string.
Consequently, it will be appreciated that the setting ports remained sealed by the isolation sleeve while running the packer and completion apparatus into the well bore, while circulating debris by high pressure jet flow from the annulus to the surface. Since the setting ports are sealed until the drop ball is flowed into place, the jet washing may proceed and there is no risk of prematurely setting the packer, even though the annulus may become blocked by debris.
Operational features and advantages of the invention will be understood by those skilled in the art upon reading the detailed description which follows with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, sectional view which illustrates installation of the setting apparatus of the present invention, as part of an expandable packer and well screens in a horizontal, uncased well bore;
FIG. 2 is a view similar to FIG. 1 in which the inflatable packer is inflated;
FIG. 3 is a longitudinal sectional view, partially broken away, of an hydraulic setting sleeve showing its components in the closed port, run position;
FIG. 4 is a view similar to FIG. 3 with the components of the hydraulic setting apparatus being shown in the open port, fill position;
FIG. 5 is a view similar to FIG. 4 with the components of the hydraulic setting apparatus being shown in the open port, fully inflated position;
FIG. 6 is a view similar to FIG. 5 with the components of the hydraulic setting apparatus being shown in the closed port, set position;
FIG. 7 is an elevational view, partially in section, showing the components of an alternative embodiment of a hydraulic setting apparatus in the run-in, sealed port position; and
FIG. 8 is a view similar to FIG. 5 in which the components of the hydraulic setting apparatus are in the open port, set position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the description which follows, like parts are indicated throughout the specification and drawings with the same reference numerals, respectively. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details of the invention.
Referring now to FIG. 1 and FIG. 2, multiple sand screens 10 are shown installed in an uncased well bore 12 which penetrates horizontally through an unconsolidated formation 14. Multiple screen sections 10 are assembled together, with the screen assembly being terminated by a float shoe 16.
The screens 10 are coupled to a work string 18 by a running tool 20 and an inflatable packer 22. As the completion equipment is run through the horizontal bore 12, water is pumped through the work string 18 and the production mandrels of the setting tool 20, the inflatable packer 22 and screens 10, where it is discharged through the float shoe 16 for washing the bore and circulating drill cuttings, filter cake and lost circulation material from the annulus 24 upwardly for recovery at the surface as indicated by the arrows. While the wash and circulation are proceeding, the packer 20 is in its deflated condition as shown in FIG. 1. It will be appreciated that the annulus 24 may become blocked by an accumulation of debris, particularly in the elbow transition region of the horizontal well bore. If that should occur, the packer 22 may inadvertently be set and seized against the uncased well bore, if the setting ports of the packer are exposed to the high pressure hydraulic fluctuations produced by operation of the float shoe 16.
Inadvertent set of the inflatable packer 22 is prevented, according to the present invention, by an isolation sleeve 26 which is shiftable from a sealing position, as shown in FIG. 3, in which a hydraulic setting port 28 is sealed, to a set position in which the setting port 28 is uncovered, as shown in FIG. 4.
The setting apparatus 20 has a tubular mandrel 30 with a longitudinal flow bore 32. The setting tool mandrel 30 is coupled to the mandrel 34 of the inflatable packer 22 by a guide tube 36. The guide tube 36 has a smooth bore 38 which is radially offset with respect to the setting tool flow bore 32.
The inflatable packer 22 includes an expandable bladder 40 which is secured and sealed by a coupling collar 42 and set screws 44, which secure the end of the bladder 40 onto a shoulder 46 formed on the guide tube 36. The guide tube 36 is intersected by the radially setting ports 28, which provide flow communication with the pressure chamber 48 defined in the annulus between the packer mandrel 34 and the bladder 40.
Referring now to FIG. 5, the isolation sleeve 26 is shiftable longitudinally along the smooth bore surface 38 of the guide tube 36. During run-in, the isolation sleeve 26 is biased to the covered, closed port position as shown in FIG. 3 by a coil compression spring 50.
Referring again to FIG. 3, a releasable seat is provided for a drop ball by an outwardly biased split C-ring 52. The C-ring 52 is received within the flow bore 54 of the isolation sleeve 26. Longitudinal displacement of the C-ring 52 is blocked by a shear collar 56. The shear collar 56 is received within a smooth counterbore 58 which intersects the isolation sleeve 26. The shear collar 56 is pinned to the isolation sleeve 26 by shear pins 60. The entrance to the setting port 28 is sealed by annular O-ring seals 62 and 64 so that the hydraulic expansion chamber 48 is sealed with respect to the flow bore 32 during run-in. The O-ring seals 62 and 64 are longitudinally spaced in slidable, sealing engagement between the isolation sleeve 26 and the smooth bore 38 of the guide tube. The C-ring seals 62 and 64 thus seal the flow bore 32 with respect to the inflation chamber 48 when the isolation sleeve is in the covered (RUN) position as shown in FIG. 3.
When it is desired to inflate the bladder 40, a drop ball 66 is dropped into the bore of the work string, and is flowed into sealing engagement against the C-ring 52. The internal C-ring 52, which is compressed within the smooth bore 54 of the isolation sleeve, has a sloped shoulder 68 which is coated with a polymeric coating 70. The coated shoulder 68 defines a valve seat for receiving and sealing against the drop ball 66.
When it is desired to expand the bladder 40 and set the packer 22, hydraulic pressure is applied sufficient to compress the spring 50 and move the isolation sleeve 26 from the covered position as shown in FIG. 3 to the uncovered position as shown in FIG. 4, thereby exposing the setting port 28. Hydraulic fluid is injected into the inflatable packer through the exposed setting port until the bladder 40 is fully expanded, as shown in FIG. 5. The hydraulic pressure is then increased to cause shearing separation of the shear pins 60.
When separation occurs, the shear collar 56 and the C-ring 52 are shifted longitudinally into the isolation sleeve counterbore 58, as shown in FIG. 5. When the C-ring 52 enters the counterbore 58, it expands radially into engagement with the counterbore surface, thereby releasing the drop ball 66 and permitting it to be flowed through the setting tool bore 32 into the packer mandrel bore 35. Simultaneously, the coil spring 50 will drive the isolation sleeve 26 back to the covered position so that the setting ports 28 are once again sealed and isolated. This will hold the hydraulic setting fluid in the packer expansion chamber 48 at the injection pressure. The packer mandrel bore 35 is also unrestricted since the C-ring ball seat has expanded radially into the isolation sleeve counterbore 58.
The drop ball 66 is then pumped into the next inflatable packer which is fitted with identical setting tool 20, and the setting process is repeated for setting the next packer.
It will be appreciated that the spring 50 may not be required for use in combination with inflatable packers which are inflated through a check valve.
The guide tube 36 is secured and sealed to the setting tool mandrel by a threaded union T, and its opposite end is secured and sealed to the packer mandrel 34 by a threaded union T.
For hydraulic packers which utilize anchor slips and expandable seal elements and for those inflatable packers which include check valve means coupled to the setting ports, the coil spring 50 is not needed. A packer setting tool with the hydraulic setting apparatus 72 constructed without a coil spring is illustrated in FIG. 7 and FIG. 8.
The construction of the setting apparatus 72 as shown in FIGS. 7 and 8 is similar to that shown in FIGS. 3 and 4, except that a bias spring is not needed. In that embodiment, the setting port 28 is releasably sealed by a shearable cup-like member or shear screw 74 which isolates pressure chamber 76 from bore 32 and pins the isolation sleeve 26 to the guide tube 36. The shear screw 74 is intersected by a longitudinally blind bore or pocket which serves as an open flow passage through the body of the screw when the screw has been separated by a shearing force. Otherwise, the construction is essentially the same as that shown in FIGS. 3 and 4.
Operation of the alternative setting tool embodiment 72 is different in that the setting port 28 is not resealed after it has been opened. This is not necessary when the setting tool 72 is used in combination with inflatable packers which are fitted with check valves, or when used in combination with hydraulically set packers which include ratchet couplings for preventing retraction of the anchor slips.
In the alternative embodiment shown in FIG. 7, the setting port 28 provides flow communication between the flow bore 32 and a hydraulic pressure chamber 76. The hydraulic chamber 76 is formed in the annulus between the guide tube 36 and a pressure cylinder 78. Pressurization of the chamber 76 causes a piston 80 to be driven longitudinally along the setting tool mandrel 84 for simultaneously applying a setting force to anchor slips and seal elements, for example as disclosed in U.S. Pat. No. 4,834,175 and U.S. Pat. No. 5,103,902, which are incorporated by reference. When it is desired to set the packer, the drop ball 66 is released and flowed into sealing engagement with the C-ring 52. The hydraulic pressure is increased until the hollow shear screws 74 separate, thus opening the setting port 74 and permitting the isolation sleeve 26 to be shifted along the smooth bore of the guide tube 36 to the uncovered position as shown in FIG. 8.
When the setting port 28 is opened, hydraulic fluid is pumped into the pressure chamber 76, thus causing the piston 80 to be driven longitudinally along the setting tool mandrel 84 for applying a setting force against the seal elements and anchor slips. After the seal elements and anchor slips have been set, the drop ball is still on the C-ring seat 70 and the shear collar 56 remains pinned to the isolation sleeve 26. The hydraulic pressure is increased until the shear pins 81 separate, thus permitting the C-ring 52 and the shear collar 56 to be shifted into the isolation sleeve counterbore 58. Upon entry into the counterbore, the C-ring 52 expands radially outwardly, thus releasing the drop ball 66 and permitting it to be flowed through the setting tool mandrel bore 85 to the next seat.
It will be appreciated that high pressure jet washing operations may be carried out while the setting tool, packer and screens are being run into the well bore, without causing premature set of the packer. Moreover, since the C-ring seat remains coupled to the isolation sleeve, it eliminates the need for an additional ball seat to set the packer.
Although the invention has been described with reference to a horizontal completion, and with reference to particular preferred embodiments for setting packers, the foregoing description is not intended to be construed in a limiting sense. For example, the hydraulic setting apparatus of the present invention may also be used for injecting completion chemicals through the exposed port into the annulus surrounding the tubing string. This arrangement permits the corrosive well treatment fluids to be pumped into the formation while isolating and protecting the interior of the hydraulically settable well completion apparatus. The hydraulic setting apparatus of the present invention may also be used to good advantage in alternative applications, for example, in oil wells, gas wells, environmental wells, including monitoring wells, recovery wells and disposal wells, and in combination with expandable packers as well as hydraulically set packers having anchor slips and other hydraulically operated tools which would benefit from selective hydraulic isolation. It is therefore contemplated that the appended claims will cover any such applications which incorporate the hydraulic setting apparatus of the present invention.
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A hydraulic setting apparatus has an isolation sleeve which covers setting ports and prevents entry of hydraulic setting fluid into a pressure settable tool such as an inflatable packer or a hydraulic packer. The mandrel of the setting tool is mechanically coupled to the mandrel of the pressure settable completion tool by a guide tube which provides an enlarged counterbore chamber. The guide tube is intersected by radial setting ports which permit entry of the pressurized fluid for pressurizing a hydraulic pressure chamber in the completion tool. A shiftable isolation sleeve opens and closes the setting ports. A radially outwardly biased split C-ring is engaged against the bore of the isolation sleeve. Longitudinal travel of the split C-ring is limited by a shear collar which is releasably pinned to the isolation sleeve.
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CROSS-REFERENCE TO RELATED APPLICATION
The present patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/622,820, filed Apr. 11, 2012, which application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The present disclosure relates generally to equipment used in fiber optic communications networks. More particularly, the present disclosure relates to apparatuses and methods used for the splicing of optical fibers in fiber optic networks.
BACKGROUND
Fiber optic communication systems are becoming prevalent in part because service providers want to deliver high band width communication capabilities to customers. Fiber optic communication systems employ a network of fiber optic cables to transmit large volumes of data and voice signals over relatively long distances. A typical fiber optic network may include a system of trunk fiber optic cables including optical fibers. Fiber optic networks also include drop cables that interconnect to fibers of the trunk cables at various locations along the lengths of the trunk cables. The drop cables can be routed from the trunk cables to subscriber locations or to intermediate structures such as drop terminals.
Optical fibers of cables (e.g., drop cables, trunk cables, etc.) are often connected to connectorized pigtails via splices (e.g., fusion splices). Splices are typically supported within splice trays. Such closures typically include sealed ports through which the trunk cables and drop cables enter the closures. While splice trays are effective for protecting splices (e.g., fusion splices) and for managing the optical fibers routed to and from splice locations, splice trays can be relatively large. Thus, at least for certain applications, splice trays can be a limiting factor in achieving high density in fiber optic connectivity.
Alternative methods and equipment for splicing of optical fibers in a fiber optic network are desired.
SUMMARY
Certain aspects of the present disclosure relate to compact and cost effective arrangements for splicing of optical fibers in a fiber optic network. Certain aspects of the present disclosure relate to compact and durable/rugged configurations for splicing connectorized pigtails to an optical fiber of a fiber optic cable.
According to one inventive aspect, the disclosure relates to an apparatus for use in a fiber optic network, the apparatus comprising a furcation tube having a first end and a second end, an optical fiber that passes through the furcation tube, the optical fiber having an end portion that extends outwardly beyond the second end of the furcation tube, and a heat-recoverable tube that fixes the optical fiber relative to the furcation tube adjacent the second end of the furcation tube, the heat-recoverable tube having a first portion affixed to the furcation tube and a second portion affixed to the end portion of the optical fiber.
A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. 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 of the broad inventive concepts upon which the embodiments disclosure herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of an optical fiber protective tubing assembly in accordance with the principles of the present disclosure;
FIG. 1A is a cross-sectional view taken along section line 1 A- 1 A of FIG. 1 ;
FIG. 2 is a transverse-cross sectional view of an optical fiber that is passed through a furcation tube of the protective tubing assembly of FIG. 1 in accordance with the principles of the present disclosure;
FIG. 3A illustrates a perspective view of an example fixation means used to fix the furcation tube to the buffer tube of the drop cable of the assembly of FIG. 1 , the fixation means provided in the form of a clamp structure;
FIG. 3B illustrates a cut-away view of the clamp structure shown in FIG. 3A ;
FIG. 3C illustrates a diagrammatic view of the clamp structure of FIG. 3A with the furcation tube affixed to the clamp structure and the buffer tube inserted within a bore of the clamp structure, the clamp structure shown in an unlocked orientation;
FIG. 3D illustrates the clamp structure of FIG. 3C in a locked orientation; and
FIG. 4 illustrates a kit for splicing a first optical fiber to a second optical fiber in accordance with the principles of the present disclosure.
DETAILED DESCRIPTION
The present disclosure relates generally to compact solutions for protecting optical fibers in a splice arrangement.
Referring to FIGS. 1 and 2 , an optical fiber protective tubing assembly 10 having features that are examples of inventive aspects in accordance with the principles of the present disclosure is illustrated.
In the illustrated example, the protective tubing assembly 10 is used in splicing a first optical fiber 12 (e.g., an optical fiber of a flat drop cable 14 having strength members 15 , see FIG. 1A ) to a second optical fiber 16 (e.g., an optical fiber protected by a buffer layer such as a tight buffer layer 96 ). In the Figures, the second optical fiber 16 is part of a connectorized pigtail 20 , wherein a first end portion 22 of the optical fiber 16 is terminated to a fiber optic connector 24 (e.g., an SC-type) and a second end portion 26 has been stripped of the buffer layer 96 and coating layers for splicing with the first optical fiber 12 as will be described in further detail below. The strength members 15 can be anchored to provide strain relief.
In accordance with an exemplary method of splicing the first optical fiber 12 to the second optical fiber 16 , an outer cable jacket 28 of the drop cable 14 is stripped to expose a length of loose buffer tube 30 (e.g., having an outer diameter of about 900 microns) of the drop cable 14 . The buffer tube 30 is then further stripped to expose a length of the first optical fiber 12 .
A transverse cross-sectional view of the optical fiber 12 that is exposed after the buffer tube 30 has been stripped is shown diagrammatically in FIG. 2 . The exposed optical fiber 12 includes a core 32 having an outer diameter of about 10 microns. A cladding layer 34 having an outer diameter of about 125 microns surrounds the inner core 32 . One or more coating layers 36 having a total outer diameter of about 250 microns surround the cladding layer 34 . In certain embodiments of the optical fiber used in the splice arrangement of the present disclosure, the coating layers 36 have a total outer diameter that is less than 400 microns. In certain embodiments, the coating layers 36 have a total outer diameter that is less than 300 microns. In certain embodiments, the coating layers 36 have a total outer diameter that is less than 270 microns. In certain embodiments, the total outer diameter of the coating layers 36 is in the range of 230 to 270 microns. In certain embodiments, the total outer diameter of the coating layers 36 is in the range of 240 to 260 microns.
It will be appreciated that the outer jacket 28 of the optical fiber 12 can be made of any number of different types of polymeric materials. In one embodiment, the outer jacket 28 is made of a medium density ultra-high molecular weight polyethylene.
The buffer tube 30 can also be made of any number of different polymeric materials. For example, the buffer tube 30 can be made of a polymeric material such as polyvinyl chloride (PVC). Other polymeric materials (e.g., polyethylenes, polyurethanes, polypropylenes, polyvinylidene fluorides, ethylene vinyl acetate, nylon, polyester, or other materials) may also be used.
The inner core 32 of the optical fiber 12 may be made of a glass material, such as a silica-based material, having an index of refraction. The cladding layer 34 is also normally made of a glass material, such as a silica based-material. The cladding layer 34 normally has an index of refraction that is less than the index of refraction of the core 32 . This difference between the index of refraction of the cladding layer 34 and the index of refraction of the core 32 allows an optical signal that is transmitted through the optical fiber 12 to be confined to the core 32 .
The inner layer of the one or more coating layers 36 is normally a polymeric material (e.g., polyvinyl chloride, polyethylenes, polyurethanes, polypropylenes, polyvinylidene fluorides, ethylene vinyl acetate, nylon, polyester, or other materials) having a low modulus of elasticity. The low modulus of elasticity of the inner layer functions to protect the optical fiber 12 from microbending. If the optical fiber 12 has more than one coating layer 36 , the outer layer is normally a polymeric material having a higher modulus of elasticity than the inner coating layer 36 . The higher modulus of elasticity of the outer layer functions to mechanically protect and retain the shape of optical fiber 12 during handling. According to another example embodiment, the one or more coating layers 36 may include acrylate as a material. Further details of examples of optical fibers are described in U.S. Pat. No. 8,041,166, the entire disclosure of which is incorporated herein by reference.
After a length of the optical fiber 12 has been exposed, a furcation tube 38 is placed over the optical fiber 12 . The furcation tube 38 includes a first end 40 and a second end 42 . The first end 40 of the furcation tube 38 is configured to be affixed to the buffer tube 30 of the drop cable 14 via a fixation means 44 . The furcation tube 38 is preferably sized or cut such that the optical fiber 12 has an end portion 46 that extends outwardly beyond the second end 42 of the furcation tube 38 after installation. For the purposes of the present disclosure, the end portion 46 of the optical fiber 12 is defined as that portion that extends outwardly beyond the second end 42 of the furcation tube 38 .
According to certain embodiments, the furcation tube 38 includes an outer diameter that is about 900 microns and inner diameter that is about 400 microns, thus allowing a 250 micron coated optical fiber 12 to pass freely through the tube 38 .
As shown in FIG. 1 , the embodiments disclosed herein can utilize a dimensionally recoverable article as the fixation means 44 to assist in fixing the first end 40 of the furcation tube 38 to the buffer tube 30 of the drop cable 14 . In certain embodiments, the first end 40 of the furcation tube 38 is slid axially into the buffer tube 30 prior to fixation. In other embodiments, the furcation tube can slide axially over the buffer tube prior to fixation.
A dimensionally recoverable article is an article the dimensional configuration of which may be made substantially to change when subjected to treatment. Usually these articles recover towards an original shape from which they have previously been deformed, but the term “recoverable” as used herein, also includes an article which adopts a new configuration even if it has not been previously deformed.
A typical form of a dimensionally recoverable article is a heat-recoverable article, the dimensional configuration of which may be changed by subjecting the article to heat treatment. In their most common form, such articles comprise a heat-shrinkable sleeve made from a polymeric material exhibiting the property of elastic or plastic memory as described, for example, in U.S. Pat. No. 2,027,962 (Currie); U.S. Pat. No. 3,086,242 (Cook et al); and U.S. Pat. No. 3,597,372 (Cook), the disclosures of which are incorporated herein by reference. The polymeric material has been crosslinked during the production process so as to enhance the desired dimensional recovery. One method of producing a heat-recoverable article comprises shaping the polymeric material into the desired heat-stable form, subsequently crosslinking the polymeric material, heating the article to a temperature above the crystalline melting point (or, for amorphous materials the softening point of the polymer), deforming the article, and cooling the article while in the deformed state so that the deformed state of the article is retained. In use, because the deformed state of the article is heat-unstable, application of heat will cause the article to assume its original heat-stable shape.
In certain embodiments (e.g., in the depicted embodiments of the present disclosure), the heat-recoverable article is a sleeve or a tube 48 that can include a longitudinal seam or can be seamless. In certain embodiments, the tube 48 has a dual wall construction including an outer, heat-recoverable annular layer, and an inner annular adhesive layer. In certain embodiments, the inner annular adhesive layer includes a hot-melt adhesive layer.
In one embodiment, the heat-recoverable tube 48 is initially expanded from a normal, dimensionally stable diameter to a dimensionally heat unstable diameter that is larger than the normal diameter. The heat-recoverable tube 48 is shape-set to the dimensionally heat unstable diameter. This typically occurs in a factory/manufacturing setting. The dimensionally heat unstable diameter is sized to allow the heat-recoverable tube 48 to be inserted over two components desired to be coupled together. After insertion over the two components, the tube 48 is heated thereby causing the tube 48 to shrink back toward the normal diameter such that the tube 48 radially compresses against the two components to secure the two components together. The adhesive layer is preferably heat activated during heating of the tube 48 .
According to one example method, when performing a field operation, a craftsperson can install the heat-recoverable tube 48 over an end of the buffer tube 30 so that there is approximately 1 inch of overlap. The craftsperson can then insert the 250 micron coated fiber into the 900 micron furcation tube 38 , after cleaning the gel/grease off the fiber. The first end 40 of the furcation tube 38 is then inserted axially into the buffer tube 30 . As so inserted, the buffer tube 30 overlaps the furcation tube 38 and the heat-recoverable tube 48 overlaps both the buffer tube 30 and the furcation tube 38 . The heat-recoverable tube 48 can then be heated and shrunken down onto the loose buffer tube 30 and the furcation tube 38 . The adhesive material within the heat-recoverable tube 48 establishes a strong bond between the buffer tube 30 and the heat-recoverable tube 48 and between the furcation tube 48 and the heat-recoverable tube 48 . This coupling of the buffer tube 30 to the 900 micron furcation tube 38 via the heat-recoverable tube 48 is completed first, and then the second end 42 of the furcation tube 38 is processed next, as will be discussed in further detail below.
Alternatively, the fixation means 44 used to fix the furcation tube 38 to the buffer tube 30 may include a clamp structure 50 . An example of a clamp structure 50 suitable for use in the protective tubing assembly 10 of the present disclosure is shown in FIGS. 3A-3D . Referring to FIGS. 3A-3D , the clamp structure 50 may include a main housing portion 52 having a first end 54 and a second end 56 and a bore 58 extending therethrough. Extending longitudinally from the second end 56 is a support structure 60 . The support structure 60 is configured to provide a platform for affixing the furcation tube 38 to the clamp structure 50 . According to one example embodiment, the furcation tube 38 can be fixed to the support structure 60 with further heat-recoverable tubing 62 , as illustrated in FIGS. 3C-3D .
The buffer tube 30 of the drop cable 14 is first inserted through the bore 58 of the clamp structure 50 in a direction extending from the first end 54 toward the second end 56 of the main housing 52 . The bore 58 and the support structure 60 are configured such that when the furcation tube 38 is placed over the exposed fiber 12 and is affixed to the support structure 60 of the clamp 50 , the furcation tube 38 generally aligns with the buffer tube 30 that has been inserted through the bore 58 of the clamp 50 , and in some embodiments can slide axially inside or axially over the buffer tube.
Clamp structure 50 further includes a lever arm 64 that is pivotable with respect to the main housing portion 52 via, for example, a living hinge 66 . The lever arm 64 includes a camming lobe portion 68 that communicates with the bore 58 of the clamp structure 50 and that is used to press down on the buffer tube 30 for locking it in place. The camming lobe 68 is preferably sized so as to not damage the optical fiber 12 within the buffer tube 30 .
A free end 70 of the pivotable lever 64 is provided with a first snap-fit structure 72 that is configured to interlock with a second snap-fit structure 74 provided on the main housing portion 52 for locking the buffer tube 30 in place after the lever 64 has been pivoted. As shown in FIGS. 3A and 3B , the first and second snap-fit structures 72 , 74 may be provided in the form of protrusions 76 on the lever arm 64 and recesses 78 on the main housing portion 52 . The protrusions 76 are angled outwardly from the lever arm 64 so as to be able to ride over portions of the main housing 52 forming the recesses 78 when the lever arm 64 is pivoted toward the main housing portion 52 and locked into place and so as to prevent their disengagement from the recesses 78 in an opposite direction. The recesses 78 include complementary shapes for providing the one-way interlock.
The clamp structure 50 is configured such that the amount of buffer tube compression is controlled by the amount of travel imparted to the lever arm 64 . The desired amount of compression to the loose buffer tube 30 is preferably engineered to be enough to mechanically interfere and clamp the tube 30 in place, but to avoid creating interference with the optical fiber inside the loose buffer tube 30 . Loose buffer tubes 30 can typically range from about 1.9 mm in outer diameter to 3.0 mm in outer diameter. According to certain embodiments, the clamp structure 50 can be configured to accommodate buffer tubes 30 of varying outer diameter. As such, the camming lobe portion 68 of the clamp 50 can be designed to provide varying amounts of interference based upon the travel of the cam-lever arm 64 for accommodating buffer tubes 30 of varying outer diameters. According to one example embodiment, the clamped buffer tube with the optical fiber therein along the clamping direction has a total outer dimension of about 1.5 mm. As such, if a 3 mm buffer tube is used, the resultant interference created by the cam lobe 68 must be about 1.5 mm. And, if a 2 mm buffer tube is used, the resultant interference created by the cam lobe 68 must be about 0.5 mm.
The clamp 50 may include a plurality of different interlock positions for locking the lever arm 64 to the main housing portion 52 for accommodating different sized buffer tubes 30 . In this manner, depending upon the size of the loose buffer 30 clamped to the main housing 52 , the varying profile of the cam lobe 68 can be utilized by locking the lever arm 64 in a plurality of discrete positions.
The bore 58 of the clamp structure 50 may include a dimension along the clamping direction of about 3.1 mm to accommodate loose buffer tubes of the varying sizes noted above. According to one example embodiment, the targeted compression location on the loose buffer tube 30 is about 12 mm from the end of the buffer tube. Thus, 12 mm of uncompressed tube could provide mechanical interference to the cam lobe 68 if the cam lobe 68 were pulled toward the end of the tube.
The clamp structure 50 or the portions of the clamp structure providing the controlled mechanical deformation to the loose buffer tube 30 can be made from a metal or a polymeric material.
In accordance with the protective tubing assembly 10 , once the buffer tube 30 and the furcation tube 38 are affixed, the end portion 46 of the optical fiber 12 that extends outwardly from the furcation tube 38 receives another heat-recoverable tube 80 . Similar to tube 48 that might be used to fix the furcation tube 38 to the buffer tube 30 of the drop cable 14 , the heat-recoverable tube 80 utilizes a layer of heat recoverable material surrounding an adhesive layer. A first portion 82 of heat-recoverable tube 80 is affixed directly on the furcation tube 38 and a second portion 84 is affixed to the optical fiber portion 46 that extends beyond the furcation tube 38 , as illustrated in FIG. 1 . As such, the second portion 84 of heat-recoverable tube 80 is affixed on the one or more coating layers 36 around the cladding layer 34 of the optical fiber 12 (e.g., via adhesive or friction).
According to one embodiment of the protective tubing assembly 10 of the present disclosure, the optical fiber 12 is centered within the second portion 84 of the heat-recoverable tube 80 so that when heat-recoverable tube 80 is stripped to expose the optical fiber 12 for splicing, it can be done without damaging the optical fiber 12 .
According to one example embodiment of the protective tubing assembly 10 of the present disclosure, the second portion 84 of heat-recoverable tube 80 that is affixed to the optical fiber 12 may have an outer diameter similar to the size of the outer diameter of the buffer tube of the connectorized pigtail 20 . According to one embodiment, the second portion 84 of heat-recoverable tube 80 that is affixed to the optical fiber 12 has an outer diameter less than 1100 microns. According to another embodiment, the second portion 84 of heat-recoverable tube 80 that is affixed to the optical fiber 12 has an outer diameter less than 1000 microns. According to another embodiment, the second portion 84 of heat-recoverable tube 80 that is affixed to the optical fiber 12 has an outer diameter in the range of 850-950 microns. According to another embodiment, the outer diameter of the second portion 84 of heat-recoverable 80 may be between about 910 microns and 925 microns. The heat-recoverable tube 80 closely surrounds the coated fiber 12 and forms a tight or semi-tight buffer about the coated fiber 12 .
According to one embodiment, heat-recoverable tube 80 is shrunk-down on the outer diameter of the optical fiber 12 such that the second portion 84 of heat-recoverable tube 80 has an inner diameter that matches the outer diameter of the optical fiber 12 . For example, when the optical fiber 12 has an outer diameter less than 400 microns, the second portion 84 of heat-recoverable tube 80 has an inner diameter that is less than 400 microns. As another example, when the optical fiber 12 has an outer diameter less than 300 microns, the second portion 84 of heat-recoverable tube 80 has an inner diameter that is less than 300 microns. As another example, when the optical fiber 12 has an outer diameter in the range of 230-270 microns, the second portion 84 of heat-recoverable tube 80 is shrunk-down on the outer diameter of the optical fiber 12 such that the second portion 84 of heat-recoverable tube 80 has an inner diameter that is in the range of 230-270 microns.
After heat-recoverable tube 80 has been affixed to both the furcation tube 38 and the optical fiber 12 of the drop cable 14 , a length of the second portion 84 of heat-recoverable tube 80 is stripped away to expose a length 86 of the optical fiber 12 that extends outwardly from heat-recoverable tube 80 . When stripping heat-recoverable tube 80 , the one or more coating layers 36 of the optical fiber 12 are also stripped at the same time to expose the cladding layer 34 of the optical fiber 12 or can be stripped in a subsequent step. As noted above, the exposed cladding layer 34 has an outer diameter of about 125 microns in certain embodiments of the optical fiber 12 .
Still referring to FIG. 1 , this exposed portion 86 of the first optical fiber 12 is the portion that is to be spliced (e.g., fusion spliced) to the second optical fiber 16 of the connectorized pigtail 20 .
As noted above, the first end portion 22 of the connectorized pigtail 20 is terminated to a fiber optic connector 24 (e.g., an SC-type) and the second end portion 26 is the portion that is configured to be spliced to the first optical fiber 12 . In a fiber optic connector having an SC footprint, a connector body 88 is surrounded by a slidable release sleeve 90 that is used to release the connector 24 from an SC-type fiber optic adapter, as is known in the art. An end of the first end portion 22 of the pigtail 20 is terminated to a ferrule 92 mounted at a front end of the connector body 88 . The connector 24 includes a boot 94 at a rear end of the connector for providing bend radius protection to the second portion 26 of the pigtail that protrudes from the fiber optic connector 24 .
The second portion 26 of the pigtail 20 that protrudes from the fiber optic connector 24 includes the tight or semi-tight buffer tube 96 that closely surrounds the second optical fiber 16 . The second optical fiber 16 can have a construction similar to the first optical fiber 12 . For example, the second optical fiber 16 can include a core having a diameter of about 10 microns, a cladding layer having an outer diameter of about 125 microns, and one or more coating layers having a total outer diameter of about 250 microns.
The tight buffer tube 96 may include an outer diameter of about 900 microns. And, similar to the first optical fiber 12 , the second optical fiber 16 , in certain embodiments, may include coating layers having a total outer diameter that is less than 400 microns. In certain embodiments, the coating layers may have a total outer diameter that is less than 300 microns. In certain embodiments, the coating layers may have a total outer diameter that is less than 270 microns. In certain embodiments, the total outer diameter of the coating layers may be in the range of 230 to 270 microns. In certain embodiments, the total outer diameter of the coating layers may be in the range of 240 to 260 microns.
According to the protective tubing assembly 10 and the splicing method of the present disclosure, the buffer tube 96 of the second end portion 26 of the connectorized pigtail 20 is stripped to expose a length 98 of the optical fiber 16 that extends outwardly from the tight buffer tube 96 of the pigtail 20 . When stripping the tight buffer tube 96 , the one or more coating layers of the second optical fiber 16 are also stripped at the same time to expose the cladding layer of the second optical fiber 16 , or can be stripped at a subsequent step. As noted above, the exposed cladding layer has an outer diameter of about 125 microns in certain embodiments of the second optical fiber 16 . Referring to FIG. 1 , this exposed portion 98 of the second optical fiber 16 is the portion that is to be spliced (e.g., fusion spliced) to the first optical fiber 12 of the drop cable 14 .
In splicing the first optical fiber 12 of the drop cable 14 to the second optical fiber 16 of the connectorized pigtail 20 , a splice protection tube or sleeve 100 is used. The splice protection tube 100 is positioned over the splice between the first optical fiber 12 and the second optical fiber 16 . According to the present assembly, the splice protection tube 100 is also a heat-recoverable tube that is affixed to the second portion 84 of the second heat-recoverable tube 80 and to the buffer layer 96 of the connectorized pigtail 20 . Similar to heat-recoverable tubes 48 , 80 , the splice protection tube 100 includes a heat recoverable layer formed of a heat recoverable material surrounding an adhesive layer. In addition, the splice protection tube 100 includes a reinforcing rod 102 positioned inside the heat recoverable layer, wherein the reinforcing rod 102 is configured to extend across the splice and be adhesively affixed to the buffer layer 96 of the connectorized pigtail 20 and the second portion 84 of heat-recoverable tube 80 . An example splice protection tube or sleeve similar to sleeve 100 and the method for use thereof are described in detail in U.S. Pat. No. 6,623,181, the entire disclosure of which is incorporated herein by reference.
According to one embodiment, both the second portion 84 of heat-recoverable tube 80 and the outer buffer layer 96 of the connectorized pigtail 20 are similarly sized in that each have an outer diameter in the range of about 850 to 950 microns. Furthermore, an active alignment device can be used to align the cores of the fibers 12 , 16 prior to splicing. Because the fiber 12 is tightly covered by the tube 80 and the tube 96 tightly covers the fiber 16 , the tubes 80 , 16 can be held by the active alignment device during active alignment of the fibers 12 , 16 .
Referring now to FIG. 4 , the optical fiber protective tubing assembly 10 of the present disclosure may be provided in the form of a kit 104 . The kit 104 can be supplied as a package containing telecommunications parts. According to one embodiment, the kit 104 includes the heat-recoverable tube 48 that is used to fix the furcation tube 38 to the buffer tube 30 of the drop cable 14 and the heat-recoverable tube 80 that is used to fix the optical fiber 12 of the drop cable 14 to the furcation tube 38 at the other end of the furcation tube 38 . As noted previously, heat-recoverable tube 48 (the one that is used for fixing the furcation tube 38 to the buffer tube 30 of the drop cable 14 ) may be replaced by the clamp structure 50 and an additional heat-recoverable tube 62 that is used with the support structure 60 of the clamp 50 . The kit 104 also includes a length of the furcation tubing 38 . The kit 104 further includes the splice protection tube or sleeve 100 that is used to be positioned over the splice between the two optical fibers 12 , 16 . A fiber optic connector 24 with a pigtail 20 extending therefrom, wherein the pigtail 20 includes an optical fiber 16 having a 900-micron buffer tubing 96 is also included in the kit 104 , as illustrated in FIG. 4 .
From the foregoing detailed description, it will be evident that modifications and variations can be made in the devices or methods of the disclosure without departing from the spirit or scope of the inventive aspects.
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An apparatus for use in a fiber optic network includes a furcation tube having a first end and a second end. An optical fiber passes through the furcation tube, the optical fiber having an end portion that extends outwardly beyond the second end of the furcation tube. A heat-recoverable tube fixes the optical fiber relative to the furcation tube adjacent the second end of the furcation tube, the heat-recoverable tube having a first portion affixed to the furcation tube and a second portion affixed to the end portion of the optical fiber.
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BACKGROUND OF THE INVENTION
The present invention relates to computers, and more particularly to determining texture coordinates in compute graphics.
Textures are used in computer graphics to make computer-generated images appear more realistic. A texture consists of a number of texture elements ("texels"). Each texel has a value corresponding to color, intensity, or some other image parameter. Texel values are used to modify the color, intensity, or other parameters of corresponding pixels in the computer image. See, for example, M. Segal et al., "Fast Shadows and Lighting Effects Using Texture Mapping", Computer Graphics, 26, 2, July 1992, pages 249-252, incorporated herein by reference.
In the computer, texels are identified by texture coordinates. Thus, finding a proper texel for a pixel involves determining the texel's texture coordinates. It is desirable to provide small and inexpensive circuits for determining the texture coordinates.
SUMMARY
The present invention provides circuits and methods for determining texture coordinates. In some embodiments, the circuits are small and inexpensive.
In some embodiments, besides the texture coordinates, a computer system uses world coordinates and screen coordinates. The world coordinates (x,y,z) are used to represent objects whose images are to be displayed on a computer screen. The screen coordinates (x',y') identify pixels on the screen. The world and screen coordinates are chosen so that a point having world coordinates (x,y,z) will be represented on the screen as a point with screen coordinates x'=x/z, y'=y/z.
The object surface to be represented on the screen is divided into polygons whose vertices have known world and texture coordinates. The screen coordinates (x',y') of the vertex images are set to (x/z, y/z) as described above. Then straight-line segments are drawn that interconnect the vertex images. Then individual points on different segments are connected by other straight-line segments to fill the polygons. See, for example, P. Burger and D. Gillies, "Interactive Computer Graphics" (1989), pages 76-110 incorporated herein by reference; J. D. Foley et al., "Computer Graphics: Principles and Practice" (1996), pages 72-104 incorporated herein by reference.
For each image point Q' having (possibly unknown) texture coordinates (u,v), let us introduce modified texture coordinates (u',v'): u'=u/z, v'=v/z, where z is the world coordinate of a point Q whose image is Q'. The images of the vertices have known texture coordinates (u,v), and therefore their modified texture coordinates (u',v') can be determined. Suppose a point Q' having screen coordinates (x',y') lies in a segment with end points Q 1 ', Q 2 '. Suppose the point Q 1 ' has screen coordinates (x 1 ',y 1 ') and modified texture coordinates (u 1 ',v 1 '), and the point Q 2 ' has screen coordinates (x 2 ',y 2 ') and modified texture coordinates (u 2 ',v 2 '). Then we find the modified texture coordinates (u',v') of Q' by linear interpolation:
(u',v')=(1-t)(u.sub.1 ',v.sub.1 ')+t(u.sub.2 ',v.sub.2 ')
where t is such that
(x',y')=(1-t)(x.sub.1 ',y.sub.1 ')+t(x.sub.2 ',y.sub.2 ')
We find the texture coordinates of Q' by dividing (u',v') by 1/z where z is the world coordinate of a point Q whose image is Q'. 1/z is determined by linear interpolation.
In some embodiments, the division by 1/z is implemented as a multiplication by the inverse of 1/z (that is, multiplication by z (which may be unknown)). To speed up determining the inverse of 1/z, a lookup table is provided that stores the inverses of some values. To make the texture coordinates circuit smaller and less expensive, the lookup table is made small. Thus, the lookup table contains fairly few inverse values (32 inverse values in some embodiments). To improve accuracy, the inverse values not contained in the lookup table are determined by linear interpolation.
Once the texture coordinates are determined, the texel values are applied to the pixel to improve the image quality.
Other features and advantages of the invention are described below. The invention is defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 illustrate an object and its image on a screen.
FIG. 3 is a block diagram of a circuit generating texture coordinates for the images of FIGS. 1 and 2.
FIG. 4 is a detailed block diagram of a portion of the circuit of FIG. 3.
FIG. 5 illustrates bit processing by a circuit which is a portion of the circuit of FIG. 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate displaying an object on a computer screen 110. The viewpoint is shown at O. The object is to be displayed so that it would appear to the viewer to be at a position 120. The image on screen 110 is a perspective projection of the object (or part of the object) onto the screen 110 with the center of projection being at the viewpoint O.
The object includes a straight-line segment with end points Q 1 , Q 2 . The point Q 1 is to be displayed at point Q 1 ' of screen 110. The point Q 2 is to be displayed at point Q 2 ' of the screen. The segment interconnecting the points Q 1 , Q 2 is to be displayed as a segment interconnecting the points Q 1 ', Q 2 '.
Object 120 is to be displayed with a texture. Points Q 1 , Q 2 have known texture coordinates (u 1 ,v 1 ) and (u 2 ,v 2 ) respectively. Clearly, Q 1 ' and Q 2 ' have the same texture coordinates as Q 1 and Q 2 respectively. For any other point Q' in the segment Q 1 'Q 2 ', texture coordinates (u,v) are determined as described below.
The world coordinate system is chosen to be a Cartesian system xyz having the origin at the viewpoint O. The x and y axes are parallel to screen 110. The z axis is perpendicular to the screen. Screen 110 is located in the plane z=1. The screen has a Cartesian screen coordinate system x'y' with the origin at the intersection O' of the screen with the z axis. It can be shown that for any point Q on object 120, if the point Q has world coordinates (x,y,z) then the image of the point Q has screen coordinates x'=x/z, y'=y/z.
Denote the world coordinates of points Q 1 and Q 2 by (x 1 ,y 1 ,z 1 ) and (x 2 ,y 2 ,z 2 ) respectively. Then the point Q 1 ' has screen coordinates (x 1 ',y 1 ')=(x 1 /z 1 ,y 1 /z 1 ) and the point Q 2 ' has screen coordinates (x 2 ',y 2 ')=(x 2 /z 2 ,y 2 /z 2 ).
The screen coordinates of the pixels in the image Q 1 'Q 2 ' are determined using known scan conversion techniques. Some scan conversion techniques are described in J. D. Foley et al., "Computer Graphics: Principles and Practice" (1996), pages 72-81 incorporated herein by reference. Given the screen coordinates (x',y') of the pixel Q', the texture coordinates (u,v) of Q' are generated by the circuitry of FIG. 3 as follows.
Circuit 310 receives the screen coordinates x',y',x 1 ',y 1 ',x 2 ',y 2 ', and generates a line parameter t such that:
(x',y')=(1-t)(x.sub.1 ',y.sub.1 ')+t(x.sub.2 ',y.sub.2 ') (1)
The equality (1) may be only approximate because, among other things, the pixels in the segment Q 1 'Q 2 ' are a discrete approximation of a straight-line segment. In some embodiments, t is generated as in the following pseudocode:
If x 1 '≠x 2 ', then t=(x'-x 1 ')/(x 2 '-x 1 ') else t=(y'-y 1 ')/(y 2 '-y 1 ')
Circuit 310 also generates the signal 1-t.
Circuit 320 receives t, 1-t and also receives the following signals:
u 1 '=u 1 /z 1 ,
v 1 '=v 2 /z 1 ,
u 2 '=u 2 /z 2 ,
u 2 '=v 2 /z 2 .
Circuit 320 generates modified texture coordinates u',v' as follows:
(u',v')=(1-t)(u.sub.1 ',v.sub.1 ')+t(u.sub.2 ',v.sub.2 ') (2)
Circuit 330 receives the signals t, 1-t, 1/z 1 , 1/z 2 and generates a signal w' as follows:
w'=(1-t)(1/z.sub.1)+t(1/z.sub.2). (3)
Circuit 340 receives u', v' and w' and generates the texture coordinates (u,v) using the formulas:
u=u'/w',
v=v'/w'. (4)
FIG. 4 is a detailed block diagram of circuit 340. To speed up the division by w', circuit 340 uses a lookup table (LUT) 410 to store the values 1/w'. To reduce the circuit cost and area, LUT 410 is made fairly small. In some embodiments, LUT 410 includes only 32 entries 1/w i . To determine 1/w more accurately, circuit 340 performs linear interpolation thus at least partially compensating for the small size of LUT 410.
LUT 410 stores the values of 1/w only for w in a predetermined interval, for example, in the interval 0.5, 1!. Normalize logic 420 normalizes the signal w' to produce a value in that interval, as described below.
LUT 410 stores thirty-two 19-bit entries. The input to LUT 410 is a 5-bit integer index i=0, 1, 2, . . . 31. In response to the index i, LUT 410 produces a 19-bit signal 1/w i where w i is in the interval 0.5, 1!. In some embodiments, the interval 0.5, 1! is divided into 32 equal parts, and the values w i are the end points of these parts. More particularly:
w.sub.i =(32+i)/64 (5)
LUT 410 stores the values LUT(i)=1/w i =64/(32+i). Each of these values is represented in a fixed point form in 19 bits. In some embodiments, LUT 410 stores the integer values LUT(i)=64/(32+i)*(2 19 -1). These values give better accuracy in the linear interpolation of 1/w'. LUT 410 for this embodiment is described in Appendix A below in the hardware description language Verilog®. Verilog® is described, for example, in D. E. Thomas, J. P. Moorby, "The Verilog® Hardware Description Language" (1991) hereby incorporated herein by reference. LUT 410 of Appendix A is implemented by combinational logic.
Operation of normalize logic 420 is illustrated in FIG. 5. Values w' are represented in 24 bits in a fixed point form. The binary point is presumed to be before the most significant bit 23. Normalize logic 420 determines the position of the most significant "1" in w'. The normalization operation is a left shift of w' so that the most significant "1" gets into the most significant bit position 23 Normalizer 420 determines the number k of the most significant zeros in w'. This number k is provided to barrel shifter 430 (FIG. 4) to perform denormalization at the output of circuit 340. In FIG. 5, k=4 since the most significant "1" is in bit position 19.
The five bits following the most significant "1" (bits w' 18:14! in the example of FIG. 5) form the index i provided to LUT 410. The remaining less significant bits of w' (bits w' 13:0! in the example of FIG. 5) form the most significant bits of 18-bit signal Δ provided to multiplier 440 to perform linear interpolation. The remaining k bits of Δ are set to 0.
Let w n denote the normalized w', i.e. w n is w' shifted left by k bits. Thus, w n is in the interval 0.5, 1!. w n =w i +Δ r , where:
i is the index provided by normalize logic 420, and w i is defined by equation (5) above, and
Δ r =0.000000Δ.
Using linear interpolation, we obtain:
1/w.sub.n =1/w.sub.i +Δr(1/w.sub.i -1/w.sub.i+1)/(w.sub.i -w.sub.i+1)(6)
where w i+1 =1 for i=31.
Equation (6) implies:
1/w.sub.n =1/w.sub.i -Δ.sub.r /(w.sub.i w.sub.i+1) (7)
LUT 450 stores the values 1/(w i w i+1 ) for each i. LUT 450 receives the index i from normalize logic 420. In some embodiments, LUT 450 is a combinational circuit. The LUT 450 output 1/(w i w i+1 ) is provided to multiplier 440. Multiplier 440 also receives the signal Δ as described above. Multiplier 440 generates the signal Δ r /(w i w i+1 ). This signal is provided to subtractor 454. Subtractor 454 also receives the 19-bit signal 1/w i from LUT 410. Subtractor 454 performs the subtraction of the equation (7) and thus generates the signal 1/w n . This signal is provided to multipliers 460, 464. Multiplier 460 receives u' and generates u'*(1/w n ). Multiplier 464 receives v' and generates v'*(1/w n ) The outputs of the two multipliers are connected to barrel shifter 430. Shifter 430 shifts u'*(1/w n ) and v'*(1/w n ) left by k bits and thus generates the respective texture coordinates u, v.
In some embodiments, the texture coordinates u, v are used to access the texture for a texel value. In some embodiments, the texture coordinates u, v are used to determine the "MIP map", which is a possibly pre-filtered texture. Then the texel value is provided by the MIP map, or by adjacent MIP maps. See U.S. patent application "Determining the Level of Detail for Texture Mapping in Computer Graphics", Ser. No. 08/749,859, filed by Sang-Gil Choi on Nov. 15, 1996 and hereby incorporated herein by reference.
Appendix B is a source code for a program simulating one embodiment of circuit 340. The program is written in the programming language C.
Since the inputs of the circuit of FIG. 3 include modified texture coordinates (u 1 ',v 1 '), (u 2 ',v 2 ') of points Q 1 ', Q 2 ' and not the texture coordinates themselves, the texture coordinates of points Q 1 ', Q 2 ' need not be known. For example, in some embodiments, Q 1 ' is a point in a segment Q 3 ', Q 4 '. Points Q 3 ', Q 4 ' are vertices with known texture coordinates. The modified texture coordinates of Q 1 ' are determined from the modified texture coordinates of Q 3 ', Q 4 ', using the linear interpolation technique of equation (2) above. The value 1/z is determined from the 1/z coordinates of points Q 3 , Q 4 using the linear interpolation technique of equation (3).
The above embodiments illustrate but do not limit the invention. In particular, the invention is not limited by the number of bits in any particular signal or by the number of entries in any lookup table. The invention is defined by the appended claims.
______________________________________APPENDIX A______________________________________/****************************************************\// This is VerilogHDL code file for//Look up table part of integer divider.\****************************************************//* PAL for division */module pla.sub.-- lut (index, out); parameter DELAY = 1; // Delay time input 4:0! index; output 18:0! out; reg 18:0! out; always @(index) begincase(index) // synopsys parallel.sub.-- case 5'b00000 : # DELAY out = 19'h7ffff; 5'b00001 : # DELAY out = 19'h7c1f0; 5'b00010 : # DELAY out = 19'h78787; 5'b00011 : # DELAY out = 19'h75075; 5'b00100 : # DELAY out = 19'h71c71; 5'b00101 : # DELAY out = 19'h6eb3e; 5'b00110 : # DELAY out = 19'h6bca1; 5'b00111 : # DELAY out = 19'h69069; 5'b01000 : # DELAY out = 19'h66666; 5'b01001 : # DELAY out = 19'h63e70; 5'b01010 : # DELAY out = 19'h61861; 5'b01011 : # DELAY out = 19'h5f417; 5'b01100 : # DELAY out = 19'h5d174; 5'b01101 : # DELAY out = 19'h5b05b; 5'b01110 : # DELAY out = 19'h590b2; 5'b01111 : # DELAY out = 19'h57262; 5'b10000 : # DELAY out = 19'h55555; 5'b10001 : # DELAY out = 19'h53978; 5'b10010 : # DELAY out = 19'h51eb8; 5'b10011 : # DELAY out = 19'h50505; 5'b10100 : # DELAY out = 19'h4ec4e; 5'b10101 : # DELAY out = 19'h4d487; 5'b10110 : # DELAY out = 19'h4bda1; 5'b10111 : # DELAY out = 19'h4a790; 5'b11000 : # DELAY out = 19'h49249; 5'b11001 : # DELAY out = 19'h47dc1; 5'b11010 : # DELAY out = 19'h469ee; 5'b11011 : # DELAY out = 19'h456c7; 5'b11100 : # DELAY out = 19'h44444; 5'b11101 : # DELAY out = 19'h4325c; 5'b11110 : # DELAY out = 19'h42108; 5'b11111 : # DELAY out = 19'h41041;endcase endendmodule______________________________________APPENDIX B______________________________________/***************************************************// This is C code file// for divider of integer. (32 entry)*****************************************************/int LUT 33!;int global.sub.-- fixed;main()void Down.sub.-- load.sub.-- lut();int Interpolate.sub.-- lut();float a, data;int i;int nbitsx;int result.sub.-- div;int fixed.sub.-- data;float result.sub.-- data;int startx, endx;float float.sub.-- fixed.sub.-- data;long long ll.sub.-- result.sub.-- div;Down.sub.-- load.sub.-- lut(); /* Compose of Look-Up Table *//* Find the number of bits effective */for(i=64; i<65535; i++){fixed.sub.-- data = (int) (16777215.0 / i);nbitsx = Find.sub.-- nbitsx(fixed.sub.-- data);result.sub.-- div = Interpolate.sub.-- lut(nbitsx,global.sub.-- fixed);ll.sub.-- result.sub.-- div = (long long)result.sub.-- div * (longlong)fixed.sub.-- data;ll.sub.-- result.sub.-- div >>= nbitsx;result.sub.-- div = (int)ll.sub.-- result.sub.-- div;float.sub.-- fixed.sub.-- data = (-16777215.0 + result.sub.-- div) /16777215.0;printf("Input %d :: Relative Err is %f \n", i,float.sub.-- fixed.sub.-- data);}}int Interpolate.sub.-- lut(nbitsx, global.sub.-- fixed)int nbitsx, global.sub.-- fixed;{int delta, lut1, lut2, index;unsigned int sublut12;float a;index = (global.sub.-- fixed >> 18) & 0x1f;delta = global.sub.-- fixed & 0x3ffff;lut1 = LUT index!;lut2 = LUT index + 1!;sublut12 = lut1 - lut2;sublut12 &= 0x3fff;sublut12 *= delta;sublut12 >>= 18;lut1 -= sublut12;/**lut1 >>= nbitsx;**/lut1 = (int)lut1;return(lut1);}int Find.sub.-- nbitsx(fixed.sub.-- data)int fixed.sub.-- data;{int i, nbitsx;int tmp.sub.-- fixed.sub.-- data=fixed.sub.-- data;for(i=1 ; i<= 24; i++){ if(tmp.sub.-- fixed.sub.-- data &0x1) nbitsx =i; tmp.sub.-- fixed.sub.-- data >>= 1;}global.sub.-- fixed = fixed.sub.-- data << (24 - nbitsx);return (nbitsx-6);}void Down.sub.-- load.sub.-- lut(){LUT 0! = 0x7ffff;LUT 1! = 0x7c1f0;LUT 2! = 0x78787;LUT 3! = 0x75075;LUT 4! = 0x71c71;LUT 5! = 0x6eb3e;LUT 6! = 0x6bca1;LUT 7! = 0x69069;LUT 8! = 0x66666;LUT 9! = 0x63e70;LUT 10! = 0x61861;LUT 11! = 0x5f417;LUT 12! = 0x5d174;LUT 13! = 0x5b05b;LUT 14! = 0x590b2;LUT 15! = 0x57262;LUT 16! = 0x55555;LUT 17! = 0x53978;LUT 18! = 0x51eb8;LUT 19! = 0x50505;LUT 20! = 0x4ec4e;LUT 21! = 0x4d487;LUT 22! = 0x4bda1;LUT 23! = 0x4a790;LUT 24! = 0x49249;LUT 25! = 0x47dc1;LUT 26! = 0x469ee;LUT 27! = 0x456c7;LUT 28! = 0x44444;LUT 29! = 0x4325c;LUT 30! = 0x42108;LUT 31! = 0x41041;LUT 32! = 0x40000;}______________________________________
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The texture coordinates (u,v) of a point Q' are determined by: (1) determining the modified texture coordinates (u',v')=(u/z,v/z) by linear interpolation, where z is a world coordinate; (2) determining 1/z by linear interpolation; and (3) dividing (u',v') by 1/z. The division is replaced with multiplying (u',v') by the inverse of 1/z. The inverse is obtained using a lookup table (LUT). The LUT stores inverses of a few values. Linear interpolation is applied to the LUT output to increase the inverse value accuracy.
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HISTORY OF THE INVENTION
This Application is a continuation application of our parent application titled VALVED VOLUME DIVIDING MEANS having Ser. No. 816,900, filed July 18, 1977, now U.S. Pat. No. 4,143,430.
The concept of selecting the amount of water to flush a toilet according to the nature and the quantity of the materials to be flushed is not new. For instance, C. W. Brown in U.S. Pat. No. 1,805,204 issued to him in 1931 proposes a "Closet Flushing Device" wherein the tank is divided into two unequal compartments. The user, as a result, is provided with the option of three flushing volumes; namely the volume of the small compartment or of the larger compartment, or of both compartments together.
The Brown Patent is interesting, further, in the sense that the in-tank mechanisms illustrated by him and of course used eariler are functionally identical to, and physically nearly identical to, the in-tank mechanisms employed today in the overwhelming majority of toilet tanks.
Considerable amount of effort has been invested by different people, as the large number of patents issued over the years indicates, to bring the concepts exemplified by Brown into the general usage. However, their efforts have met with limited success at best. For the most part, the devices and means proposed in the prior art appear to be able to perform their intended functions satisfactorily. Yet, none of these patented inventions has made any significant impact on the industry. Toilets, water closets, toilet in-take mechanisms and flush actuators are essentially the same today as they were several decades ago. The following sets forth some of the inadequacies of the prior art devices and explains why they have not made any commercial impact.
First, the prior art devices generally do not employ the existing in-tank mechanisms, as such. To employ these devices the in-tank mechanisms, or the flush actuating means have to be replaced or modified significantly. Secondly, a large proportion of the prior art devices are cumbersome and therefore, they either have to be incorporated in the original equipment at the factory, or require the services of a skilled craftsman, if installed in the existing toilets of a home. Thirdly, the prior art devices frequently require a change of user habits in manipulating the flushing mechanism. Fourth, a number of devices in the prior art utilize an additional discharge valve connected to the main discharge column of a toilet. But in doing so they introduce an extra risk of water leakage by way of the second discharge valve. The loss of water due to valve leakage is considered a major problem of the toilet tanks. The following examples will serve to illustrate the above points.
U.S. Pat. No. 3,344,439 to Davies, involves the insertion of a box-like compartment in the water closet and utilizes a counter balanced flapper valve, both of which require modification or replacement of the flush actuating means. The so called "double-flush" proposals such as U.S. Pat. No. 3,795,016 to Eastman and U.S. Pat. No. 3,380,077 to Armstrong, also suffer from one or more of the shortcomings listed above.
Therefore, it is the objects of this invention to provide a multiple flush volume means which,
1. requires no modifications or replacements of the tank or its inside mechanisms.
2. does not introduce any additional risk of water loss due to a valve leakage.
3. requires no specialized skills or tools for its installation.
4. is simple and economical in structure.
5. resists corrosion and functions reliably in the presence of in-tank incrustations common in many parts of the country.
6. requires a minimum change of habit or adaption for the user.
7. may be installed and removed from existing toilet tanks without disturbing the in-tank mechanisms significantly.
BRIEF DESCRIPTION OF THE INVENTION
The invention is a device which when installed in a tank permits an operator to selectively discharge various volumes of liquid from the tank. Specifically, it is a valved tank dividing means which is operably connected to the trip lever of a water closet so as to permit the user to discharge a part or the full tank volume of water to the toilet bowl. This is done by rotating the flush handle in the usual manner either partially or fully.
The invention is comprised of four principle units;
1. the `compartmentalizing unit` by means of which the toilet tank is divided into two or more separate volumes.
2. a `valve unit` to permit the liquid to flow from one compartment to the other.
3. an `adjustment means` whereby the angle of rotation of the trip lever between the first and the second valve actuation is adjusted.
4. an `actuator linking unit` by means of which an `adjustment lever` is operably connected to the existing trip lever of the tank.
The `compartmentalizing unit` may be a bulkhead or divider wall which is expanded against the sides of the water closet and sealed therewith by soft gasketing material. Alternatively, the compartmentalizing unit may be a tank or a container which is placed within the water closet. In either instance, the compartmentalizing unit is designed to permit water to enter the second compartment, once the water in the first compartment reaches a predetermined level.
The `valve unit` is preferably a flapper type valve. It is located in the wall of the vertical compartmentalizing unit or may be at the bottom of the tank unit. In the preferred embodiment, a flapper valve is employed having a magnetic closure and a floatation means.
The `adjustment means` which is located above the flapper valve is connected with the valve with a flexible linkage. The adjustment means provides a means of adjusting the angle of rotation of the trip lever within the available free space in the tank. It may also provide an adjustment for the `feel` of the opening of the flapper valve. In the preferred embodiment the adjustment means comprises a small strip of an appropriate length with a series of holes along its length. It is hinged to the divider wall or to one of the vertical walls of the tank unit. Alternatively the adjustment means may be a series of split tubes of various lengths which snap over the stem of the flush valve so as to reduce the degree of flush handle rotation required to open the toilet flush valve. It should be understood that both adjustment means may be employed advantageously in the same installation.
The `actuator linkage` unit provides a connection between the existing trip lever of the water closet and the valve. In the preferred embodiment, an extension arm is secured to the end of the existing trip lever. This is further connected to the adjustment lever with an adjustable linkage. The adjustment lever is also connected to the valve means by way of a flexible linkage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of the in-tank flush mechanisms of a conventional toilet tank.
FIG. 2 is a schematic elevational view similar to that of FIG. 1 showing the units of a preferred embodiment of the invention in place.
FIG. 3 is a schematic elevational view similar to that of FIG. 1 showing the elements of another preferred embodiment of the invention in place.
FIG. 4 is a pictorial view of valve actuator adaptor of this invention.
FIG. 5 is a pictorial view of another valve actuator adaptor of this invention.
FIG. 6 is a pictorial view of an actuator linkage unit of this invention which is secured to the flush arm by threaded means.
FIG. 7 is a pictorial view of an actuator linkage unit whereby the connecting cord is coupled directly to the flush arm.
FIG. 8 is a pictorial view of an alternative means of linking the valve unit of this invention to the existing flush arm.
FIG. 9 is a pictorial view of a compartmentalizing unit of this invention.
FIG. 10 is a sectioned elevational view of the compartmentalizing unit installed in a toilet tank and having the valve closed.
FIG. 11 is a sectioned view similar to that of FIG. 10 with the valve open.
FIG. 12 is a fragmentic pictorial view of the valve unit.
FIG. 13 is a pictorial view of another compartmentalizing unit of this invention.
FIG. 14 is a sectioned elevational view of a device similar to that of FIG. 13 with alternative tank securing means.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, like terms and like numbers will refer to like objects.
Referring now to FIGS. 1 through 3. The in-tank elements are shown here in schematic representation for the sake of clarity. The general components of tank 1 are flush valve 2, flush valve actuating mechanism 3 and float valve 4.
Referring now to FIG. 1. The sequence of events which occur when the toilet is flushed are as follows: Trip lever 10 is rotated downward causing flush arm 11 to rotate upward. Flush arm 11 carries with it valve linkage 12 which rises until it engages valve stem 13. Flush arm 11 is now in the position 14 which is outlined in dashed lines. Continued rotation of flush arm 11 causes stopper 15 to raise and permit the water in tank 1 to exit through valve 2 and flush the toilet. Flush arm 11 generally continues to rotate to the upper limit of its travel which is shown as upper position 16 in dashed lines. Trip lever 10 is then released to permit flush arm 11 and valve linkage 12 to return to their original position. As water flows out of tank 1, float 18 of float valve 4 descends with the level of the water in tank 1 until it opens water intake valve 20 which admits water into tank 1 at a rate slower than water flowing out of tank 1 through flush valve 2. When the water in tank 1 drops to a low enough level, stopper 15 which was buoyed up by the water, seats to close flush valve 2 and tank 1 begins to refill with water. As the water level in tank 1 approaches the full level float 18 rises and thereby closes intake valve 20 which terminates the influx of water into tank 1 and the flush cycle is completed.
Referring now to FIGS. 2 and 3. Two embodiments of the device of this invention are shown in schematic representation. In FIG. 2 a bulkhead or divider wall type of compartmentalizing unit 50 is illustrated while in FIG. 3 an insert tank type of compartmentalizing unit 50' is illustrated. Valve actuator adapter unit 52 is shown in place surrounding valve stem 13. Actuator linkage unit 51 is shown attached to flush arm 11 and joined to valve unit 53 as shown. Units 50, 51', 51, 52, 53 will be discussed in detail hereinafter.
Referring now specifically to FIG. 2. Trip lever 10 is rotated downward rotating flush arm 11 upward until flush valve linkage 12 brings adapter unit 52 into contact with valve stem 13 at a point where flush arm 11 has rotated a very short distance. Continued rotation of trip lever 10 will cause valve 2 to open as described above. If the flush handle 10 is released after opening valve 2 the water in tank 1 minus the water retained by compartmentalizing unit 50 will be free to exit tank 1 as described above permitting a partial discharge of tank 1.
However, if rotation of flush handle 10 is continued to a location 60 shown dashed, linkage unit 51 draws cord 65 taut. Continued rotation of trip lever 10 will cause flush arm 11 to be rotated to position 61 shown dashed and thereby, cause linkage unit 51 acting through connector 55 to raise adapter arm 56 which creates a tension in cord 65, to open valve unit 53. Floatation means 67 serves to maintain valve unit 53 in the open position until water has drained out of the volume contained by compartmentalizing units 50 thereby permitting a full discharge of tank 1.
It should be noted that an operator without knowledge that the device of this invention was located in the toilet tank would rotate trip lever 10 fully and affect a full discharge of tank 1 as would be normal. A knowledgable operator could at his option use a partial discharge to flush liquids or to do light disposal work when flushing away a facial tissue or the like.
Referring now to FIG. 3. Tank type compartmentalizing unit 50' is here shown to have valve unit 53 positioned at the bottom of the tank. Cord 65 joins valve unit 53 to flush arm 11 by way of linkage unit 51'. Tank type compartmentalizing unit 50' is shown to be secured to the top of toilet tank 1 by a conventional clamping arrangement 30. Clamping arrangement 30 is provided for the purpose of securing tank type compartmentalizing unit 50' against the buoyant forces exerted upon it during the period that compartmentalizing unit 50' is empty and tank 1 is filling with water. As tank 1 becomes completely filled water will flow over the top of compartmentalizing unit 50' and thereby bring the pressures inside and outside compartmentalizing unit 50' to equilibrium.
Referring now to FIGS. 4 and 5. Valve actuator adapter 52 and 52' are shown to encompass valve stem 13 below stem ring 75 and above linkage ring 76 of valve linkage 12. Adapter 52 and 52' are substantially cylinders through which stem 13 may freely slide. The raising of linkage 12 causes ring 76 to raise towards ring 75. The engaging of ring 76 with ring 75 ordinarily precedes the raising of stem 13 which opens the toilet valve 2. The interposing of adapter 52 or 52' between rings 75 and 76 causes the raising of valve stem 13 when ring 76 is lower than ring 75 by a distance equal to the height of adapter 52 or 52'. The employment of adapter 52 or 52' enables the user to adjust the amount of vertical travel required before linkage 12 causes stem 13 to be raised.
Adapter 52 of FIG. 4 is shown as a split tube type of adapter which may be snapped onto stem 13 as shown without the need for any tools and without the need for disturbing the existing mechanisms. If it is desired to change the length of adapter 52 it may be removed from stem 13 and a suitable length of adapter cut off.
Adapter 52' is shown as a cylinder having scored segments 77 and a longitudinal slot 78. The length of adapter 52' may be reduced by removing one or more scored segments 77 from adapter 52'.
Referring now to FIGS. 6, 7, and 8 which show actuator linkages of this invention which may be secured to flush arm 11 without disturbing any of the in-tank mechanisms.
Referring now to FIG. 6. Actuator linkage 80 is secured to flush arm 11 by means of screws 82 or similar means passing through holes in flush arm 11. The holes in flush arm 11 are provided as alternate locations for the positioning of valve linkage 12. Cord 65 may be secured to actuator linkage 80 by means of knot 64 as shown so as to engage actuator linkage 80 when flush arm 11 is rotated upward.
Referring now to FIG. 7. The valve unit of this invention may be operably linked to flush arm 11 by means of cord 65 being secured directly to flush arm 11 substantially as shown. Although the linkage shown in FIG. 7 is operable, it is not preferred in that the direct connection of cord 65 to flush arm 11 does not ordinarily provide the best mechanical arrangement for actuating the valve unit.
Referring now to FIG. 8. Actuator linkage 80' may be frictionally engaged with flush arm 11 by means of sleeve 83 which may be of rubber or plastic or other such resilient material which will provide a secure frictional engagement of actuator linkage 80' with flush arm 11. Cord 65 may be snapped into clevis 84 as shown.
Referring now to FIGS. 9, 10, 11, and 12. Compartmentalizing unit 50 serves to divide the tank into two separate liquid holding compartments, reserve compartment 91 and main compartment 92. Port 93 provides a passage through which liquid may pass from reserve compartment 91 into main compartment 92. Port 93 is opened and closed by means of valve unit 53 which will be discussed in detail hereinafter.
Referring now to FIG. 9. Compartmentalizing unit 50 comprises an adjustable bulkhead 100 formed of two movable segments, first segment 94 and second segment 95, a flexible gasket 96 and fastening means 97. Bulkhead 100 is installed by placing bulkhead 100 in toilet tank 1 (not shown) in the desired position and adjusting bulkhead 100 so that it presses gasket 96 against the sides and bottom of tank 1. Fastening means 97 are then secured to hold bulkhead 100 in position.
Two points should be noted. The first being that the seal afforded by gasket 96 between bulkhead 100 and tank 1 need not be 100% effective in order that the device of this invention perform its intended function satisfactorily. A small amount of leakage between reserve compartment 91 and main compartment 92 can be tolerated without any adverse affect on the performance of the unit. The second point being that leakage around bulkhead 100 or through valve unit 53 will not result in water loss from tank 1 which is in counter distinction to what is the case with many prior art devices.
Referring now to FIGS. 10, 11, and 12. Valve unit 53 serves to open and close port 93. Valve unit 53 comprises a flapper 110, a float means 111 which may be any buoyant means and is here shown as a styrofoam block attached to flapper 110 a first magnetic member 112 and a second magnetic member 113 with first magnetic member 112 being a part of flapper and second magnetic member 113 being a part of the compartmentalizing unit, a flapper guide means here shown as being 114 and a cord attachment means here shown as eye 115.
Referring now to FIGS. 10 and 11. Valve means 53 is maintained in a closed position primarily by the magnetic attraction between first magnetic member 112 and second magnetic member 113. When flush arm 11 acting through linkage unit 51 by way of adapter arm 56 and connector 55 causes tension in cord 65, flapper 110 is caused to rotate on hinge 114 and open port 93 to permit water to exit reserve compartment 91. The buoyancy of float 111 exceeds the magnetic attraction between first magnetic member 112 and second magnetic member 113 once the two members are drawn apart from each other a short distance. As the water level in reserve compartment 91 drops, float 111 permits flapper 110 to drop until the magnetic attraction between first magnetic member 112 and second magnetic member 113 draws flapper 110 against bulkhead 100 thereby closing port 93 and to complete the cycle.
Referring now to FIG. 13. Compartmentalizing unit 50' comprises a minitank 130 which is secured to tank 1 by means of screw clamps 120 and supported above the bottom of tank 1 by feet 133. Screw clamps 120 serve to frictionally engage compartmentalizing unit 50' with toilet tank. Minitank 130 may thereby be quickly and conveniently installed and secured in tank 1. The operation of compartmentalizing unit 50' is substantially as described in conjunction with FIGS. 9 through 12.
Referring now to FIG. 14. Compartmentalizing unit 50' comprises a minitank 130 which may be secured to tank 1 by means of adjustable clamps 131 which are secured by fastening means 132 and supported above the bottom of tank 1 by feet 133. Valve unit 53 and port 93 are located at the bottom surface of minitank 130. Minitank 130 is provided with adjustable clamps 131 so as to enable minitank 130 to resist the buoyant forces which will be exerted upon it when main compartment 92 of tank 1 is filling with water after both tanks have been emptied and valve unit 53 has sealed. Feet 133 are provided to permit leveling of minitank 130 and to provide a space under minitank 130 through which water may flow out of minitank 130. The operation of valve unit 53 is similar to that discussed in conjunction with FIGS. 9 through 12.
It will become apparent to one skilled in the art that equivalent means may be provided to perform the functions of the units discussed herein. For example a conventional bulb type flush valve may replace the valve unit in compartment 50' or a spring or toggle means may replace the magnetic closure securing means of valve unit 53, or that a chain or linkage may replace cord 65 and so on.
However, the recitation of such equivalent means would cause the specifications to become prolix and to unduly multiply the drawings and claims. For that reason the preferred embodiments of the invention have been set forth in the specifications but the invention should be understood to be limited only by the appended claims and to all equivalents thereto which would become apparent to one skilled in the art.
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This invention relates to water conserving devices to be used in the water closets of bathroom toilets. The devices may also find applications in other liquid containing and discharging vessels. The invention consists of a partition wall or alternatively a minitank installable in the water closet of a toilet so as to divide the water closet into two separate liquid holding compartments. A flapper valve with a magnetic closure, fitted into the partition wall or into the minitank, opens and closes a port which communicates between the compartments. The actuating means of the flapper valve is operably connected to the existing trip lever of the water closet in such a way that the valve will be actuated only after the existing discharge valve has been actuated first. This arrangement permits the user to discharge water from one or both compartments of the water closet according to his needs. In the preferred embodiments, the devices are installable by anyone possessing only the skills and tools commonly found in an ordinary household.
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BACKGROUND
One method for validating extensible markup language (XML) documents against an XML schema includes breadth-first validation. Breadth-first validation may include a traversal of an XML schema using a finite state machine (FSM). A FSM may be thought of as a model of behavior composed of a finite number of states, transitions between those states, and actions. Regarding breadth-first validation, there may be a parent node with child nodes A and B. Child node A may have child nodes C and D. In breadth-first validation, child nodes A and B of a parsed XML document must both be validated before child nodes C and D (i.e., descendants) are traversed using a FSM. In other words, the document must be verified to conform to a certain standard (e.g., XML schema). In this scenario, each top-level compositor represents a FSM, and new FSMs are instantiated upon traversal of child nodes (e.g., child nodes A and B). Unfortunately, this non-parallel, breadth-first methodology fails to properly leverage the core capacity available with parallel processing in multicore processors and/or multithread software processing.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, incorporated in and constituting a part of this specification, illustrate one or more implementations consistent with the principles of the invention and, together with the description of the invention, explain such implementations. The drawings are not necessarily to scale, the emphasis instead being placed upon illustrating the principles of the invention. In the drawings:
FIG. 1 is a state diagram for a finite state machine for a breadth first validation.
FIG. 2 is a state diagram concerning one embodiment of the invention.
DETAILED DESCRIPTION
The following description refers to the accompanying drawings. Among the various drawings the same reference numbers may be used to identify the same or similar elements. While the following description provides a thorough understanding of the various aspects of the claimed invention by setting forth specific details such as particular structures, architectures, interfaces, and techniques, such details are provided for purposes of explanation and should not be viewed as limiting. Moreover, those of skill in the art will, in light of the present disclosure, appreciate that various aspects of the invention claimed may be practiced in other examples or implementations that depart from these specific details. At certain junctures in the following disclosure descriptions of well known devices, circuits, and methods have been omitted to avoid clouding the description of the present invention with unnecessary detail.
As will be explained more fully below, after an XML schema has been received and an XML document parsed and available as a tree structure, each node may have access to its immediate (i.e., direct descendent) children and can easily traverse a single compositor FSM. A compositor may describe the composition of a type's content. An XML schema may define multiple compositors that can be used in complex type definitions. Compositors may contain particles, which may include things like other compositors, element declarations, wildcards, and model groups. Once a single node has been locally validated (i.e., one node among many nodes is individually validated), the target schema type for each child node may be available, and new FSM validation traversals can be instantiated. For example, an XML Schema is defined in the following table.
TABLE 1
<xsd:schema xmlns:xsd=“http://www.w3.org/2001/XMLSchema”>
<xsd:element name=“root”>
<xsd:complexType>
<xsd:sequence>
<xsd:element name=“a”>
<xsd:complexType>
<xsd:sequence>
<xsd:element name=“aChild” type=“xsd:string”/>
</xsd:sequence>
</xsd:complexType>
</xsd:element>
<xsd:element name=“b”>
<xsd:complexType>
<xsd:choice>
<xsd:element name=“bChoice1” type=“xsd:integer”/>
<xsd:element name=“bChoice2” type=“xsd:integer”/>
</xsd:choice>
</xsd:complexType>
</xsd:element>
</xsd:sequence>
</xsd:complexType>
</xsd:element>
</xsd:schema>
The pseudocode in the above table may build a self contained FSM for the total complex type, along with a FSM for each new complex type. Each FSM may be linked into a host FSM at the state where validation for the child FSM becomes legal. In the above pseudocode, the complex type FSM associated with element “a” may be linked into the complex type FSM associated with “root” at the state immediately following a transition on element “a”.
Through FSM chaining, a single master FSM may consist of smaller local FSMs, each of which may contain a start state and one or more accept states. The master FSM for the XML schema in the above table may be seen in FIG. 1 , with machine instantiations shown as thicker arrows. The XML Schema has been translated into a FSM, where each complex element node links into a child FSM. Node 105 indicates a start state (represented by a double-ring non-bolded symbol). Using the above table, node 105 assumes the root element has been located. Consequently, validity of a structure with child node element a followed by child node element b is now determined. Node 110 represents an intermediate state after child node element a has been located. Node 115 represents an accepted state (represented by a double-ring bolded symbol) and that child node element b has been located. Node 120 represents a start state. Node 125 is an accepted state and represents that child node element aChild has been located and validated. Node 130 represents a start state. Node 135 represents an accepted state and that child node element bChoice 1 has been located and validated. Node 140 represents an accepted state and that child node element bChoice 2 has been located and validated. Using a traditional breadth-first validation, the nodes would be validated in the following sequence: 105 , 110 , 115 , 120 , 125 , 130 , and then 135 or 140 .
In contrast in the traditional breadth-first analysis described above, “eager” breadth-first validation may take place concurrently with respect to any other breadth-first FSM validation. Therefore, any node being eagerly validated may validate each of its children eagerly. In other words, eager validation allows for parallel processing of XML schema validation.
FIG. 2 is a depiction of one embodiment of the invention. The pipe-lined result of eager breadth-first validation is illustrated using sequential time slices time slices 145 , 150 , 155 , 160 . There may or may not be intervening time slices among time slices 145 , 150 , 155 , 160 . As a state is entered, any FSM associated with that target node can be instantiated in parallel. More specifically, node 105 indicates a start state in time slice 145 . Again, using Table 1, node 105 assumes the root element has been located. In time slice 150 , node 110 again represents an intermediate state after child node element A (which descends from a parent node) has been located. However, still in time slice 150 , node 120 represents a start state. In time slice 155 , nodes 115 , 125 and 130 are addressed in parallel. In other words, child node element B (which descends from the parent node) is validated concurrently (i.e., eagerly) with child node element aChild (i.e., a grandchild node that descends from child node element A). Node 130 again represents a start state. In time slice 160 , node 135 again represents an accepted state and that child node element bChoice 1 has been located and validated. Furthermore, node 140 represents an accepted state and that child node element bChoice 2 has been located and validated. Thus, taking the XML Schema found in Table 1, a child state machine may validate against the XML Schema concerning the content of element “a” (e.g., <xsd:element name=“aChild” type=“xsd:string”/>) in parallel to another child state machine validating against the XML Schema concerning, for example, the sibling of element “a” such as element “b” (e.g., <xsd:element name=“b” type=“ . . . ”). Furthermore, concurrent or parallel validation (i.e., eager validation) does not necessarily require that two validations begin and end simultaneously, although that is possible and included within the scope of the invention.
Thus, at each intermediate state in the FSM, the child element being processed can be “eagerly” validated against the associated follow-up FSM. This is legal because of the deterministic nature of XML Schema, as defined by Unique Particle Attribution in the W3C XML Schema specification. With no look-ahead requirement, once a state is entered, that state may become part of the master traversal, and no back-tracking may be necessary.
Accordingly, eager breadth-first validation may effectively support parallel operations. In one embodiment of the invention, such parallel operations may be conducted in a software multithreading environment. In one embodiment of the invention, such parallel operations may be conducted using a set of independent, interconnected processing elements (e.g., multicore processor). As a result, eager breadth-first validation may allow for job latency to scale downward as processing element count increases, thereby increasing utilization and throughput, even in workloads with a small number of tasks. This may allow higher core utilization looking forward, where intra-document parallelism may be a requirement. In one embodiment of the invention, any node eligible for validation can be processed on any available computing resource, such as a processor core. Through deterministic processing of the state machine, and the node-availability present in DOM models, a node may become eligible for validation one computation time slice after both the node's previous sibling and the node's parent have been validated. As the breadth-first walk proceeds, opportunities for parallelism increase as no structural limitations derived from the shape of the document tree apply. For example, if a parent node has a childA node, a grandchildA node descending from childA, a childB node, and a grandchildB node descending from childB, a processor core may process childA and grandchildB while another processor core processes childB and grandchildA.
Embodiments may be implemented in code that can be executed in many different system types. For example, embodiments may be implemented in computer systems such as server computers, personal computers, mobile devices such as cellular telephones and so forth. In such processor-based systems, an algorithm in accordance with an embodiment may be performed in a general-purpose processor such as a microprocessor, a graphics processing unit (GPU) or other such processing unit.
Embodiments may be implemented in code and may be stored on a storage medium having stored thereon instructions which can be used to program a system to perform the instructions. The storage medium may include, but is not limited to, any type of disk including floppy disks, optical disks, compact disk read-only memories (CD-ROMs), compact disk rewritables (CD-RWs), and magneto-optical disks, semiconductor devices such as read-only memories (ROMs), random access memories (RAMs) such as dynamic random access memories (DRAMs), static random access memories (SRAMs), erasable programmable read-only memories (EPROMs), flash memories, electrically erasable programmable read-only memories (EEPROMs), magnetic or optical cards, or any other type of media suitable for storing electronic instructions.
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.
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In one embodiment, the invention may include receiving an XML schema and document with first, second, third, and fourth nodes. The second and third nodes may descend from the first node. The fourth node may descend from the second node. The third and fourth nodes may be simultaneously validated.
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The present invention generally relates to snow skis and snowboards and methods of making the same. Hereinafter the term “ski” refers to skis or snowboards.
BACKGROUND OF THE PRESENT INVENTION
One present conventional method of making skis and snowboards uses a mold made from relatively thick aluminum plate which is laboriously carved out in accordance with the shape of the ski. A base layer of the ski is placed in the mold and then separate edge members are placed in the mold at the outer perimeter. Epoxy resin is then painted into the mold to wet the base layer and edge members. Layers of fiberglass wet with resin or other layers of zicral aluminum or carbon, are then laid into the mold. A core, pre-cut typically from wood, is then laid on top in the mold and more epoxy resin is repainted in the mold on the core and then two more layers of fiberglass are laid on top of the core. More epoxy is applied and a top layer which may have graphics, is laid on the top. The mold with the assembly of layers therein is then placed in a press under pressure and heat to impart a camber to the assembly and to cure the resins. When the assembly is removed from the mold the product is very rough. The finishing process is very expensive and takes several more steps. First a band saw is used to cut the fiberglass and glue hanging out between the layers. Then up to twenty sanding processes to get the skis or boards to a final finish state may be required. At this point extensive final base finishing is required as the product tends to change shape while curing. It takes several stone grinding and edge finishing passes to get a finish that is usable.
OBJECTS OF THE PRESENT INVENTION
One object of the present invention is to provide novel and improved skis and snowboards as well as methods of making the same.
A further object of the present invention is to provide a novel method of making skis and snowboards that will facilitate the manufacture of different ski shapes and sizes while avoiding the need to create a new mold with the desired shape or size of the ski for each new ski design. Included herein is a novel method and assembly of ski layers and edges that will permit skis of different shapes and sizes to be made without the need of conventional molds or the need to make a new mold for every different model or size of the ski.
A further object of the present invention is to provide skis or snowboards that are easier and less expensive to manufacture than some conventional skis and snowboards and yet will provide a stronger structure and allow improved performance.
A still further object of the present invention is to provide methods of making skis which are an improvement over conventional methods such as that described above from the standpoints of labor, cost, versatility, and efficiency.
SUMMARY OF PREFERRED FORMS OF THE PRESENT INVENTION
A ski or snowboard in accordance with one preferred embodiment of the present invention includes a metallic layer preferably a plate of high carbon steel cut with the desired ski or snowboard shape (in plan view). A recess is formed in one side of the plate in the shape of a base layer which is received in the recess. The recess cut into the plate leaves integral flanges projecting downwardly around the edge portions of the plate to serve as the edges of the ski. A base layer is cut preferably from a sintered polyethylene plastic such as P-Tex 7500 and fits snugly within the flanges where it is bonded to the plate. The plate with the base layer is laid on a generally flat support surface and then successive core layers and a top layer are applied with resin to the metal plate on the side opposite the base layer. The assembly is then drawn or pressed together and heated to cure the resin.
In another preferred form of the present invention, the core and top layers are pre-cut to the desired ski shape and assembled one on top of the other on a base layer with resin in between the layers. A sheet of material from which the base layer is made is supported on a generally flat support plate and has a slot or other opening cut about its perimeter defining the shape of the ski in plan view. Edge members which will form the edges of the ski are inserted in the slot. All the layers are pressed and bonded together with the edge members and heat is applied to cure the resin. In order to make skis of different sizes or shapes the slot cut into the base layer is simply changed accordingly through a computer which controls the cutting of the slot. This avoids the need of making a new mold as in conventional practice.
DRAWINGS
Other objects and advantages of the present invention will become apparent from the detailed description below taken in conjunction with the attached drawings in which:
FIG. 1 is a perspective view of a ski constituting a preferred embodiment of the present invention with a mid-section broken away and shown in cross-section to show the layers of the ski;
FIG. 2 is a transverse and exploded, cross-section of the ski of FIG. 1 showing the various layers of the ski;
FIG. 3 is a perspective view of a sub-assembly of another ski during its construction on a support plate;
FIG. 4 is a transverse and exploded view of the ski being constructed in FIG. 3 showing all of its various layers;
FIG. 5 is a plan view of the sub-assembly of the ski of FIG. 3 but before the core layer 44 shown in FIG. 3 is laid; and
FIG. 6 is a fragmental, cross-sectional view of edge members inserted in a base layer of the ski of FIG. 4 .
DETAILED DESCRIPTION
Referring to the drawings in detail, there is shown for illustrative purposes a ski 10 constructed in accordance with one preferred version of the present invention. Referring to FIG. 1 , the ski includes a first layer 12 made preferably of a sheet of structural carbon steel, for example, 1.8 mm thick. At the perimeter of layer 12 is an integral, continuous, flange 14 projecting downwardly from the main body 16 to define a cavity for receiving a base layer 18 formed preferably from a sheet of P-Tex 7500 which is a sintered polyethylene plastic, for example, 1.3 mm thick. The depth of the cavity in layer 16 is the same dimension, 1.3 mm, as the thickness of base layer 18 so that it fits snugly in the cavity as shown in FIG. 1 where it is glued to layer 12 . The width of the flanges 14 in the shown embodiment is, for example, 3 mm. Flanges 14 form the edges of the ski 10 and eliminates the need of separate edge pieces to be attached to the ski as required by conventional ski designs and constructions. The above assembly may be performed on a generally flat support surface which will also support the ski layers while the core and upper layers are assembled as now will be described.
The core of the ski 10 is formed by two pre-cut core layers 20 and 24 . For example, core 20 layer is approximately 1.0 mm thick and made of a wood like vertically laminated bamboo. Other woods like aspen, or for very high performance, pre-cured carbon Kevlar may also be used instead. Layer 20 is glued to the top surface of the steel layer 12 which is preferably rough-sanded to increase bonding. The core material provides the necessary flexibility or stretching needed at the bottom of the ski.
The main core 24 is pre-cut and also preferably made of vertically laminated bamboo having a thickness varying from about 2 mm at the tip and tail to about 12 mm at the center waist of the ski. Of course other woods like oak or maple may be used for layer 24 instead of bamboo. Layer 24 is laid on a film of epoxy on top of layer 20 . The top of the ski is under compression when the bottom of the ski stretches so the top layer 26 is made from a very hard compression-resistant wood like oak, bamboo or maple, 2 to 3 mm thick depending on the performance required out of the ski. Top layer 26 is laid on a film of resin on the top of core 24 .
The above assembly is pressed or drawn together with a predetermined camber as the epoxy is cured by heat. The camber or final shape of the ski can be obtained in any suitable manner. However preferably, the layers are drawn or pressed together by placing them in a vacuum bag where the vacuum in a bag draws or presses the layers together with the desired camber. Also the layers can be cured while being pressed together in a vacuum in an oven. The thermal qualities of the ski layers can be such as to shape the ski upon heating and curing the layers. Alternatively the camber shape can be provided by pressing the ski layers against a curved surface during the curing step. Any other method may be employed to provide a camber shape.
Referring now to FIGS. 3 , 4 and 5 , there is shown another ski construction and method of making it using a generally planar support member 30 , preferably made of a generally rectangular, aluminum plate for example, 10 mm thick, 2200 mm long and 500 mm wide. Two ski sub-assemblies 32 for two identical skis are shown on plate 30 , however all of the layers of each ski are shown in FIG. 4 as will be described below. In the preferred embodiment, the top surface of plate 30 has a recess 1.3 mm deep formed in it as best shown in FIG. 3 at 34 for receiving a sheet of base material 36 , sintered polyethylene plastic, preferably P-Tex 7500 from which the base layer 37 of the ski is cut with computer controlled cutting equipment. Recess 34 in the specific embodiment is rectangular and snugly receives the rectangular base material sheet 36 with their top surfaces flush with each other. This relationship secures base sheet material 36 against horizontal movement on plate 30 . Base material sheet 36 in the specific embodiment is 2000 mm long, 328 mm wide and 1.3 mm thick. Referring to FIG. 5 , base material sheet 36 is cut to provide a slot or other opening 38 , for example, 2 mm wide along the entire perimeter of the base layer 37 of the ski as seen in plan view in FIG. 5 .
Referring to FIG. 4 , elongated steel edge members 40 are provided in slot 38 to provide the edges of the ski. In one embodiment the edges are 2 mm wide and 1.8 mm in depth, and have an inverted “L” shape cross-section to allow the top of the edge member 40 to engage the base layer 37 as shown in FIG. 6 to prevent the edge members from moving downwardly through slot 38 . In addition, the edge members 40 may be further secured in place by using magnets 60 positioned under the edge members (as shown in FIG. 6 ) or the aluminum support 30 . The edges of the ski can be formed by one continuous or a plurality of edge members 40 . Since the shape of the base layer 37 is determined by the slot 38 cut into the base sheet 36 , different ski shapes are easily made by varying the cut through the computer which controls the cutting machine.
One or more layers 42 in the shape of the ski in plan view and made of structural material such as 1 mm thick sheets of fiberglass and fiberglass and Kevlar mix is wet with epoxy resin and laid on the base layer 37 .
A core layer 44 of the same shape as previous layer 42 and preferably made from a vertically laminated wood such as poplar, ash or bamboo or a combination of them depending on the performance requirements, is laid on a film of epoxy resin on the previous layer 42 . As shown in FIG. 5 , core layers 44 of both skis being assembled on the support plate 30 are laid together through their interconnection by tabs 46 which are eventually cut away from the skis after they are completed. Tabs 46 facilitate positioning and securement of the core layers 44 . Further in this regard, it is preferred that upstanding abutments 48 or posts be provided to project upwardly from the support plate 30 and engage the core layer 44 and the other layers above the core layer 44 to be described below. Abutments 48 serve to secure the layers in position and may be provided in holes formed through the support plate 30 at the positions along the outside edges of both cores 44 as shown in FIG. 3 . Abutments 48 are removable from their respective holes however magnets or any other suitable means may be used to keep them in place during assembly of the skis on the plate 30 .
A layer or layers 50 of composite materials such as fiberglass and glass basalt mix are laid on a film of epoxy resin on the core layer 44 . Layer 50 can also be a 0.5 mm thick sheet of high grade aluminum for certain skis requiring high speed use.
The top layer 52 is a 0.5 mm sheet of nylon, such as for example, Intersport 8210 which is laid on a film of epoxy resin on the previous composite layer 50 . Any suitable graphics may be applied to top layer 52 before it is laid. The assembly is now complete and the next step is to draw or press the layers together preferably by using a vacuum bag or other vacuum chamber which receives the assembly. Additionally the assembly is heated in an oven to cure the resin. The oven may have a vacuum in the heat chamber to squeeze the layers together as the resin is cured.
The support plate 30 may have its forward portion curved upwardly to impart that shape to the ski after the ski layers are drawn or squeezed together while the resin is curing. Also if it is desired to have the rear end of the skis gradually curved upwardly, the support plate 30 can be formed with a recess (not shown) to receive an insert having the desired shape to impart to the end of the ski. Any other suitable method may be used to provide a desired shape or camber to the ski such as described above. After the ski layers are squeezed together and the resin is cured, only minor finishing operations remain like sanding, trimming the core 44 , and beveling the edges 40 and varnishing.
In another embodiment and method of the present invention, the support plate 30 has a generally flat top surface without the recess 34 used in the embodiment of FIG. 3 . However the support plate 30 is provided with abutments and/or clamps or any other suitable means for securing the ski layers in fixed horizontal position during their assembly.
It will be seen from the above that the methods and ski assemblies of the present invention for making skis avoid the need of a mold in the conventional sense. Indeed skis of different shapes and sizes may be made using the above ski assemblies and methods without requiring molds for each new ski shape or size. Moreover the present inventions do not require any mold for bonding the edge members to the base of the ski. It will also be seen that skis may be made in accordance with the present inventions to increase strength and durability of the ski while at the same time reducing labor and other costs of manufacture.
Although certain preferred embodiments and forms of the present invention have been shown and described above, it will be apparent to those skilled in the art that certain modifications and variations of the skis and construction methods of the present invention may be made but without departing from the scope of the present invention indicated in the appended claims.
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A ski or snowboard includes a metal layer having integral flanges projecting from its opposite sides to define a cavity for receiving a base layer. Several additional layers of laminated wood and in some versions synthetic polymer or carbon are pressed and bonded together on the metal layer. A method of manufacturing includes a support plate which holds a base layer and edge members received in a slot in the perimeter of the base layer. Additional layers of the ski or snowboard are successively laid on the base layer and pressed and bonded together.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Provisional Patent Application:
[0000] Ser. No. 60/349,955 Filed: Jan. 13, 2003
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] A novel resettable jar tool for use downhole in a borehole for enhancing the retrieval of stuck objects. The stuck object may be part of a tool string that includes the jar tool of this invention. The jar tool can withstand high temperature and other deleterious downhole conditions without significantly reducing the magnitude of the stored energy employed for actuating the jar tool.
[0005] The jar tool is resettable as many times as required to dislodge a stuck object by manipulating the operating wireline that allows electronic communication between apparatus connected to the bottom of the tool and the surface by an electrical conductor that extends through the entire jar tool. The jar includes a hammer, anvil and releasable latch device cooperatively interconnected to increase the safety of the tool and to deliver a powerful uphole thrust responsive to wireline tension.
BRIEF SUMMARY OF THE INVENTION
[0006] In the art of producing fluid from a borehole, sometime a borehole is drilled fairly straight, sometime it is crooked, or is deliberately slanted. Most boreholes are crooked, thereby tremendously increasing the probability of a string of tools becoming stuck downhole in a borehole. This invention is directed to a wireline actuated jar tool for use in retrieving a stuck downhole tool from a borehole. Hence, it is apparent that the stuck tool string must somehow be unstuck without resorting to placing undue tension on the supporting wireline.
[0007] A parted wireline is considered a catastrophe in the oil patch for a costly fishing job is then necessary, and such a delay will be disastrous for any delicate instrument package left downhole long enough to be fried by the bottom hole temperatures. The jar tool of this invention overcomes the necessity of ever applying excessive tension in the wireline that supports the tool string. This is achieved in accordance with the present invention by a resettable, stored energy jar tool system capable of multiplying the tension of the E-line as much as ten fold, as will be more fully appreciated as this disclosure is further digested.
[0008] The preferred embodiment of the jar tool of this invention discloses a downhole tool string which includes the downhole jar tool. The jar tool includes an upper member opposed to a lower member with the two members being coupled together by means of a lost motion coupling in a manner to provide axial slidable movement therebetween, whereby the opposed members provide opposed masses that are selectively moved towards and away from one another a distance determined by the lost motion coupling which is attached therebetween.
[0009] The lower member of the jar tool is attached to most any desired downhole tool, apparatus, or device, including an instrument package, for example, that might also be insulated from the high temperature formations, while the upper jar tool member is provided with a unique plurality of spaced stored energy chambers therein, whereby a plurality of forces are advantageously added together and made available for creating a powerful upthrust when one member is released from the other and is accelerated responsive the magnitude of the stored energy.
[0010] Means are provided for releasing the energy of said stored energy chambers upon demand to effect rapidly accelerating movement of one member respective the other member and thereby propel one said member away from the other member. At a selected length of stroke, an internal part of the tool acts as a hammer with the hammer being positioned to strike another internal part of the tool which acts as an anvil, thereby providing sudden deceleration of a magnitude and direction to accelerate the entire tool string uphole with sufficient thrust to un-stick the tool string when it is stuck down-hole. This action incrementally drives the entire downhole tool string in an uphole direction with a thrust which un-sticks the stuck tool string.
[0011] An outstanding feature of this invention is the provision of a longitudinally extending passageway disposed along the central axis of the jar tool and extends from the up-hole tool end, through each of the jar tool members, including the lost motion coupling, where the passageway terminates within the lowermost member of the jar tool and thereby allows for the employment of an insulated conductor within the passageway that continues through the remainder of the jar tool to an instrument package therebelow enabling transmission of important data along the conductor from and to the surface of the earth. Provision is made to eliminate problems associated with change in length of the insulated con-ductor as the jar tool components are extended in length and then retracted as the jar tool moves from the extended configuration following a jarring action into the retracted standby configuration.
[0012] Furthermore, safe protection of the insulated conductor that extends through the jar tool is provided by a through tubing positioned within the recited axial passageway which encloses the insulated conductor so that the conductor is protected, whereby one terminal end of the insulated conductor ultimately is placed into electrical communication with the downhole instrument package, for example, or other tool package, with the opposed terminal end of the conductor being electrically connected to the wireline or other means for data transmission uphole to a surface receiver. Accordingly, the downhole instrument can conduct or electronically transfer various vital information between the instrument package, through the axial conductor within the jar tool, and finally to an above ground facility.
[0013] Some instrument packages are extremely valuable, and contain confidential information and design secrets which must be protected from damage as well as from evil plagiarists. Therefore, it is essential that in such a situation, the electronic package must not remain downhole for extended lengths of time because the apparatus must be kept out of harms way. The present invention provides a unique safe guard for such valuable apparatus.
[0014] This disclosure further provides means for resetting the jar tool a multiplicity of times to thereby again store energy within spaced energy storing chambers thereof so that the jar tool of this invention can provide a multiplicity of sequential jarring actions that sooner or later result of the jar tool being translocated axially away from the stuck location, dragging along any attached apparatus therewith.
[0015] Another outstanding feature of this invention is the provision of a jar tool having multiple sources of energy available to strike the recited anvil with a powerful blow of the hammer, which jointly provide unexpected improvements in jar tools. These forces are realized by the joint action of the E-line tension, and the force derived from the multiplicity of energy storage devices. Further, adjustment means related to the magnitude and timing of the effect obtained from the use of the several stored energy devices is taught herein. Variation in the length of stroke of the two interconnected coacting jar tool parts, the cumulative force available from the stored energy chambers, and the tension required in the E-line to trigger the hammer blow is considered to be within the comprehension of this invention. Equally important is the novel concept and method of extending an electrical conductor through the axis of the jar tool, as well as the unique safety features presented and claimed herein. Other objects and advantages of this invention will be evident from the following description.
[0016] Accordingly, a primary object of this invention is the provision of a down-hole jar tool for use in a bore-hole for enhancing the retrieval of stuck objects. The stuck object may be part of a tool string that includes the jar tool. The jar tool is made of suitable alloys which can withstand high temperature and other deleterious down-hole conditions without significantly or unduly reducing the operating efficiency of the jar tool.
[0017] Another object of this invention is the provision of a preferred embodiment of the jar tool, having an upper member and a lower member coupled together by a lost motion coupling in the form of opposed members arranged for limited axially slidable movement thereof, whereby the opposed members provide opposed masses that are selectively moved towards and away from one another as determined by the characteristics of the a motion coupling located therebetween; thereby providing means by which a hammer and an anvil of the jar tool are manipulated to impact one said member against the other member with sufficient force which results in uphole thrust of the members. This action drives the entire downhole tool string in an uphole direction with a powerful upthrust which invariably un-sticks the stuck tool.
[0018] A further object of this invention is provision of the above downhole jar tool wherein one said member thereof can be attached within most any desired downhole tool string, including an instrument package, for example, that often will be insulated from high temperature formations while the other said member of the jar tool is provided with a unique plurality of spaced stored energy chambers therein whereby a plurality of forces are advantageously added together and made available for creating upthrust when one impacts against the other, thereby unsticking a stuck downhole tool or tool string in a new and unobvious manner.
[0019] A still further object of this invention is the above recited jar tool wherein means are provided for releasing the energy of said stored energy chambers upon demand to effect rapid accelerating movement of one jar tool member respective the other jar tool member and thereby propel one said member away from the other said member in a manner to move both members uphole. At a selected length of stroke, a part of the tool acts as a hammer positioned to strike a part of the tool which acts as an anvil, and thereby provides sudden deceleration having an impact of a magnitude to accelerate the entire tool string uphole with sufficient thrust to un-stick the tool when the tool is stuck down-hole.
[0020] Another and still further object of the invention is a jar tool having the provision of a central passageway that lays along the longitudinal central axis of the tool extending from the up-hole tool end to the lowermost tool end and thereby allows for safe protection of an insulated conductor to be placed into communication with a downhole instrument or other package, whereby the downhole instrumentation can conduct and transfer electronically various vital information between the instrument package and an above ground facility.
[0021] An additional object of the invention is the provision of means for resetting the tool set forth in the above objects, by manipulation of the wireline tension to thereby again store energy within the spaced energy storing chambers so that the jar tool of this invention can provide a multiplicity of sequential jarring actions.
[0022] Still another and further object of this invention is the provision of adjustment means related to the magnitude and timing of the stored energy devices. In particular, the length of stroke of the two coacting tool parts, the force available from selected stored energy chambers, and the tension required in the E-line to trigger the hammer blow is considered to be within the comprehension of this invention.
[0023] These and other objects and advantages of this invention will become readily apparent to those skilled in the art upon digesting the following detailed description and claims and by referring to the accompanying drawings.
[0024] The above objects are attained in accordance with the present invention by provision of a combination of elements which are fabricated in a manner substantially as described herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025] FIG. 1 is a part schematical, part diagrammatical, part cross-sectional representation of a wellbore that produces fluid from a fluid producing strata and discloses the present invention associated therewith in the standby configuration ready to jar;
[0026] FIG. 2 is an enlarged, broken or composite view of the tool disclosed in FIGS. 1 and 4 illustrating the proper arrangement of the tool of FIGS. 2A, 2B , 2 C, 2 D, 2 E, and 2 F;
[0027] FIGS. 2A, 2B , 2 C, 2 D, 2 E and 2 F, when taken together, set forth an enlarged, detailed, part schematical, part diagrammatical, part cross sectional representation of the invention disclosed in FIGS. 1, 2 , and 3 ;
[0028] FIG. 3 is a part schematical, part diagrammatical, part cross-sectional, side view showing the assembled tool of this invention in the alternate extended configuration;
[0029] FIG. 4 is a hypothetical plot illustrating the dissipation of the stored energy of the tool of the previous figures of the drawings during impact of a jar action.
DETAILED DESCRIPTION OF THE INVENTION
[0030] FIGS. 1 and 2 of the drawings disclose an oil well or borehole 10 within which there is supported a tubing string 12 telescopingly received within a casing 14 . Casing 14 is located within the formed borehole 10 that extends from wellhead 18 at the surface 11 of the earth, through a formation or payzone F, and continues on downhole at 14 ′, or might instead curve into payzone F as noted at F 2 , such as is achieved with directional drilling. Casing 14 is perforated in the usual manner at P or P 1 .
[0031] A wire line tool string 15 has been run into tubing string 12 contained within casing 14 of borehole 10 on an E-line 17 , a slick line or wire rope having an electrical conductor therein. Sometime the tool may be run into the borehole on the end of any suitable elongate member, such as a suitable conduit or elongate tendon such as a pipe, a sucker rod string, or most any logical support member suitable for the occasion.
[0032] Usually, a wire rope 17 having a suitable insulated elec-trical conductor therewithin, is used for supporting a tool string 15 . A lifting rig 20 can take on any number of different forms and should include a weight indicator connected to determine tension of the wire rope or E-line 17 which is spooled onto a drum with the downhole end of E-line 17 terminating in a rope socket 19 at the up-hole end of a sinker bar 22 of tool string 15 . The insulated conductor is electrically connected to continue through a passageway formed in sinker bar 22 , through a jar tool 16 , made in accordance with the present invention, and to the lowermost apparatus 31 supported by the lower end of jar tool 16 , thereby providing transfer of electronic data signals downhole and uphole along E-line 17 that supports tool string 15 .
[0033] Sometime borehole 10 is relatively straight, as seen in FIG. 2 . Sometime a borehole is crooked, or is deliberately slanted as illustrated in FIG. 1 . Most boreholes are crooked and this increases the probability of a string of tools becoming stuck downhole in the borehole, as seen illustrated in FIG. 1 at 118 , for example.
[0034] The uphole end of the jar tool 16 preferably terminates in a closure that takes on the form of a sub 30 presenting a box end 30 ′ opposed to the downhole end 31 , where various different apparatus, including instrument packages and the like, can be supported. The opposed ends 30 , 31 are easily interfaced with other tools by standard subs in a manner that is known in this art.
[0035] FIG. 3 discloses additional details of tool string 15 of FIG. 1 , comprising, commencing at the upper end of FIG. 2 , a wire line or E-line 17 , a rope socket 21 , a sinker bar 22 , the jar tool 16 of this invention, and an adaptor sub 31 which terminates in attached relation respective any desired tool or instrument package 24 that reasonably can be supported from the lower end 31 thereof.
[0036] Still looking at FIG. 3 , sinker bar 22 can be of any desired length, so long as its mass enables resetting jar tool 16 after a jarring action of the jar tool has taken place, thereby enabling multiple sequential jarring actions to be carried out, as will be more fully appreciated later on herein. At the top 30 of jar tool 16 and in underlying relationship respective sinker bar 22 , it will be seen that the diagrammatical representation of the jar tool 16 of FIGS. 2 and 3 has been subdivided into the indicated FIGS. 2A through 2F , thereby enabling the details of each of these assembled Figures to be more fully disclosed on six different sheets of drawing, submitted herewith and forming part of this non-provisional patent application. It should be appreciated that an E-line 17 or equivalent, is connected to a conductor extending axially through sinker bar 22 into communication respective the uppermost end 30 of jar tool 16 , and thereafter the electrical conductor extends axially through jar tool 16 into electrical contact respective the instrument package 24 .
[0037] FIG. 2A illustrates the preferred embodiment of the uphole marginal length of jar tool 16 in greater detail. An upwardly opening box end 30 forms the upper end of jar tool 16 and threadedly engages the lower end of the before mentioned sinker bar 22 by using a suitable interfacing sub as may be necessary. An axial passageway 32 extends longitudinally through the entire jar tool 16 , as well as through the sinker bar 22 . Hence numeral 32 indicates the initial part of the annular passageway formed between connector 35 and the connector 42 .
[0038] The upper terminal end of a hollow protective tubing 33 is anchored or or removably received in close tolerance relationship within connector 142 in order to sealingly accommodate the electrically insulated conductor 34 suitably protected therewithin for providing a source of power to any desired instrument package 24 attached at the lowermost end 31 of jar tool 16 for data transmission from below jar tool 16 uphole to the surface 11 , as previously noted.
[0039] Cylindrical insulator 35 provides for attachment of the conductor 34 at terminal end 36 of through conductor 34 . Connectors 37 , 39 are male and female connectors that are telescopingly fitted together and mounted within the enlarged portion 38 of passageway 32 to facilitate assembly of the various threadedly connected tool components of this invention. Seal means (not shown) are suitably seated within the seal grooves 40 and preferably are high temperature o-rings. Chamber 141 formed within the bell shaped member 41 isolates connector 39 therewithin to enable access to connector 39 and to continue through chamber 241 into the next adjacent chamber 51 of FIG. 2C .
[0040] In FIG. 2B , axial passageway 32 that accommodates tube 33 continues down through the central axis of jar tool 16 where it is concentrically arranged respective to a larger annular chamber formed between the outside diameter of protective tubing 33 and the inside diameter of the main housing 49 .
[0041] Main housing 49 includes a marginal length of the hollow main shaft member 43 reciprocatingly received therein. Looking again now to FIG. 2A together with FIG. 2B , the sealed connection device 142 in chamber 141 seals the working chamber or annulus 146 respective the hollow main shaft 43 . Any number of different seal devices can be used, this example being for teaching purposes in order to enable full comprehension of the disclosure.
[0042] In FIGS. 2B and 2C , conductor 34 , tube 33 and axial passageway 32 continue axially through jar tool 16 in order to protect insulated electrical conductor 34 which is coextensive therewith. The illustrated through conductor 34 is protected by suitable insulation which further is protected by the before mentioned through tubing 33 .
[0043] The before mentioned hollow main shaft member 43 is threadedly engaged by adjustment nut 44 which is locked thereto by adjustable fastener means as indicated by numeral 45 . The lower end of adjustment nut 44 abuttingly engages the uphole end of the illustrated annular Bellville washer stack 46 having a strong spring or biasing action. Bellville washer stack 46 terminates with the downhole end thereof abuttingly engaging the uphole end of a powerful, fully compressible spring device 47 , with there being a spacer or separator 48 , such as a washer, placed therebetween and separating annulus 149 into stored energy chambers 146 , 147 .
[0044] Main housing 49 of FIGS. 2A, 2B , and 2 C is seen to be sectioned into multiple lengths to facilitate assembly, and are connected together by means of a sub 50 ( FIG. 2C ) through which the before mentioned main shaft member 43 ( FIGS. 2B and 2C ) reciprocatingly extends. Main shaft 43 continues into threaded engagement with respect to an internal shaft connector 51 , which also serves as a guide that is slidably received within main housing 149 , which is considered a continuation of housing 49 .
[0045] The tube 33 , positioned within axial passageway 32 , continues through hollow main shaft member 43 and includes insulated conductor 34 therein, all of which continues through main housing 49 , 149 as shown in FIGS. 2A, 2B , 2 C and 2 D. Note that the upper housing 49 , 149 are positioned above the lost motion coupling 68 of FIG. 2D while the lower housing 249 of FIG. 2E is therebelow, as will be more fully discussed later on herein. The housing 49 as seen in FIG. 2C , is connected to housing 149 by means of a sub 50 , having opposed faces 150 , 250 through which internal threaded bores are formed for threadedly receiving the before mentioned hollow shaft member 43 into threaded engagement with respect to internal slidable connector 51 .
[0046] As shown in FIG. 2C , axial passageway 32 continues on through main housing 49 , 149 , sub 50 , internal connector 51 , and axially through the lower spring chamber 154 where it is connected to the releasable latch apparatus 56 , 57 , 156 disclosed in FIG. 2C .
[0047] Adjustment nut 52 , as best seen in FIG. 2C , threadedly engages the marginal threaded end 43 ′ of the lower end 43 ″ of hollow main shaft part 43 , while the lower end thereof also threadedly engages internal connector 51 as noted at 151 in FIG. 2C . Internal main shaft connector 51 threadedly engages the uphole end 243 ′ of releasing member 53 ′ and is a continuation of the before mentioned main shaft part 43 . It can be seen that sub 51 is slidably received in a reciprocating manner within the interior of main housing 149 .
[0048] In FIGS. 2C and 2D , the upper end of power spring 54 abuttingly engages the lower end of sub 51 as noted by numeral 151 in FIG. 2C , and is contained within the illustrated annular spring chamber 55 . As seen in FIG. 2D , the lower end of spring 54 abuttingly engages the upper enlarged end of sleeve 156 , while the opposed circumferentially extending end 58 of sleeve 56 bears against internal shoulder 59 of the main housing. Sleeve 56 , 156 can be moved axially within its chamber 154 between spring 54 and shoulder 156 responsive to movement of main shaft 43 . The sleeve has a counterbore forming an interior shoulder at 156 which abuttingly engages a complimentary shoulder 157 formed on enlargement 57 of latch member 60 that is formed at the lower end of main shaft 43 . Hence, lower terminal end 356 of sleeve 156 abuttingly engages shoulder 59 formed internally on main housing 149 . Enlargement 60 , which is part of latch apparatus 60 , 61 is a continuation of main shaft 43 and forms the male latch part 143 , 156 , 57 , the skirt 356 , and the enlargement 60 at the lower terminal end thereof. Male latch part 60 , when forced into the interior of female latch member 61 of the latch device 60 , 61 , occurs responsive to downhole movement of the main housing which concurrently compresses the before mentioned three spaced biasing or spring members seen in stored energy chambers 149 , 147 and 55 when the tool is reset into the standby configuration, ready to deliver a jarring action. At terminal end 63 of enlargement 60 is a passageway 132 that is a continuation of passageway 32 that slidably receives through tube 32 therewithin, remembering that the tube is anchored to the before mentioned seal 142 , and thereby enables relative movement between main shaft 43 and the through tube 32 while the tube 32 forms a protective housing for conductor 34 . It should be noted at this time that the conductor 34 does not significiently telescope respective to the telecoping tube 32 .
[0049] As further seen in FIGS. 2D and 2E , releasable latch apparatus 60 , 61 includes female member 61 made of a multiplicity of radially arranged, circumferentially extending, longitudinally disposed resilient fingers 62 which enlarge at 64 to threadedly engage elongated lower main shaft member 65 while the lower end of main housing 149 threadedly engages a bottom closure member in the form of a sub 66 (see FIG. 2D ). Sub 66 includes guide pin 168 ′ received within a keyway or spline 168 formed on lost motion coupling 68 to maintain closure member or sub 69 of lower housing 249 and sub 66 of upper housing 149 aligned respective to one another as the confronting faces 70 , 71 of the spaced jar tool subs 66 , 69 are moved towards and away from one another, but always remain spaced apart from one another a slight amount after the tool is scoped together for reset, and assumes the illustrated configuration of FIGS. 2D,2E following a jarring action and prior to reset. The spaced distance between subs 66 , 69 is the measure of one stroke.
[0050] In FIGS. 2E and 2F , sub 69 is seen to include a radially formed longitudinal counterbore that forms blind passageway 73 within which a guide member 72 is reciprocatingly received such that upper terminal end 74 thereof is always spaced from the blind end of the counterbore that forms radial passageway 73 .
[0051] As particularly illustrated in FIG. 2E , one end of guide member 73 is affixed to a pressure differential traveling piston 74 . The piston has seals grooves 75 suitably formed thereon, thereby isolating chambers 76 , 77 from one another as fluid enters and leaves through the ports 78 , thereby isolating chamber 77 from well fluids while subjecting chamber 76 , to the hydrostatic head of the well fluids.
[0052] Chamber 77 is filled with a non-compressible, non-conducting mineral oil to reduce the likelihood of well fluids contaminating the electronic components of the jar tool.
[0053] Accordingly, piston 74 moves in low friction relationship respective the interior of main housing 249 and the exterior surface of through tube 32 through which conductor 34 extends, thereby avoiding contamination of the interior of tube 32 .
[0054] Conductor 34 , as shown in FIG. 2E , is formed into a looped or serpentine configuration as indicated at numeral 80 , allowing the feed through wire tube 32 to move along the central axis of the jar tool while always having slack at 80 in order to accommodate undue wire tension during reciprocation of tube 32 within main shaft member 43 , noting that tube 32 reciprocates concurrently respective sub 49 seen at the anchor seal at the upper end of the jar tool. Enlargement 81 forms a stop member on the interior of main housing 249 for limiting travel of piston 74 in the unlikely event of leakage of well fluid thereinto.
[0055] In FIG. 2F , the lowermost end of conductor 34 is received by electrical connector 82 and continues through lowermost sub 83 that forms the lower terminal end of jar tool 16 and thereby enables jar tool 16 to be connected to any desired apparatus at threaded end 283 . As further seen in FIG. 2F , a connector 84 is received within enlarged axial counterbore 85 for conducting current flow at 86 to and from the illustrated instrument package 24 . Seals 87 and 88 prevent entry of fluid into the lower end of jar tool 16 .
[0056] FIG. 4 illustrates a hypothetical analyses of the action of jar tool 16 during one jar action. Curve 4 is a plot of the wire line tension commencing with the tool static, hanging free within the in borehole. Curves 1 - 3 illustrate the upthrust realized from each of the three spring or stored energy chambers. The remaining curve that reaches 1,000 pounds is the sum of curves 1 - 4 .
[0057] Characteristics of curves 1 - 3 can be modified by various changes to the tool as set forth herein, and this, of course, results in a modification of the 1,000 pound curve. In actual practice, it is possible to develop approximately 3,000 pounds upthrust with this embodiment of the invention.
In Operation
[0058] In operation, the assembled jar tool 16 is adjusted or set to be actuated at a predetermined fraction of the maximum tensile strength of the E-line. For example, if the E-line breaking strength is 1,000 pounds, the operator may elect to adjust the release tension of the tool latch 61 to be triggered by an uphole force of 200-300 pounds, as read on a weight indicator. This is the force required for the E-line to trigger or pull the male end 60 from the female end 62 of the releasable latch member 60 , 61 . Resetting the tool for subsequent jar actions requires a downhole force applied to the upper end of the jar tool, similar to the releasing force, depending on the design of releasable latch member 60 , 61 . Hence, sinker bar 22 must be of a weight greater than the releasing value of latch 61 in order to be on the safe side. Those skilled in the art know to consider the entire weight of the E-line and tool string when viewing the weight indicator at the surface.
[0059] Adjusting nut 52 should be set by the shop technician who should make certain that latch means 61 is also adjusted into proper position respective sleeve 56 , and reduced diameter passageway at 349 , at this time by properly spacing out the component parts of the jar tool. Adjusting nut 44 , located immediately adjacent the upper stored energy or spring chamber 146 , is rotated or set for minor adjustments in the field. This action gains the desired releasing value of latch assembly 61 and is realized through trial and error while studying the situation using a suitable weight indicator for accuracy.
[0060] The adjustments of nut 44 pre-loads the three spring chambers of the upper spaced spring chambers which in turn places a continuous uphole force on male member 60 of releasable latch assembly 60 , 61 . Accordingly, this action commences a releasing action which is somewhat analogous to the action of the E-line as the release tension force is applied.
[0061] The complex action of the jar tool is easily comprehended when it is appreciated that the operating mandrel or main shaft 43 extends from enlargement 43 ′ located at the upper extremity thereof and extends through first spring chamber 146 , through second spring chamber 147 , through sub 50 , adjustment nut 52 , and operating chamber 152 , where it is joined to the threaded internal connector 51 , continues through the third and lowermost spring or energy storage chamber 55 , and terminates as the illustrated male part 60 of releasable latch device 61 . The main shaft 43 therefore can be forced to slide axially between the limits provided by opposed confronting faces 151 , 252 and 250 , 152 within chamber 350 .
[0062] In FIG. 2D , hammer 166 and anvil 165 are illustrated in the impact position.
[0063] Male release member 60 together with female latch member 61 are unique in that it cooperates with the third spring chamber 55 in several different manners. Note sleeve 56 is slidably received within the third spring chamber 154 and has an enlargement 156 thereon that abuttingly engages power spring 54 as well as the enlarged diameter part 349 that forms shoulders 59 , 59 ′ formed on an inner limited length of main upper housing 149 . Also note enlarged member 57 on latch member 60 that is also part of the main shaft 43 and engages member 156 at shoulder 157 . Further, sleeve 56 has a downhole end 58 that abuttingly engages shoulder 59 of outermost housing 249 . The third spring 54 biases sleeve 56 downhole while abutting internal slidable connector 51 to thereby provide part of the stored energy for contributing to the upthrust of main body 49 together with the other biasing means or stored energy devices of this disclosure. Hence, sleeve 56 is always biased or urged downhole against shoulder 59 by adjacent spring 54 as shown, except when main upper housing 149 moves downhole towards lower main housing 249 during reset. In order for connected or engaged latch assembly 61 to telescope into smaller diameter chamber 260 , the latch parts 60 , 61 must be fully engaged while they are within the large diameter latch chamber 261 , because the latch assembly 61 cannot be reset nor released once it is positioned within small diameter chamber 169 , due to the relative diameters of the coacting members.
[0064] The latch 60 telescopes into chamber large diameter bore that forms chamber 261 where latch parts 60 , 61 have ample room to expand into latched engagement, while they are within the large part 349 of the latch chamber. Hence the latch cannot be set nor released once it is positioned within small diameter bore 359 of chamber 260 .
[0065] Those skilled in the art having digested this disclosure will appreciate that the lower main housing of the jar tool, when stuck or otherwise held stationary, while the upper box end 30 is forced downward respective thereto, the lost motion coupling 68 telescopes into closure member or sub 66 , while the anvil 65 is reposition further towars the upper tool end as the main housing decends, thus moving the latch means and anvil uphole away from hammer 65 concurrently with the separation of faces 70 , 71 , respectively, of the confronting subs 66 , 69 while at the same time moving enlargement or anvil 65 along with the female latch part 162 into the latched position, which occures only in the large diameter latch chamber. Accordingly, confronting faces 70 , 71 of the main chamber members are brought into proximity of one another, but preferably, they always remain slightly spaced apart.
[0066] At this time, main housing 49 connector sub 50 contacts nut 52 , thereby forcing main shaft 43 downhole which compresses each spring associated with the three spring chambers 146 , 147 , 155 and latches members 60 , 62 together.
[0067] During this movement, the male latch part 60 is telescopingly received within the resilient fingers 62 of the female member of the latch device 61 as the female part 62 encapsulates the downwardly moving male part 60 of the latch device 61 , 61 . Simultaneously with this action, energy is stored within the three spring chambers.
[0068] In addition to the ability to preload the various springs by addition of spacers and the like, the adjustment means 44 near the upper end of the main shaft as well as the other adjustment means 52 located within chamber 53 between sub 50 and internal slidable connector 51 are adjusted to control the required tension in the E-line for triggering the release of latch 60 , 61 . It should be noted that the uphole enlarged terminal end of main shaft 43 is always spaced from anchor and seal means 42 as shown to prevent impact therebetween. Further, nut 44 , when torqued against spring device 46 , preloads both the first and second spring devices with the equivalent of 50 pounds wireline tension, and consequently places an uphole force on male member 60 of the releasable latch device, thereby providing a means by which the tension in the E-line for releasing the latch device can be selected in the field.
[0069] When adjusting nut 52 is moved along threaded surface 53 ′, the length of the jarring stroke is changed, while at the same time should the adjusting nut 52 be torqued against the downhole face of sub 50 , this action will force male part 60 further into female part 61 of the latch device while pre-compressing the springs in all three stored energy chambers. Further, it should be noted that latch device 60 , 61 can always be set into the latched position so long as the parts are properly spaced out to provide for the before mentioned adjustment.
[0000] springs in all three stored energy chambers. Further, it should be noted that latch device 60 , 61 can always be set into the latched position so long as the parts are properly spaced out to provide for the before mentioned adjustment.
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A wireline jar tool delivers instrument packages into wellbores and retrieves tools when they get stuck. The jar has several stored spring chambers connected to accelerate an upper spring chamber away from a stuck lower carrier chamber that supports instrument packages. Wireline tension actuates the jarring action and then lowers a sinker bar for reset as many times as required to incrementally jar the un-stick fish uphole. The wire line connects to a conductor that extends inside the tool through a main operating shaft, release coupling, hammer and anvil, lost motion coupling, into the lower chamber where the end connects to the instruments for communication to the surface. A small wireline tension provides unexpected large impact forces.
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RELATED APPLICATIONS
[0001] This patent application claims the benefit under title 35, United States Code, Section 119(e) to the United States Provisional Patent Application having Ser. No. 60/398,625 filed on Jul. 24, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of multimedia compression systems. In particular the present invention discloses methods and systems for specifying variable accuracy inter-picture timing with reduced requirements for processor intensive division operation.
BACKGROUND OF THE INVENTION
[0003] Digital based electronic media formats are finally on the cusp of largely replacing analog electronic media formats. Digital compact discs (CDs) replaced analog vinyl records long ago. Analog magnetic cassette tapes are becoming increasingly rare. Second and third generation digital audio systems such as Mini-discs and MP3 (MPEG Audio—layer 3) are now taking market share from the first generation digital audio format of compact discs.
[0004] The video media formats have been slower to move to digital storage and digital transmission formats than audio media. The reason for this slower digital adoption has been largely due to the massive amounts of digital information required to accurately represent acceptable quality video in digital form and the fast processing capabilities needed to encode compressed video. The massive amounts of digital information needed to accurately represent video require very high-capacity digital storage systems and high-bandwidth transmission systems.
[0005] However, video is now rapidly moving to digital storage and transmission formats. Faster computer processors, high-density storage systems, and new efficient compression and encoding algorithms have finally made digital video transmission and storage practical at consumer price points. The DVD (Digital Versatile Disc), a digital video system, has been one of the fastest selling consumer electronic products in years. DVDs have been rapidly supplanting Video-Cassette Recorders (VCRs) as the pre-recorded video playback system of choice due to their high video quality, very high audio quality, convenience, and extra features. The antiquated analog NTSC (National Television Standards Committee) video transmission system is currently in the process of being replaced with the digital ATSC (Advanced Television Standards Committee) video transmission system.
[0006] Computer systems have been using various different digital video encoding formats for a number of years. Specifically, computer systems have employed different video coder/decoder methods for compressing and encoding or decompressing and decoding digital video, respectively. A video coder/decoder method, in hardware or software implementation, is commonly referred to as a “CODEC”.
[0007] Among the best digital video compression and encoding systems used by computer systems have been the digital video systems backed by the Motion Pictures Expert Group commonly known by the acronym MPEG. The three most well known and highly used digital video formats from MPEG are known simply as MPEG-1, MPEG-2, and MPEG-4. VideoCDs (VCDs) and early consumer-grade digital video editing systems use the early MPEG-1 digital video encoding format. Digital Versatile Discs (DVDs) and the Dish Network brand Direct Broadcast Satellite (DBS) television broadcast system use the higher quality MPEG-2 digital video compression and encoding system. The MPEG-4 encoding system is rapidly being adapted by the latest computer based digital video encoders and associated digital video players.
[0008] The MPEG-2 and MPEG-4 standards compress a series of video frames or video fields and then encode the compressed frames or fields into a digital bitstream. When encoding a video frame or field with the MPEG-2 and MPEG-4 systems, the video frame or field is divided into a rectangular grid of pixelblocks. Each pixelblock is independently compressed and encoded.
[0009] When compressing a video frame or field, the MPEG-4 standard may compress the frame or field into one of three types of compressed frames or fields: Infra-frames (I-frames), Unidirectional Predicted frames (P-frames), or Bi-Directional Predicted frames (B-frames). Intra-frames completely independently encode an independent video frame with no reference to other video frames. P-frames define a video frame with reference to a single previously displayed video frame. B-frames define a video frame with reference to both a video frame displayed before the current frame and a video frame to be displayed after the current frame. Due to their efficient usage of redundant video information, P-frames and B-frames generally provide the best compression.
SUMMARY OF THE INVENTION
[0010] A method and apparatus for performing motion estimation in a video codec is disclosed. Specifically, the present invention discloses a system that quickly calculates estimated motion vectors in a very efficient manner without requiring an excessive number of division operations.
[0011] In one embodiment, a first multiplicand is determined by multiplying a first display time difference between a first video picture and a second video picture by a power of two scale value. This step scales up a numerator for a ratio. Next, the system determines a scaled ratio by dividing that scaled numerator by a second first display time difference between said second video picture and a third video picture. The scaled ratio is then stored to be used later for calculating motion vector estimations. By storing the scaled ratio, all the estimated motion vectors can be calculated quickly with good precision since the scaled ratio saves significant bits and reducing the scale is performed by simple shifts thus eliminating the need for time consuming division operations.
[0012] Other objects, features, and advantages of present invention will be apparent from the company drawings and from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The objects, features, and advantages of the present invention will be apparent to one skilled in the art, in view of the following detailed description in which:
[0014] FIG. 1 illustrates a high-level block diagram of one possible digital video encoder system.
[0015] FIG. 2 illustrates a series of video pictures in the order that the pictures should be displayed wherein the arrows connecting different pictures indicate inter-picture dependency created using motion compensation.
[0016] FIG. 3 illustrates the video pictures from FIG. 2 listed in a preferred transmission order of pictures wherein the arrows connecting different pictures indicate inter-picture dependency created using motion compensation.
[0017] FIG. 4 graphically illustrates a series of video pictures wherein the distances between video pictures that reference each other are chosen to be powers of two.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] A method and system for specifying Variable Accuracy Inter-Picture Timing in a multimedia compression and encoding system with reduced requirements for division operations is disclosed. In the following description, for purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention. For example, the present invention has been described with reference to the MPEG multimedia compression and encoding system. However, the same techniques can easily be applied to other types of compression and encoding systems.
Multimedia Compression and Encoding Overview
[0019] FIG. 1 illustrates a high-level block diagram of a typical digital video encoder 100 as is well known in the art. The digital video encoder 100 receives an incoming video stream of video frames 105 at the left of the block diagram. The digital video encoder 100 partitions each video frame into a grid of pixelblocks. The pixelblocks are individually compressed. Various different sizes of pixelblocks may be used by different video encoding systems. For example, different pixelblock resolutions include 8×8, 8×4, 16×8, 4×4, etc. Furthermore, pixelblocks are occasionally referred to as ‘macroblocks.’ This document will use the term pixelblock to refer to any block of pixels of any size.
[0020] A Discrete Cosine Transformation (DCT) unit 110 processes each pixelblock in the video frame. The frame may be processed independently (an intra-frame) or with reference to information from other frames received from the motion compensation unit (an inter-frame). Next, a Quantizer (Q) unit 120 quantizes the information from the Discrete Cosine Transformation unit 110 . Finally, the quantized video frame is then encoded with an entropy encoder (H) unit 180 to produce an encoded bitstream. The entropy encoder (H) unit 180 may use a variable length coding (VLC) system.
[0021] Since an inter-frame encoded video frame is defined with reference to other nearby video frames, the digital video encoder 100 needs to create a copy of how each decoded frame will appear within a digital video decoder such that inter-frames may be encoded. Thus, the lower portion of the digital video encoder 100 is actually a digital video decoder system. Specifically, an inverse quantizer (Q −1 ) unit 130 reverses the quantization of the video frame information and an inverse Discrete Cosine Transformation (DCT −1 ) unit 140 reverses the Discrete Cosine Transformation of the video frame information. After all the DCT coefficients are reconstructed from inverse Discrete Cosine Transformation (DCT −1 ) unit 140 , the motion compensation unit will use that information, along with the motion vectors, to reconstruct the encoded video frame. The reconstructed video frame is then used as the reference frame for the motion estimation of the later frames.
[0022] The decoded video frame may then be used to encode inter-frames (P-frames or B-frames) that are defined relative to information in the decoded video frame. Specifically, a motion compensation (MC) unit 150 and a motion estimation (ME) unit 160 are used to determine motion vectors and generate differential values used to encode inter-frames.
[0023] A rate controller 190 receives information from many different components in a digital video encoder 100 and uses the information to allocate a bit budget for each video frame. The rate controller 190 should allocate the bit budget in a manner that will generate the highest quality digital video bit stream that that complies with a specified set of restrictions. Specifically, the rate controller 190 attempts to generate the highest quality compressed video stream without overflowing buffers (exceeding the amount of available memory in a video decoder by sending more information than can be stored) or underflowing buffers (not sending video frames fast enough such that a video decoder runs out of video frames to display).
Digital Video Encoding with Pixelblocks
[0024] In some video signals the time between successive video pictures (frames or fields) may not be constant. (Note: This document will use the term video pictures to generically refer to video frames or video fields.) For example, some video pictures may be dropped because of transmission bandwidth constraints. Furthermore, the video timing may also vary due to camera irregularity or special effects such as slow motion or fast motion. In some video streams, the original video source may simply have non-uniform inter-picture times by design. For example, synthesized video such as computer graphic animations may have non-uniform timing since no arbitrary video timing is imposed by a uniform timing video capture system such as a video camera system. A flexible digital video encoding system should be able to handle non-uniform video picture timing.
[0025] As previously set forth, most digital video encoding systems partition video pictures into a rectangular grid of pixelblocks. Each individual pixelblock in a video picture is independently compressed and encoded. Some video coding standards, e.g., ISO MPEG or ITU H.264, use different types of predicted pixelblocks to encode video pictures. In one scenario, a pixelblock may be one of three types:
1. I-pixelblock—An Intra (I) pixelblock uses no information from any other video pictures in its coding (it is completely self-defined); 2. P-pixelblock—A unidirectionally predicted (P) pixelblock refers to picture information from one preceding video picture; or 3. B-pixelblock—A bi-directional predicted (B) pixelblock uses information from one preceding picture and one future video picture.
[0029] If all the pixelblocks in a video picture are Intra-pixelblocks, then the video picture is an Intra-frame. If a video picture only includes unidirectional predicted macro blocks or intra-pixelblocks, then the video picture is known as a P-frame. If the video picture contains any bi-directional predicted pixelblocks, then the video picture is known as a B-frame. For the simplicity, this document will consider the case where all pixelblocks within a given picture are of the same type.
[0030] An example sequence of video pictures to be encoded might be represented as:
[0031] I 1 B 2 B 3 B 4 P 5 B 6 B 7 B 8 B 9 P 10 B 11 P 12 B 13 I 14 . . .
[0000] where the letter (I, P, or B) represents if the video picture is an I-frame, P-frame, or B-frame and the number represents the camera order of the video picture in the sequence of video pictures. The camera order is the order in which a camera recorded the video pictures and thus is also the order in which the video pictures should be displayed (the display order).
[0032] The previous example series of video pictures is graphically illustrated in FIG. 2 . Referring to FIG. 2 , the arrows indicate that pixelblocks from a stored picture (I-frame or P-frame in this case) are used in the motion compensated prediction of other pictures.
[0033] In the scenario of FIG. 2 , no information from other pictures is used in the encoding of the intra-frame video picture I. Video picture P 5 is a P-frame that uses video information from previous video picture I 1 in its coding such that an arrow is drawn from video picture I 1 to video picture P 5 . Video picture B 2 , video picture B 3 , video picture B 4 all use information from both video picture I 1 and video picture P 5 in their coding such that arrows are drawn from video picture I 1 and video picture P 5 to video picture B 2 , video picture B 3 , and video picture B 4 . As stated above the inter-picture times are, in general, not the same.
[0034] Since B-pictures use information from future pictures (pictures that will be displayed later), the transmission order is usually different than the display order. Specifically, video pictures that are needed to construct other video pictures should be transmitted first. For the above sequence, the transmission order might be:
[0035] I 1 P 5 B 2 B 3 B 4 P 10 B 6 B 7 B 8 B 9 P 12 B 11 I 14 B 13 . . .
[0036] FIG. 3 graphically illustrates the preceding transmission order of the video pictures from FIG. 2 . Again, the arrows in the figure indicate that pixelblocks from a stored video picture (I or P in this case) are used in the motion compensated prediction of other video pictures.
[0037] Referring to FIG. 3 , the system first transmits I-frame I 1 which does not depend on any other frame. Next, the system transmits P-frame video picture P 5 that depends upon video picture I 1 . Next, the system transmits B-frame video picture B 2 after video picture P 5 even though video picture B 2 will be displayed before video picture P 5 . The reason for this is that when it comes time to decode video picture B 2 , the decoder will have already received and stored the information in video pictures I 1 and P 5 necessary to decode video picture B 2 . Similarly, video pictures I 1 and P 5 are ready to be used to decode subsequent video picture B 3 and video picture B 4 . The receiver/decoder reorders the video picture sequence for proper display. In this operation I and P pictures are often referred to as stored pictures.
[0038] The coding of the P-frame pictures typically utilizes Motion Compensation, wherein a Motion Vector is computed for each pixelblock in the picture. Using the computed motion vector, a prediction pixelblock (P-pixelblock) can be formed by translation of pixels in the aforementioned previous picture. The difference between the actual pixelblock in the P-frame picture and the prediction pixelblock is then coded for transmission.
P-Pictures
[0039] The coding of P-Pictures typically utilize Motion Compensation (MC), wherein a Motion Vector (MV) pointing to a location in a previous picture is computed for each pixelblock in the current picture. Using the motion vector, a prediction pixelblock can be formed by translation of pixels in the aforementioned previous picture. The difference between the actual pixelblock in the P-Picture and the prediction pixelblock is then coded for transmission.
[0040] Each motion vector may also be transmitted via predictive coding. For example, a motion vector prediction may be formed using nearby motion vectors. In such a case, then the difference between the actual motion vector and the motion vector prediction is coded for transmission.
B-Pictures
[0041] Each B-pixelblock uses two motion vectors: a first motion vector referencing the aforementioned previous video picture and a second motion vector referencing the future video picture. From these two motion vectors, two prediction pixelblocks are computed. The two predicted pixelblocks are then combined together, using some function, to form a final predicted pixelblock. As above, the difference between the actual pixelblock in the B-frame picture and the final predicted pixelblock is then encoded for transmission.
[0042] As with P-pixelblocks, each motion vector (MV) of a B-pixelblock may be transmitted via predictive coding. Specifically, a predicted motion vector is formed using nearby motion vectors. Then, the difference between the actual motion vector and the predicted is coded for transmission.
[0043] However, with B-pixelblocks the opportunity exists for interpolating motion vectors from motion vectors in the nearest stored picture pixelblock. Such motion vector interpolation is carried out both in the digital video encoder and the digital video decoder.
[0044] This motion vector interpolation works particularly well on video pictures from a video sequence where a camera is slowly panning across a stationary background. In fact, such motion vector interpolation may be good enough to be used alone. Specifically, this means that no differential information needs be calculated or transmitted for these B-pixelblock motion vectors encoded using interpolation.
[0045] To illustrate further, in the above scenario let us represent the inter-picture display time between pictures i and j as D i,j , i.e., if the display times of the pictures are T i and T j , respectively, then
[0046] D i,j =T i −T j from which it follows that
[0047] D i,k =D i,j +D i,k
[0048] D i,k =−D k,i
[0000] Note that D i,j may be negative in some cases.
[0049] Thus, if MV 5,1 is a motion vector for a P 5 pixelblock as referenced to then for the corresponding pixelblocks in B 2 , B 3 and B 4 the motion vectors as referenced to I 1 and P 5 , respectively would be interpolated by
[0050] MV 2,1 =MV 5,1 *D 2,1 /D 5,1
[0051] MV 5,2 =MV 5,1 *D 5,2 /D 5,1
[0052] MV 3,1 =MV 5,1 *D 3,1 /D 5,1
[0053] MV 5,3 =MV 5,1 *D 5,3 /D 5,1
[0054] MV 4,1 =MV 5,1 *D 4,1 /D 5,1
[0055] MV 5,4 =MV 5,1 *D 5,4 /D 5,1
[0000] Note that since ratios of display times are used for motion vector prediction, absolute display times are not needed. Thus, relative display times may be used for D i,j inter-picture display time values.
[0056] This scenario may be generalized, as for example in the H.264 standard. In the generalization, a P or B picture may use any previously transmitted picture for its motion vector prediction. Thus, in the above case picture B 3 may use picture I 1 and picture B 2 in its prediction. Moreover, motion vectors may be extrapolated, not just interpolated. Thus, in this case we would have:
[0057] MV 3,1 =MV 2,1 *D 3,1 /D 2,1
[0000] Such motion vector extrapolation (or interpolation) may also be used in the prediction process for predictive coding of motion vectors.
Encoding Inter-Picture Display Times
[0058] The variable inter-picture display times of video sequences should be encoded and transmitted in a manner that renders it possible to obtain a very high coding efficiency and has selectable accuracy such that it meets the requirements of a video decoder. Ideally, the encoding system should simplify the tasks for the decoder such that relatively simple computer systems can decode the digital video.
[0059] The variable inter-picture display times are potentially needed in a number of different video encoding systems in order to compute differential motion vectors, Direct Mode motion vectors, and/or Implicit B Prediction Block Weighting.
[0060] The problem of variable inter-picture display times in video sequences is intertwined with the use of temporal references. Ideally, the derivation of correct pixel values in the output pictures in a video CODEC should be independent of the time at which that picture is decoded or displayed. Hence, timing issues and time references should be resolved outside the CODEC layer.
[0061] There are both coding-related and systems-related reasons underlying the desired time independence. In a video CODEC, time references are used for two purposes:
[0062] (1) To establish an ordering for reference picture selection; and
[0063] (2) To interpolate motion vectors between pictures.
[0000] To establish an ordering for reference picture selection, one may simply send a relative position value. For example, the difference between the frame position N in decode order and the frame position M in the display order, i.e., N-M. In such an embodiment, time-stamps or other time references would not be required. To interpolate motion vectors, temporal distances would be useful if the temporal distances could be related to the interpolation distance. However, this may not be true if the motion is non-linear. Therefore, sending parameters other than temporal information for motion vector interpolation seems more appropriate.
[0064] In terms of systems, one can expect that a typical video CODEC is part of a larger system where the video CODEC coexists with other video (and audio) CODECs. In such multi-CODEC systems, good system layering and design requires that general functions, which are logically CODEC-independent such as timing, be handled by the layer outside the CODEC. The management of timing by the system and not by each CODEC independently is critical to achieving consistent handling of common functions such as synchronization. For instance in systems that handle more than one stream simultaneously, such as a video/audio presentation, timing adjustments may sometimes be needed within the streams in order to keep the different streams synchronized. Similarly, in a system that handles a stream from a remote system with a different clock timing adjustments may be needed to keep synchronization with the remote system. Such timing adjustments may be achieved using time stamps. For example, time stamps that are linked by means of “Sender Reports” from the transmitter and supplied in RTP in the RTP layer for each stream may be used for synchronization. These sender reports may take the form of:
[0065] Video RTP TimeStamp X is aligned with reference timestamp Y
[0066] Audio RTP TimeStamp W is aligned with reference timestamp Z
[0000] Wherein the wall-clock rate of the reference timestamps is known, allowing the two streams to be aligned. However, these timestamp references arrive both periodically and separately for the two streams, and they may cause some needed re-alignment of the two streams. This is generally achieved by adjusting the video stream to match the audio or vice-versa. System handling of time stamps should not affect the values of the pixels being displayed. More generally, system handling of temporal information should be performed outside the CODEC.
A Specific Example
[0067] As set forth in the previous section, the problem in the case of non uniform inter-picture times is to transmit the inter-picture display time values D i,j to the digital video receiver in an efficient manner. One method of accomplishing this goal is to have the system transmit the display time difference between the current picture and the most recently transmitted stored picture for each picture after the first picture. For error resilience, the transmission could be repeated several times within the picture. For example, the display time difference may be repeated in the slice headers of the MPEG or H.264 standards. If all slice headers are lost, then presumably other pictures that rely on the lost picture for decoding information cannot be decoded either.
[0068] Thus, with reference to the example of the preceding section, a system would transmit the following inter-picture display time values:
[0069] D 5,1 D 2,5 D 3,5 D 4,5 D 10,5 D 6,10 D 7,10 D 8,10 D 9,10 D 12,10 D 11,12 D 14,12 D 13,14 . . .
[0000] For the purpose of motion vector estimation, the accuracy requirements for the inter-picture display times D i,j may vary from picture to picture. For example, if there is only a single B-frame picture B 6 halfway between two P-frame pictures P 5 and P 7 , then it suffices to send only:
[0070] D 7,5 =2 and D 6,7 =−1
[0000] where the D i,j inter-picture display time values are relative time values.
[0071] If, instead, video picture B 6 is only one quarter the distance between video picture P 5 and video picture P 7 then the appropriate D i,j inter-picture display time values to send would be:
[0072] D 7,5 =4 and D 6,7 =−1
[0000] Note that in both of the preceding examples, the display time between the video picture B 6 and video picture video picture P 7 (inter-picture display time D 6,7 ) is being used as the display time “unit” value. In the most recent example, the display time difference between video picture P 5 and picture video picture P 7 (inter-picture display time D 6,7 ) is four display time “units” (4*D 6,7 ).
Improving Decoding Efficiency
[0073] In general, motion vector estimation calculations are greatly simplified if divisors are powers of two. This is easily achieved in our embodiment if D i,j (the inter-picture time) between two stored pictures is chosen to be a power of two as graphically illustrated in FIG. 4 . Alternatively, the estimation procedure could be defined to truncate or round all divisors to a power of two.
[0074] In the case where an inter-picture time is to be a power of two, the number of data bits can be reduced if only the integer power (of two) is transmitted instead of the full value of the inter-picture time. FIG. 4 graphically illustrates a case wherein the distances between pictures are chosen to be powers of two. In such a case, the D 3,1 display time value of 2 between video picture P 1 and picture video picture P 3 is transmitted as 1 (since 2 1 =2) and the D 7,3 display time value of 4 between video picture P 7 and picture video picture P 3 can be transmitted as 2 (since 2 2 =4).
[0075] Alternatively, the motion vector interpolation of extrapolation operation can be approximated to any desired accuracy by scaling in such a way that the denominator is a power of two. (With a power of two in the denominator division may be performed by simply shifting the bits in the value to be divided.) For example,
[0076] D 5,4 /D 5,1 ˜Z 5,4 /P
[0000] Where the value P is a power of two and Z 5,4 =P*D 5,4 /D 5,1 is rounded or truncated to the nearest integer. The value of P may be periodically transmitted or set as a constant for the system. In one embodiment, the value of P is set as P=2 8 =256.
[0077] The advantage of this approach is that the decoder only needs to compute Z 5,4 once per picture or in many cases the decoder may pre-compute and store the Z value. This allows the decoder to avoid having to divide by D 5,1 for every motion vector in the picture such that motion vector interpolation may be done much more efficiently. For example, the normal motion vector calculation would be:
[0078] MV 5,4 =MV 5,1 *D 5,4 /D 5,1
[0000] But if we calculate and store Z 5,4 wherein Z 5,4 =P*D 5,4 /D 5,1 then
[0079] MV 5,4 =MV 5,1 *Z 5,4 /P
[0000] But since the P value has been chosen to be a power of two, the division by P is merely a simple shift of the bits. Thus, only a single multiplication and a single shift are required to calculate motion vectors for subsequent pixelblocks once the Z value has been calculated for the video picture. Furthermore, the system may keep the accuracy high by performing all divisions last such that significant bits are not lost during the calculation. In this manner, the decoder may perform exactly the same as the motion vector interpolation as the encoder thus avoiding any mismatch problems that might otherwise arise.
[0080] Since division (except for division by powers of two) is a much more computationally intensive task for a digital computer system than addition or multiplication, this approach can greatly reduce the computations required to reconstruct pictures that use motion vector interpolation or extrapolation.
[0081] In some cases, motion vector interpolation may not be used. However, it is still necessary to transmit the display order of the video pictures to the receiver/player system such that the receiver/player system will display the video pictures in the proper order. In this case, simple signed integer values for D i,j suffice irrespective of the actual display times. In some applications only the sign (positive or negative) may be needed to reconstruct the picture ordering.
[0082] The inter-picture times D i,j may simply be transmitted as simple signed integer values. However, many methods may be used for encoding the D i,j values to achieve additional compression. For example, a sign bit followed by a variable length coded magnitude is relatively easy to implement and provides coding efficiency.
[0083] One such variable length coding system that may be used is known as UVLC (Universal Variable Length Code). The UVLC variable length coding system is given by the code words:
[0000] 1=1
2=0 1 0
3=0 1 1
4=0 0 1 0 0
5=0 0 1 0 1
6=0 0 1 1 0
7=0 0 1 1 1
8=0 0 0 1 0 0 0 . . .
[0084] Another method of encoding the inter-picture times may be to use arithmetic coding. Typically, arithmetic coding utilizes conditional probabilities to effect a very high compression of the data bits.
[0085] Thus, the present invention introduces a simple but powerful method of encoding and transmitting inter-picture display times and methods for decoding those inter-picture display times for use in motion vector estimation. The encoding of inter-picture display times can be made very efficient by using variable length coding or arithmetic coding. Furthermore, a desired accuracy can be chosen to meet the needs of the video codec, but no more.
[0086] The foregoing has described a system for specifying variable accuracy inter-picture timing in a multimedia compression and encoding system. It is contemplated that changes and modifications may be made by one of ordinary skill in the art, to the materials and arrangements of elements of the present invention without departing from the scope of the invention.
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A method and apparatus for performing motion estimation in a digital video system is disclosed. Specifically, the present invention discloses a system that quickly calculates estimated motion vectors in a very efficient manner. In one embodiment, a first multiplicand is determined by multiplying a first display time difference between a first video picture and a second video picture by a power of two scale value. This step scales up a numerator for a ratio. Next, the system determines a scaled ratio by dividing that scaled numerator by a second first display time difference between said second video picture and a third video picture. The scaled ratio is then stored calculating motion vector estimations. By storing the scaled ratio, all the estimated motion vectors can be calculated quickly with good precision since the scaled ratio saves significant bits and reducing the scale is performed by simple shifts.
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CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a U.S. National Phase application under 35 U.S.C. §371 of International Application No. PCT/EP2010/056075, filed on May 5, 2010 and which claims benefit to German Patent Application No. 10 2009 025 917.1, filed on Jun. 4, 2009. The International Application was published in German on Dec. 9, 2010 as WO 2010/139515 A1 under PCT Article 21(2).
FIELD
[0002] The present invention provides a hinge plate for connecting a leaf of a door or a sash of a window or the like to a frame so as to be hinged about a hinge axis, with a frame hinge plate part, which can be fastened to the frame and which includes a frame fastening part and a frame hinge part, with a leaf or sash hinge plate part, which can be fastened to the leaf or sash and includes a leaf or sash fastening part and a leaf or sash hinge part, and with a hinge plate pin, which defines the hinge axis, wherein a primary coil surrounding the hinge plate pin is disposed in the frame hinge part, wherein a secondary coil surrounding the hinge plate pin is disposed in the leaf or sash hinge part and wherein the hinge plate pin is formed as a core for both coils which conducts magnetic flux lines.
BACKGROUND
[0003] Doors for structures such as houses, shops or emergency doors, increasingly have devices which are operated by means of electrical energy for improving safety or convenience.
[0004] To supply them with energy, these devices are either galvanically connected, for example, via sliding contacts or flexible cables, to an external energy source, or they have energy stores themselves, for example, rechargeable cells or batteries.
[0005] In the first-mentioned case, there is the disadvantage that sliding contacts are susceptible to faults and cable connections significantly impair visual appearance. In the second case, the necessity for separate stores increases operating costs. The space required by the stores moreover impairs functionality and visual appearance.
[0006] DE 10 2004 017 341 A1 discloses a hinge plate with a built-in transformer for contactless energy transmission. This hinge plate includes a primary coil disposed in a frame hinge plate part and a secondary coil disposed in a leaf or sash hinge plate part. A hinge plate pin passing through both coils serves for the magnetic coupling of the secondary coil to the primary coil, which are spaced apart from each other in the direction of the hinge axis.
[0007] Although the contactless energy transmission from a fixed frame into a leaf or sash disposed pivotably on the frame is in principle desirable to avoid the aforementioned disadvantages, tests have shown that, with the hinge plate disclosed in DE 10 2004 017 341 A1, only very small levels of electrical power can be transmitted from the primary side to the secondary side since the power loss in the transmission is very high.
SUMMARY
[0008] An aspect of the present invention is to provide a hinge plate which allows for the contactless transmission of electrical energy to an extent necessary for the operation of commonly-used convenience and safety devices provided on the leaf or sash.
[0009] In an embodiment, the present invention provides a hinge plate for connecting a leaf of a door or a sash of a window or the like to a frame so as to be hinged about a hinge axis which includes a frame hinge plate part configured to be fastened to the frame. The frame hinge plate part comprises a frame fastening part and a frame hinge part. A leaf or sash hinge plate part is configured to be fastened to the leaf or sash. The leaf or sash hinge plate part comprises a leaf or sash fastening part and a leaf or sash hinge part. A primary coil is disposed in the frame hinge part and a secondary coil is disposed in the leaf or sash hinge part. The primary coil and the secondary coil are each configured to surround a hinge plate pin defining the hinge axis. The hinge plate pin is provided as a core for both the primary coil and the secondary coil and is configured to conduct magnetic flux lines. The hinge plate pin comprises a support element configured to transmit a mechanical force between the leaf or sash and the frame. A flux element is configured to conduct the magnetic flux lines between the primary coil and the secondary coil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is described in greater detail below on the basis of embodiments and of the drawings in which:
[0011] FIG. 1 shows a longitudinal section along the hinge axis of an exemplary embodiment, but without details of the configuration of the hinge plate pin;
[0012] FIGS. 2 a )- e ) show various configurations of the hinge plate pin, at least partially in section in the direction of the hinge axis;
[0013] FIG. 3 shows a section along sectional line III-III in FIG. 1 ;
[0014] FIG. 4 shows an embodiment of the electrical contacting of a coil in a longitudinal section through the hinge axis; and
[0015] FIG. 5 shows the same electrical contacting in a view from below as shown in FIG. 4 .
DETAILED DESCRIPTION
[0016] In an embodiment of the present invention, the hinge plate pin includes a support element for transmitting mechanical forces between the leaf or sash and the frame and a flux element for conducting magnetic flux lines between the primary and secondary coils. The hinge plate pin consequently has a dual function: on the one hand (as in the case of a conventional hinge plate) it transmits the mechanical forces between the frame and the leaf or sash, on the other hand, it provides an improved magnetic coupling between the primary and secondary coils. Since these two functions are brought about by different elements of the hinge plate pin, the two elements can be especially adapted to the respective function. For the support element, for example, the material may be chosen exclusively on the basis of its mechanical properties. Magnetic properties need not be taken into consideration. For example, steel alloys of sufficient toughness and hardness are suitable, but so too are modern plastics, which may, for example, contain fiber reinforcements. For the flux element, materials with ferromagnetic properties may be used, for example, those with the highest possible permeability.
[0017] It has surprisingly been found that, on account of this functional separation, it is possible as a result of the use of suitable materials for the support element and for the flux element to produce hinge plate pins of the same dimensions as in the case of a conventional hinge plate which are suitable for the transmission of forces at the previous level, but on the other hand, have a permeability that leads to a magnetic coupling of the secondary coil to the primary coil which is adequate for the contactless transmission of electrical energy to an extent necessary for the operation of commonly used convenience or safety devices provided on the leaf or sash.
[0018] To allow different embodiments for achieving the desired mechanical properties to be realized on the support element, it can be advantageous if the flux element is provided as a material which has ferromagnetic properties and can be processed in a flowable state. The material of the flux element can then, for example, be introduced into recesses, depressions, cavities, etc. of the support element in a flowable state and subsequently cured.
[0019] An example of a material which has ferromagnetic properties and can be processed in a flowable state is a sinterable powder material, for example, produced from starting materials such as iron (III) oxide and barium or strontium carbonate. However, it is also possible to produce the flux element from a mixture of ferromagnetic particles, for example, once again from the starting materials iron (III) oxide and barium or strontium carbonate, and to produce a plastics material which can be made to set or sets itself and in which the ferromagnetic particles are then embedded.
[0020] This plastics material may be a thermoplastic material. The hinge plate pin is then produced by feeding the thermoplastic material in powder form, provided with the ferromagnetic particles, to the intended locations of the support element of the hinge plate pin, subsequently heating it to above the melting temperature, and finally cooling it down again, or feeding it to these locations of the support element already in a state in which it has been heated above the melting temperature and is flowable.
[0021] It is also possible, for example, to use as a curable plastics material a multi-component material or such a material which, for example, cures under the influence of electromagnetic energy and with which the ferromagnetic particles have been admixed before the curing operation.
[0022] In an embodiment of the present invention, the plastics material can, for example, also have friction-reducing properties, since in this case it is possible to dispense with bearing bushes that are otherwise often necessary for friction reduction, and the volume otherwise required for the bearing bush is additionally available for the hinge plate pin and/or the coils. Materials such as POM with additions of PTFE or chalk, as well as polyamides with additions of MoSO 4 or other sliding-bearing-modifying properties can, for example, be used. In an embodiment of the hinge plate according to the present invention, an elongate component can, for example, be provided for the support element made of a mechanically stable material and connecting the flux element fixedly to the support element in such a way that the lateral surface of the flux element at least partially covers the support element. If made of a material with friction-reducing properties, the flux element can lie against the inner lateral surfaces of the coils without an additional sleeve-shaped sliding element so as to provide a gap that is as small as possible between the flux element and the coil to improve the magnetic coupling.
[0023] In order to provide a particularly secure connection between the support element and the flux element, it can be advantageous if the support element includes at least one channel, which runs obliquely in relation to the hinge axis and into which the flux element protrudes, in other words: which is filled with material having ferromagnetic properties. Apart from the improvement in the fastening of the flux element to the support element by the positive connection thereby created, the proportion by volume of the material having ferromagnetic properties in the overall volume of the hinge plate pin is also increased on account of this measure, and its suitability for conducting magnetic flux lines is therefore further improved.
[0024] For the further improvement of the magnetic coupling between the coils and the flux element, the flux element may completely surround the support element.
[0025] It is also possible to improve the fastening of the flux element to the support element to provide a cage at least partially surrounding the flux element. This cage may be made of a material having friction-reduced properties, and assume the function of a separate sliding sleeve. In this case, the cage can, for example, be embedded in the material of the flux element so as not protrude radially beyond the flux element, or only slightly, in order that the air gap between the coil and the hinge plate pin is as small as possible.
[0026] In the case of the embodiment of the hinge plate pin described above, the support element is at least substantially disposed inside the flux element. However, it is likewise possible to provide the flux element in a central volume in the support element. This embodiment of the hinge plate pin may be recommendable if, by contrast with the material used for the support element, the material used for the flux element does not have any material properties suitable for forming the surface of the hinge plate pin and the surface of the hinge plate pin is intended to be formed by the materials of the support element. In this case, however, the coupling between the secondary coil and the primary coil could worsen on account of the greater distance between the interior of the coil and the core formed by the hinge plate pin.
[0027] In order to bring about an improvement in this respect, channels which are filled with the material having ferromagnetic properties may be provided so as to extend transversely in relation to the hinge axis from the volume to the lateral surface of the support element. The flux element is then located in a distributed manner over the lateral surface of the hinge plate pin, at least at the locations close to the interior of the coil where the channels pass through the lateral surface of the holding element.
[0028] In an embodiment of the hinge plate according to the present invention, which, however, is not restricted to the variant with a hinge plate pin including a support element and a flux element, and to this extent has its own inventive significance independently thereof, at least one of the coils can, for example, includes contact elements which are disposed on an end face and interact with mating contact elements which are disposed on a side of a connecting element that is facing the end face. On account of this measure, the electrical contacting of the coils so configured is made considerably easier, since the coil can first be inserted into the hinge part of the respective hinge plate part without any electrical conduction and the electrical contacting can be brought about by subsequently inserting the connecting element.
[0029] The hinge plate denoted as a whole in the drawing by 100 is formed as a so-called two-part hinge plate. It includes a lower frame hinge plate part 1 for mounting the hinge plate 100 on a frame (not represented in the drawing), and an upper leaf or sash hinge plate part 2 , on which a leaf or sash (not represented in the drawing) can be mounted. The frame hinge plate part 1 includes a frame fastening part 3 and a frame hinge part 4 , the leaf or sash hinge plate part 2 includes a leaf or sash fastening part 5 and a leaf or sash hinge part 6 .
[0030] The frame hinge plate part 1 and the leaf or sash hinge plate part 2 are connected to each other pivotably about a hinge axis S by means of a hinge plate pin 7 , the center longitudinal axis of which coincides with the hinge axis S and consequently defines the latter.
[0031] The hinge plate pin 7 passes through the frame hinge part 4 in a hinge plate pin receptacle 8 and the leaf or sash hinge part 6 in a hinge plate pin receptacle 9 . A lower bearing bush 10 in the hinge plate pin receptacle 8 and an upper bearing bush 11 in the hinge plate pin receptacle 9 serve for the bearing of the hinge plate pin 7 in the hinge plate pin receptacles 8 , 9 . The bearing bushes are produced from a friction-reducing plastics material, for example on the basis of POM, as already known for the configuration of such bearing bushes in the case of conventional hinge plates.
[0032] Seen from below, the lower bearing bush 10 extends only over part of the length of the hinge plate pin receptacle 8 ; seen from above, the upper bearing bush 11 accordingly extends only over part of the length of the hinge plate pin receptacle 9 . Disposed in the remaining length of the hinge plate pin receptacle 8 is a primary coil 12 , the coil winding 13 of which is wound concentrically in relation to the hinge axis S. The coil is singly wound and, depending on the power being transmitted, has at least two winding layers. The coil winding 13 is enclosed by a casing 14 . Its outer contour is adapted to the contour of the hinge plate pin receptacle 8 in such a way that the primary coil 12 is accommodated in the frame hinge part 4 in a rotationally fixed manner. The casing is supported with its lower end face 15 on the lower bearing bush 10 . The upper end face 16 of the casing 14 forms a rest for the lower end face 17 of a casing 18 of a secondary coil 19 , which is mounted in a way corresponding to the primary coil 12 in the hinge plate pin receptacle 9 in the leaf or sash hinge part 6 and is accordingly supported with its upper end face 20 on the upper bearing bush 11 . The secondary coil 19 has the same structure as the primary coil 12 , it being possible for the coil winding to be formed differently with regard to the number of windings and the dimension of the coil wire used if the electrical energy fed to the primary coil 12 is intended to be transformed in the case of inductive transmission to the secondary coil 19 .
[0033] In order to improve the inductive coupling between the primary coil 12 and the secondary coil 19 , the hinge plate pin 7 , which in FIG. 1 is only represented by its contours, includes a support element 21 , for transmitting mechanical forces between the leaf or sash and the frame, and a flux element 22 , for conducting magnetic flux lines of the primary and secondary coils (see FIG. 2 ). Various hinge plate pins, which differ in the configuration of the support element 21 and the flux element 22 , are represented in FIGS. 2 a ) to e ).
[0034] In the case of the hinge plate pin represented in longitudinal section in FIGS. 2 a ) and b ), the support element 21 takes the form of a rod. It is provided as a steel alloy with properties which are suitable for the transmission of the forces acting from the leaf or sash to the frame in the case of the respective application. The support element 21 is encapsulated with a thermoplastic material 23 , with which particles 24 of ferromagnetic material have been admixed.
[0035] In the case of the exemplary embodiment represented in FIG. 2 a ), the plastics material 23 is surrounded by a cage 25 , which is made of a friction-reducing plastics material, so as to reduce the friction between the hinge plate pin 7 and the bearing bushes 11 , 12 and between the inner lateral surfaces of the casings 14 , 18 and the coils. The cage 25 is formed as a sleeve 26 with rows of holes 27 . In these holes, the plastics material 23 including the particles 24 reaches as far as the lateral surface 28 of the hinge plate pin, so as to improve the inductive coupling between the flux element 22 and the coils 12 , 19 .
[0036] End pieces 29 , 30 form the upper and lower terminations of the embodiment of the hinge plate pin as shown in FIG. 2 a ) and b). For fastening to the support element 21 , these end pieces have studs 31 , which respectively form a press fit with blind-hole bores 32 of the support element 21 .
[0037] A further exemplary embodiment of the hinge plate pin 7 is represented in longitudinal section in FIG. 2 c ). In the case of this exemplary embodiment, the support element 21 is completely enclosed by the flux element 22 . The flux element is once again made of plastics material 23 with ferromagnetic particles 24 . The plastics material is a thermosetting material, for example, based on polyester or epoxy resin, the surfaces of which can be machined after curing.
[0038] In the case of the further exemplary embodiment shown partially in longitudinal section in FIG. 2 d ), the hinge plate pin 7 is provided with a flux element 22 only over part of a length. For this purpose, the support element 21 has an annular groove 33 , the length L of which corresponds approximately to the length that is covered by the two coils 12 , 19 . Through-channels 34 are provided in the region of the annular groove; the annular groove 33 and the channels 34 are filled with plastics material 23 mixed with particles 24 .
[0039] In the case of the further embodiment of the hinge plate pin 7 as shown in FIG. 2 e ), the flux element 22 is provided within a volume 35 which extends at the top over a length of the support element 21 that is covered by the two coils 12 , 19 . For this purpose, this volume 35 is at least partially filled with ferromagnetic particles 24 , which once again may be embedded in a plastics material. Provided to improve the inductive coupling with the coils 12 , 19 are channels 36 , which reach from the volume 35 to the lateral surface 28 and in which the flux element 22 then once again protrudes as far as the lateral surface 28 .
[0040] It should be noted that the representation of the plastics material 23 and particles 24 is merely schematic; in particular, the particle size represented and the proportion by volume thereof in relation to the plastics material do not correspond to reality. The particles may be considerably smaller, the proportion by volume thereof in relation to the proportion of plastic may be considerably greater. Furthermore, it is likewise possible to produce the flux elements from ferritic material without embedding particles in a polymer matrix, for example by sintering with a powder material, as long as a sufficiently solid connection of the flux element 22 to the support element is provided.
[0041] The two coils 12 , 19 may be fixedly provided with electrical connecting lines 37 , 38 . These may then be led out from the hinge plate pin receptacles 8 , 9 through transverse bores 39 , 40 in the frame hinge part 4 and the leaf or sash hinge part 6 and led to the frame or the leaf or sash through channels 41 provided in the frame fastening part 3 and the leaf or sash fastening part 5 . As can be seen in FIG. 3 , the channels 41 can be closed with the aid of a cover 42 so that lines 37 , 38 cannot be seen or manipulated from the outside. FIG. 3 only illustrates the routing of the lines on the basis of the leaf or sash hinge plate part 2 , but it can be performed in a corresponding way in the case of the frame hinge plate part 1 .
[0042] In particular if the space available for the contacting and the cable routing is limited, the mounting of the coils 12 , 19 in the corresponding hinge plate pin receptacles 8 , 9 may present difficulties on account of the connecting cables that are fixedly connected to the coils. This can be remedied by the electrical contacting that is shown in FIGS. 4 and 5 . In the case of this contacting, the coils, of which only the primary coil 12 is represented by way of example in FIGS. 4 and 5 , have on an end face contact elements 43 , which in the fitted state interact with mating contact elements 44 . The mating contact elements 44 are attached to a connecting element 45 , which may have the form of a disk, and are connected in an electrically conducting manner to the electrical lines 37 . It goes without saying that this type of contacting may be used independently of the special configuration of the hinge plate pin represented further above, and consequently also has independent inventive significance.
[0043] The present invention is not limited to embodiments described herein; reference should be had to the appended claims.
LIST OF DESIGNATIONS
[0000]
100 hinge plate
1 frame hinge plate part
2 leaf or sash hinge plate part
3 frame fastening part
4 frame hinge part
5 leaf or sash fastening part
6 leaf or sash hinge part
7 hinge plate pin
8 hinge plate pin receptacle
9 hinge plate pin receptacle
10 lower bearing bush
11 upper bearing bush
12 primary coil
13 coil winding
14 casing
15 lower end face
16 upper end face
17 lower end face
18 casing
19 secondary coil
20 upper end face
21 support element
22 flux element
23 plastics material
24 particles
25 cage
26 sleeve
27 holes
28 lateral surface
29 end piece
30 end piece
31 studs
32 blind-hole bores
33 annular groove
34 channels
35 volume
36 channels
37 lines
38 lines
39 transverse bore
40 transverse bore
41 channels
42 cover
43 contact elements
44 mating contact elements
45 connecting element
L length
S hinge axis
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A hinge plate for connecting a leaf of a door to a frame includes a frame hinge plate part comprising a frame fastening part and a frame hinge part. A leaf or sash hinge plate part comprises a leaf or sash fastening part and a leaf or sash hinge part. A primary coil is disposed in the frame hinge part and a secondary coil is disposed in the leaf or sash hinge part, each being configured to surround a hinge plate pin defining a hinge axis. The hinge plate pin is provided as a core for both the primary coil and the secondary coil and is configured to conduct magnetic flux lines. The hinge plate pin comprises a support element configured to transmit a mechanical force between the leaf and the frame. A flux element is configured to conduct the magnetic flux lines between the primary coil and the secondary coil.
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FIELD OF THE INVENTION
The present invention relates to a novel dehairing and fibre opening process for complete elimination of lime and sodium sulfide. More particularly, the present invention provides an improved process for making pelt by dehairing and fibre opening employing enzyme and non-toxic silicate salt. The process has enormous potential application in tanning industry for processing hides/skins in an eco-benign way without adding to pollution load.
BACKGROUND AND PRIOR ART REFERENCES
Conventional leather processing involves four important operations, viz., pre-tanning, tanning, post tanning and finishing. It includes a combination of single and multi-step processes that employs as well as expels various biological, organic and inorganic materials as described by Germann (Science and Technology for Leather into the Next Millennium, Tata McGraw-Hill Publishing Company Ltd., New Delhi, p. 283, 1999). Beam house processes (liming and reliming) employ lime and sodium sulfide and purifies the skin matrix by the removal of hair, flesh and other unwanted materials. Various application methods include pit, paddle, drum and painting on flesh side. After this stage, the hide/skin is termed as pelt. Deliming, bating and pickling processes prepare the skin for subsequent tanning. Tanned skin matrix further retanned to gain substance, fatliquored to attain required softness and dyed to preferred shades.
Generally, liming-reliming process liquors contribute to 50-70% of the total biochemical oxygen demand (BOD) and chemical oxygen demand (COD) load from a tannery wastewater and 15-20% in the case of total solids (TS) load as reported by Aloy et al (Tannery and Pollution, Centre Technique Du Cuir: Lyon, France, 1976). Apart from this, a great deal of solid wastes containing lime sludge, fleshings, and hair are generated. The extensive use of sulfide bears unfavorable consequences on environment and the efficacy of effluent treatment plants as reported by Colleran et al (Antonie van Leeuwenhoek, 67, 29, 1995).
Several lime and sulfide free liming methods have evolved during the past century. Bose and Dhar (Leather Science, 2, 140, 1955; 21, 39, 1974) have reviewed the use of enzymes such as proteolytic, amylolytic, etc from various sources namely animal, mold, bacterial and plant for dehairing hides and skins. However, these methods include the use of lime. Rosenbusch (Das Leder, 16, 237, 1965) has reported the use of chlorine dioxide for dehairing. Morera et al (Journal of the Society of Leather Technologists and Chemists, 81, 70, 1997) have studied the use of hydrogen peroxide in alkaline medium for dehairing by oxidation mechanism. However, the reduction in pollution load especially COD is not significant. Sehgal et al (Journal of the Society of Leather Technologists and Chemists, 80, 91, 1996) have developed a non-enzymatic sulfide free dehairing process using 1% nickel carbonate, 1% sodium hydroxide, 5% lime and kaolin along with water by painting. However, disposal or recovery of nickel compounds poses serious health problems. Schlosser et al (Journal of the Society of Leather Technologists and Chemists, 70, 163, 1986) have reported the use of lacto-bacillus based enzymes at acidic conditions for dehairing. This method leads to the solubilisation of collagen at the experimental conditions. Valeika et al (Journal of the Society of Leather Technologists and Chemists, 81, 65, 1997; 82, 95, 1998) have attempted to replace lime for dehairing using sodium hydroxide and sodium sulfide. They also found that the addition of salts such as sodium chloride, sodium sulfate, sodium formate or sodium hydrogen phosphate influence the extent of hair removal as well as opening up of the dermis structure. Commercial application of these methods is not popular in the global leather sector. Thanikaivelan et al (Journal of the Society of Leather Technologists and Chemists 84, 276, 2000) have developed a lime free enzymatic dehairing process along with reduced amount of sodium sulfide, which ensures complete dehairing within 18 hrs. However, enzyme-assisted lime-sulfide dehairing is being followed in some parts of the world. All the methods are applicable for only dehairing of skins/hides in leather processing. The dehaired pelts require fibre opening. Conventionally the fibre opening is obtained by treatment with lime through osmotic swelling.
Liming removes all the interfibrous materials especially proteoglycans and produces a system of fibres and fibrils of collagen which are clean as described by Campbell et al (Journal of American Leather Chemists Association, 68, 96, 1973). This is achieved by the alkali action as well as osmotic pressure built up in the skin matrix. Thanikaivelan et al (Environmental Science & Technology, 36, 4187, 2002) have successfully developed lime free fibre opening process employing x-amylase. However, no successful attempt has been made to eliminate lime and sodium sulfide completely in leather processing.
In our earlier application PCT/N03/00074, we have shown a novel process for an unhairing process using animal and/or herbal enzymes. The claimed process provides with a dime-sulphide free process for unhairing. The previously claimed method was restricted in the pH range of 4.0-10.0. In addition, the effect of use of silicate salt was not discussed and other parameters, which distinguishes our present work from the previous work. For example, identification and use of different enzymes and silicate salts for forming the paste and comparative study of the present invention with respect to the conventional lime-sulphide process. The present invention also makes an attempt to make a comparison between the quality of leather in the conventional method and present case.
Silicates have been widely used in various industrial applications for a long time. In leather manufacture, by contrast, the silica compounds have so far been of only minor importance. Wet-white tanning agent based on sodium aluminium silicate has been reported by Zauns and Kuhm (Journal of American Leather Chemists Association, 90, 177, 1995). Silicon dioxide based tanning system has been established by Fuchs and Kupfer (Journal of American Leather Chemists Association, 90, 164, 1995). Recently, Kanagaraj et al (Journal of American Leather Chemists Association, 95, 368, 2000) have developed a less salt preservation system based on silica gel and low amount of salt.
OBJECTS OF THE INVENTION
The main objective of the present invention is to provide a novel dehairing and fibre opening process for complete elimination of lime and sodium sulfide, which obviates the drawbacks stated above.
Another objective of the present invention is to provide a complete set of beam-house processes that employs only enzyme and non-toxic chemical.
Yet another objective of the present invention is to provide a bio-chemical based beam-house process that provides softer and smoother leathers.
Still another objective of the present invention is to provide a biochemical based beam-house process that leads to significant reduction in chemical oxygen demand and total solids load.
Yet another objective of the present invention is to provide a lime and sodium sulfide free beam-house process that totally obviates the formation of dry sludge.
BRIEF DESCRIPTION OF THE FIGURES AND TABLES
Table 1: Comparative data on various environmental and economic parameters
FIG. 1 : Evaluation data for leathers obtained from conventional method and present invention
DETAILED DESCRIPTION OF THE INVENTION
Accordingly, the present invention provides a novel dehairing and fibre opening process for complete elimination of lime and sodium sulfide, which comprises
i) adding 5-10% w/w, based on the weight of soaked hides/skins, of water to 0.5-1.5% w/w, based on the weight of soaked hides/skins, of proteolytic enzyme, exhibiting optimum activity at pH 7.5-11.0 and temperature 25-40° C., optionally in the presence of not more than 1.5% w/w, based on the weight of soaked hides/skins, of silicate salt, to prepare a paste, ii) applying the paste, as formed in step (i), on the flesh or grain side of the hides/skins by known method, iii) piling the pasted hides/skins grain to grain for a period of not less than 12 hours followed by removing the hair by known method to get dehaired hides/skins, iv) treating the dehaired hides/skins, as obtained in step (iii), with 5-10% w/w, based on the weight of dehaired hides/skins, of silicate salt in presence of 50-250% w/w of water, preferably under stirring condition, for a period of not less than 3 hrs, followed by fleshing by known method to get pelt for subsequent post fibre opening processes.
In an embodiment of the present invention, the proteolytic enzyme used may be selected from bacterial protease, fungal protease, either individually or in any combination.
In another embodiment of the present invention, the silicate salt used may be selected from sodium metasilicate, water glass, sodium orthosilicate, either individually or in combination.
The process of the present invention is described below in detail.
A dehairing paste is prepared by mixing proteolytic enzyme in the range of 0.5-1.5% w/w, on the weight of soaked skins or hides with 5-10% w/w of water on the weight of soaked skins or hides, optionally in the presence of not more than 1.5% w/w of silicate salt. The dehairing paste, thus prepared is applied on the flesh or grain side of the soaked skins or hides by known manual or mechanical method and the pasted hides/skins are piled grain to grain for a period of not less than 12 hrs. The skins or hides are then dehaired by conventional method.
The dehaired skins or hides are mixed with 50-250% w/w of water on the weight of dehaired skins or hides and treated with 5-10% w/w of silicate salt on the weight of dehaired skins or hides preferably under stirring condition, for a period of not less than 3 hrs followed by fleshing by known method to get pelt for subsequent post fibre opening processes.
The novelty and non obviousness of the present development lies in using proteolytic enzymes and non-toxic silicate salt for dehairing and fibre opening, thereby providing an eco-benign bio-chemical based beam house process that totally eliminates the use of lime and sodium sulfide.
The applicant have compared the various pollution parameters, time, water and power requirement between the conventional and novel dehairing and fibre opening processes in accompanying Table 1. The softness and other bulk properties have been compared by hand and visual examination and the rating are given in accompanying FIG. 1 .
TABLE 1 Conventional lime- Novel lime-sodium S1. sodium sulfide sulfide free No. Parameters process process 1. Dry sludge formation 120-150 kg/t of No dry sludge raw skins/hides formed 2. Total solids load 100-200 kg/t of 50-120 kg/t of raw skins/hides raw skins/hides 3. COD load 40-100 kg/t of 20-60 kg/t of aw raw skins/hides skins/hides 4. Time requirement 3-5 days 1-3 days 5. Water requirement 4-8 l/kg of raw 2-3 l/kg of raw skins/hides skins/hides 6. Power requirement 50-100 kWh 15-45 kWh 7 Toxicity Sodium sulfide is Enzyme and highly toxic silicate salts are not toxic.
The invention is described in detail in the following examples, which are provided by way of illustration only and therefore should not be construed to limit the scope of the present invention.
EXAMPLE 1
Three wet salted goatskins, weighing 2.8 kg, were soaked in 8.4 lit water for 2 hrs in a pit. Then the skins were again soaked in 8.4 lit fresh water for 2 hrs. The soaked skins were drained to remove surface water and the weight was found to be 3 kg. 30 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 30 gms sodium metasilicate were mixed in 180 ml water to form a paste. The prepared paste was applied on the flesh side of the goatskins and piled flesh side of one skin to flesh side of the other and left undisturbed for 12 hrs. The skins were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired skins was found to be 2.1 kg.
The dehaired goatskins were loaded in a drum with 4200 ml water. To this, 105 gms sodium orthosilicate was added to the drum. The duration of treatment was one day with 5 min running per hour for 6 hrs and left overnight in the bath. The bath was drained off and the skins were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 2.8 kg. The resultant pelts were taken for further processing.
EXAMPLE 2
Three dry salted sheepskins, weighing 4.7 kg, were soaked in 14.1 lit water for 3 hrs in a pit. Then the skins were again soaked in 14.1 lit fresh water for 3 hrs. The soaked skins were drained to remove surface water and the weight was found to be 6 kg. 30 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) was mixed in 300 ml water along with 90 gms sodium orthosilicate to form a paste. The prepared paste was applied on the flesh side of the sheepskins and piled flesh side of one skin to flesh side of the other and left undisturbed for 12 hrs. The skins were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired skins was found to be 3.6 kg.
The dehaired skins were loaded in a drum with 7200 ml water. To this, 180 gms sodium metasilicate was added to the drum. The duration of treatment was one day with 5 min running per hour for 6 hrs and left overnight in the bath. The bath was drained off and the skins were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 4.5 kg. The resultant pelts were taken for further processing.
EXAMPLE 3
Four green cow sides, weighing 23 kg, were soaked in 69 lit water for 2 hrs in a pit. The soaked sides were drained to remove surface water and the weight was found to be 24 kg. 240 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 120 gms Erhavit MC (alkaline fungal protease from Together For Leather (TFL), Germany) were mixed in 2400 ml water along with 360 gms water glass to form a paste. The prepared paste was applied on the grain side of the cow sides and piled grain side of one side to grain side of the other and left undisturbed for 18 hrs. The sides were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired sides was found to be 20 kg.
The dehaired sides were loaded in a drum with 50000 ml water. To this, 2 kg sodium metasilicate was added and the drum was run for 5 min per hour for 6 hrs and left overnight in the bath. The bath was drained off and the sides were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 25 kg. The resultant pelts were taken for further processing.
EXAMPLE 4
Four green cow sides, weighing 23 kg, were soaked in 69 lit water for 2 hrs in a pit. The soaked sides were drained to remove surface water and the weight was found to be 24 kg. 240 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 120 gms Microdep C (alkaline bacterial protease from Textan Chemicals Private Limited, Chennai, India) were mixed in 2400 ml water along with 360 gms water glass to form a paste. The prepared paste was applied on the grain side of the cow sides and piled grain side of one side to grain side of the other and left undisturbed for 18 hrs. The sides were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired sides was found to be 20 kg.
The dehaired sides were loaded in a drum with 50000 ml water. To this, 2 kg sodium metasilicate was added and the drum was run for 5 min per hour for 6 hrs and left overnight in the bath. The bath was drained off and the sides were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 25 kg. The resultant pelts were taken for further processing.
EXAMPLE 5
Three dried buffcalfs, weighing 17 kg, were soaked in 51 lit water for 3 hrs in a pit. Then the skins were again soaked in 51 lit fresh water for 4 hrs with 17 gms wetting agent. The soaked calfs were drained to remove surface water and the weight was found to be 22 kg. 220 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 220 gms water glass were mixed in 1540 ml water to form a paste. The prepared paste was applied on the grain side of the calfs and piled grain side of one calf to grain side of the other and left undisturbed for 18 hrs. The calfskins were dehaired using conventional beam and blunt knife technique. Weight of the dehaired calfs was found to be 18 kg.
The dehaired calfs were loaded in a drum with 36000 ml water. To this, 360 gms water glass, 900 gms sodium metasilicate and 180 gms sodium orthosilicate were added to the drum. The duration of treatment was one day with 5 min running per hour for 6 hrs and left overnight in the bath. The bath was drained off and the calfskins were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 23 kg. The resultant pelts were taken for further processing.
EXAMPLE 6
Three wet salted goatskins, weighing 2.8 kg, were soaked in 8.4 lit water for 2 hrs in a pit. Then the skins were again soaked in 8.4 lit fresh water for 2 hrs. The soaked skins were drained to remove surface water and the weight was found to be 3.2 kg. 32 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 16 gms Microdep C (alkaline bacterial protease from Textan Chemicals Private Limited, Chennai, India) were mixed in 160 ml water to form a paste. The prepared paste was applied on the flesh side of the goatskins and piled flesh side of one skin to flesh side of the other and left undisturbed for 12 hrs. The skins were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired skins was found to be 2.2 kg.
The dehaired goatskins were loaded in a drum with 1100 ml water. To this, 132 gms sodium metasilicate was added to the drum. The drum was run for 20 min per hour for 3 hrs. The bath was drained off and the skins were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 2.9 kg. The resultant pelts were taken for further processing.
EXAMPLE 7
Four freezed cow sides, weighing 24 kg, were soaked in 72 lit water for 3 hrs in a pit. The soaked sides were drained to remove surface water and the weight was found to be 25 kg. 250 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) and 250 gms sodium metasiliacte were mixed in 1750 ml water to form a paste. The prepared paste was applied on the grain side of the cow sides and piled grain side of one side to grain side of the other and left undisturbed for 18 hrs. The sides were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired sides was found to be 20 kg.
The dehaired sides were loaded in a drum with 50000 ml water. To this, 1.6 kg sodium orthosiliacte and 400 g sodium metasilicate were added and the drum was run for 20 min per hour for 10 hrs. The bath was drained off and the sides were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 26 kg. The resultant pelts were taken for further processing.
EXAMPLE 8
Three dry salted sheepskins, weighing 5.0 kg, were soaked in 15 lit water for 3 hrs in a pit. Then the skins were again soaked in 15 lit fresh water for 3 hrs. The soaked skins were drained to remove surface water and the weight was found to be 6.2 kg. 62 gms Biodart (alkaline bacterial protease from Southern Petrochemical Industries Corporation (SPIC) Limited, Chennai, India) was mixed in 372 ml water along with 46.5 gms sodium metasilicate to form a paste. The prepared paste was applied on the flesh side of the sheepskins and piled flesh side of one skin to flesh side of the other and left undisturbed for 12 hrs. The skins were then dehaired using conventional beam and blunt knife technique. Weight of the dehaired skins was found to be 3.8 kg.
The dehaired skins were loaded in a drum with 3800 ml water. To this, 76 gms sodium metasilicate and 114 gms sodium orthosilicate were added to the drum. The total duration of treatment was 20 min running per hour for 3 hrs. The bath was drained off and the skins were scudded using conventional beam and blunt knife technique and fleshed in a hydraulic fleshing machine. Weight of the pelts was found to be 4.8 kg.
The resultant pelts were taken for further processing.
The following are the advantages of the present invention:
1. This process hardly requires any complicated control measures. 2. It completely eliminates the formation of dry sludge. 3. Provides significant reduction in total solids and chemical oxygen demand. 4. The process leads to significant reduction in time, power and water. 5. Provides rationalization of fibre opening processes. 6. Suitable for all kinds of raw materials. 7. The product produces soft and supple leathers. 8. Cheaper and commercially available chemicals and enzymes are used for the process of the present invention. 9. Provides an easy means for splitting the thick hide after fibre opening. 10. Pelts are easy to handle after fibre opening.
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The use of lime and sodium sulfide in leather making creates a lot of environmental concern. However, there is no commercial beam house process that could totally eliminate the use of lime and sodium sulfide. In this invention, a novel bio-chemical process has been standardized employing specific enzymes and non-toxic chemical that could totally eliminate the use of lime and sodium sulfide in leather processing. It has been found that the extent of hair removal and opening up of fiber bundles is comparable to that of the conventional limed leathers. Performance of the leathers is shown to be on par with conventionally leathers. The process also enjoys reduction in chemical oxygen demand and total solids load compared to conventional process.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 08/527,756, filed Sep. 13, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to yarn guides for laying yarn on cross-wound bobbins, or cheeses, at the work stations of a cheese-producing textile machine, whose common drive comprises a traversing rod that is supported, driven to reciprocate, in the machine frame, the traversing rod being guided in such a way, by support rollers disposed at the work stations, that a rectilinear guidance exists.
Yarn guides for laying the yarn on cones that are jointly driven by a traversing rod are used in open-end spinning machines, for instance. The yarn guides of the spinning stations disposed next to one another are driven jointly, simultaneously, by a traversing rod extending along the spinning stations.
2. Description of the Related Art
To assure rectilinear guidance over the long path along the machine and to enable problem-free installation and dismantling, so-called roller guide elements have already been proposed in U.S. Pat. No. 4,580,737 (DE 33 45 743 C2). Those are rollers with a cylindrical outer jacket, which are disposed in so-called element pairs on a base plate. Since each of the base plates are bent at an angle of approximately 120°, the two support rollers disposed one above the other support the traversing rod at an angle of 120°. The securing of the element pairs is done alternatingly from one work station to the next, first with the support rollers oriented toward the spinning station and at the next work station on the opposite side of the traversing rod, remote from the work station. Because of the high number of work stations, a great number of support rollers is needed for supporting and rectilinearly guiding the traversing rod.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a yarn guide assembly for laying yarn on cones, which overcomes the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which simplifies the rectilinear guidance and support of the traversing rod while maintaining the good guiding results.
With the foregoing and other objects in view there is provided, in accordance with the invention, a yarn guide assembly for laying yarn on cross-wound bobbins at the work stations of a cross-wound bobbin or cheese-producing textile machine. The yarn guide assembly comprises:
a common drive for a plurality of yarn guides, the common drive including a traversing rod supported in the machine frame, and a drive for reciprocating the traversing rod, the traversing rod having a circumference;
support rollers disposed at the work stations for rectilinearly guiding the traversing rod, a single one of the support rollers being disposed at a respective one of the work stations;
each support roller having a periphery, two ends, and a wheel flange formed at one of the ends on the periphery;
four successively adjacent support rollers each being angularly distributed about the circumference of the traversing rod in such a way that, viewed in the circumferential direction of the traversing rod, identical wheel flanges are disposed adjacent to one another; and
two support rollers which are disposed circumferentially adjacent one another and whose wheel flanges face toward one another each having an identical angular spacing relative to the other two of the four support rollers.
In other words, only a single support roller is now provided at each work station, which divides the number of support rollers in half compared with conventional bearings. The wheel flange on one side on the circumference of the support rollers enables exact rectilinear guidance of the traversing rod. The arrangement according to the invention of the four support rollers each in succession prevents twisting of the traversing rod during shogging of the traversing rod from lifting away from one another as a result of moments generated by the wheel flanges, and it assures uniform support if the resultant of the supporting forces passes through the center line of the traversing rod. Moments generated by the individual wheel flanges in the traversing rod are contrary in the circumferential direction, depending on the position of the wheel flange, so that if there is a simultaneous demand for reliable straight-ahead guidance of the traversing rod, the minimum number of support rollers becomes four. It is also possible to dispose a greater number of support rollers about the rod circumference for the purpose of equalization torques and supporting forces, but because of the increased rod length this would cause an increased strain on the traversing rod.
In accordance with an added feature of the invention, the yarn guide assembly includes a support plate which is secured to the machine frame at given attachment points, each the support rollers being disposed on the support plate, and the attachment points for securing the support plates to the machine frame being disposed on mutually opposite sides for facilitating an alternating positioning of the support rollers.
In accordance with an additional feature of the invention, the traversing rod contacts the support rollers with tension.
In accordance with another feature of the invention, the traversing rod has a given rod diameter, a diameter of a circular arc enclosed by lines of contact of successive support rollers and the traversing rod being smaller by not more that 10% as compared to the given rod diameter.
In accordance with a further feature of the invention, the traversing rod has a given rod diameter, a diameter of a circular arc enclosed by lines of contact of successive support rollers and the traversing rod being smaller by not more than 1% to 3% of the given rod diameter.
With the foregoing and other objects in view there is also provided a yarn guide assembly which comprises: a common drive with a traversing rod supported in the machine frame, and a drive for reciprocating the traversing rod, the traversing rod having a circumference; cylindrical support rollers disposed at the work stations for rectilinearly guiding the traversing rod, a single one of the support rollers being disposed at a respective one of the work stations; at least three successive rollers being angularly distributed uniformly over the circumference of the traversing rod.
In accordance with yet another feature of the invention, the support rollers have shafts and the support rollers are each located in one plane; the shafts of the support rollers being perpendicular to a respective the plane; the planes intersecting one another at a center line of the traversing rod; and tangent lines at contact points between the support rollers and the traversing rod at the circumference of the traversing rod each being oriented perpendicularly to a plane through a respectively contacting support roller.
Calm shogging of the traversing rod is attained if the support rollers contact the traversing rod in such a way that they are under tension. The tension advantageously has the effect that each support roller rests on the traversing rod, is entrained by it and also guides it continuously. This avoids banging and oscillation of the traversing rod and clattering of the support rollers. The tension can by way of example be generated by pressing the support rollers against the traversing rod by means of springs. However, such an embodiment is complicated. It is simpler to press the support rollers without play and tautly against the traversing rod, without clamping them. To that end, when a support plate is installed, for instance, the plate is swiveled about a fastening point such that the diameter of a circular arc enclosed by the lines of contact of the successive support rollers with the traversing rod is smaller than the traversing rod diameter itself. The theoretical reduction in traversing rod diameter by the closing up of the support rollers should be a maximum of 10%. As a rule, a closing up of the support rollers by a few tenths of a millimeter suffices to achieve the desired tension. In this preferred range of the closing up, the theoretical reduction in traversing rod diameter is between 1% and 3%, in terms of an actual traversing rod diameter of about 10 mm. The particular closing up of the support rollers causes a hardly perceptible, non-critical sagging of the traversing rod, which causes the tension in the traversing rod. The support rollers may also be embodied cylindrically, as will be explained below.
Exact rectilinear guidance of the traversing rod with one support roller per work station is attained when at least three cylindrical rollers are each distributed successively and uniformly over the circumference of the traversing rod.
The axes of rotation of the support rollers are each in a plane located at right angles to the center axis of the traversing rod. By this provision as well, still-adequate rectilinear guidance of the traversing rod is attained. The bearing of the support rollers is made more economical and simple as a result.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a yarn guide assembly for laying yarn on cones, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The 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
FIG. 1 is a fragmentary, diagrammatic, side elevational view of three mutually adjacent winding stations in a textile machine with the traversing rod bearing according to the invention;
FIG. 2 is an enlarged, fragmentary, front elevational view of a machine frame at a work station, with a bearing point of the traversing rod;
FIG. 3 is a diagrammatic frontal view of four successively adjacent support rollers in their angular distribution about the circumference of the traversing rod;
FIGS. 4a is a similar view of two successive support rollers which rest alternatingly opposite one another (and longitudinally offset) on the traversing rod;
FIG. 4b is a similar a view of two mutually adjacent support rollers which follow the support rollers of FIG. 4a;
FIG. 5 is a partly sectional, front elevational view of one structural option for guiding the traversing rod with tension by means of the support rollers;
FIG. 6 is a view similar to FIG. 4 showing the disposition of support rollers which guide the traversing rod without play and tautly; and
FIG. 7 is a diagrammatic front elevational view showing three cylindrical support rollers distributed about the circumference of the traversing rod.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there are seen three work stations 2a, 2b and 2c, which are three winding stations for winding cross-wound bobbins or cones. The three winding stations form a part of a textile machine 1 that produces cones. Only those characteristics that contribute to understanding of the invention are shown and described.
In the machine frame 3, which is the side walls of the work stations, the drive mechanism and bearing of the winding rollers 4a, 4b and 4c are accommodated, although not shown here. The cones 5a, 5b and 5c each rest with their circumferential face on the respective winding roller 4a, 4b, 4c driving them.
A yarn guide 6a, 6b and 6c moves in front of each cone 2a-2c for laying the yarn in cross-wound layers within the shogging region defined by the shogging boundaries 7 and 8. To prevent the yarn guides from tilting during their reciprocating motion, represented by the double-headed arrow 9, in the present exemplary embodiment they are guided in a grooved rail 10 that extends along the work stations.
Each of the yarn guides 6a, 6b and 6c is secured to a traversing rod 11, which extends along all the work stations of the textile machine. The reciprocating drive of the traversing rod 11, likewise represented by the double-headed arrow 9, is produced by a device not shown here but known from the prior art. The bearing of the traversing rod 11 is accomplished in accordance with the invention at each work station, of which the work stations 2a, 2b and 2c are shown here, by means of one support roller. Each of the four support rollers 121, 122, 123, and 124 visible here is supported on a support plate 13. Each of the support plates 13 is secured to the machine frame 3 at the respective securing points 14 and 15. Each support roller has a wheel flange 16. The support rollers are disposed such that that they rest, distributed over the circumference of the traversing rod 11, with their wheel flanges 16 on the traversing rod. The disposition of the support rollers will be described in further detail in conjunction with FIG. 3.
In FIG. 1, the support roller 121 in the work station 2a is disposed such that the support plate 13 is toward the observer. For the observer of FIG. 1, the shafts 24 of the support rollers are each located alternatingly above and below the center line 27 of the traversing rod 11. In the case of the support rollers 121 and 123, whose shafts 24 are located below the center line 27 of the traversing rod 11, the support rollers have their wheel flanges alternatingly facing one another. The same is true for the support rollers 122 and 124, whose shafts 24 are located above the center line 27 at the traversing rod 11. After the support roller 124, the ensuing support rollers follow in an arrangement that begins with a support roller in a position that corresponds to that of the support roller 121. This cycle of disposition continues in the same way along the entire machine.
FIG. 2 shows the bearing of the traversing rod at the work station 2b. A portion of the machine frame for work station 2b is shown. During winding, the cone 5b is driven by the winding roller 4b. While the winding roller rotates in the direction of the arrow 17, the cone 5b supported on it is driven in the direction of the arrow 18. The traversing rod 11, on which the yarn guide 6b, not shown here, is disposed for laying the yarn on the cone 5b, is guided through an opening 19 on the machine frame 3. At the securing points 14 and 15, the support plate 13 is secured to a support roller 122. The support plate 13 is disposed behind the traversing rod 11, if the observer is looking toward the work station 2b, and the support roller 122 guides the traversing rod 11 in the upper region. The support roller 122 is disposed such that the wheel flange 16 is toward the work station.
As can be seen from FIG. 2, the support plate 13 is secured to the machine frame 3 by two bent tabs 20 and 21. The support plate 13 itself is bent at an angle α of 120°. The tabs 20 and 21 are of different lengths and have hexagonal nuts 22 and 23, welded to the tabs 20 and 21, for securing them to the securing points 14 and 15. The shaft 24 of the support roller 122 is perpendicular to the support plate 13. The support plate 13, with the tabs 20 and 21 and the respective support roller disposed on it, forms a structural unit.
In FIG. 3, one of the possible arrangements of support rollers along the traversing rod at the various work stations is shown. These are the four support rollers 121-124 of FIG. 1. For greater clarity of illustration, the machine frames and the bobbin winders have been omitted from the drawing. The shafts 24 of the support rollers are each perpendicular to a plane that passes through the support roller and the center line 27 of the traversing rod 11, as the angle 45 indicates. As the contact point B of the traversing rod 11 and support roller, through which point the plane passes, the tangent t to the circumference u of the traversing rod 11 is perpendicular to the plane. The support rollers 121 and 124 that to the observer of FIG. 1 are located in front of the traversing rod 11, as well as all the ensuing support rollers, are at the same angular spacing from one another in the present exemplary embodiment, at an angle 50 of 120°.
The support rollers are disposed such that the wheel flanges 16 are toward one another. The support rollers 122 and 123 that to the observer of FIG. 1 are located behind the traversing rod 11 and all the following support rollers are likewise at the same angular spacing in the present exemplary embodiment, at an angle 51 of 90°, from one another.
Once again, the support rollers are arranged such that the wheel flanges 16 are toward one another. The support rollers 121 and 124 of the support roller arrangement located in front of the traversing rod 11 are spaced apart from the support rollers 122 and 123 of the support roller arrangement located behind the traversing rod 11 at the same angle 52 from one another in the present exemplary embodiment. It is also conceivable that the angle may be different between the support rollers 121 and 123 and ensuing support rollers, on the one hand, and 122 and 124 and the ensuing support rollers, on the other.
Because the mutually opposed support rollers 121 and 122, and 123 and 124, rest on the traversing rod 11 with their wheel flanges 16 on opposite sides, an exact rectilinear guidance of the traversing rod 11 is attained. If the supporting force exerted by the support rollers on the traversing rod does not act in the respective planes 41-44 through the center line 27 of the traversing rod 11, the result is moments that act upon the traversing rod. Such moments occur particularly whenever the traversing rod is supported on the support rollers in the region of the wheel flanges. For instance, if shifting of the traversing rod occurs, such that it is supported on the support roller 124 at the point 55, and if a supporting force 56 acts upon the traversing rod 11 at that point, then this can be broken down into one component 57 perpendicular to the center line 27 and one component 58 tangent to the traversing rod 11. The component 58 tangent to the traversing rod seeks to exert a torque on the traversing rod. As a rule, the shifting of the traversing rod on one roller will lead to a shifting on the opposite roller, in the present case the roller 123. The force 60 acting there at the point 59 again be broken down into one component 61 tangent to the traversing rod 11 and a second component 62 perpendicular to the center line 27. The force 61 seeks to exert a torque on the traversing rod that is counter to the torque effected by the force 58. The moments are not of equal magnitude, but because of the shifting relative to the other support rollers, the total moments acting on the circumference of the traversing rod will cancel one another out over the length of the rod.
The distribution of support rollers shown in FIG. 3, especially because of the disposition of the support rollers 122 and 123 located behind the traversing rod 11, can intercept the forces exerted by the yarn tension on the yarn guide and thus exerted on the traversing rod and can avert sagging acting preferentially in the direction of the aforementioned rollers.
In FIGS. 4a and 4b, a special arrangement of the support rollers on the circumference of the traversing rod 11 is shown. The mutually adjacent support rollers 12o and 12u as well as 112o and 112u are located directly opposite one another in a plane 26. They rest on the traversing rod 11 in such a way that their respective wheel flanges 16 face one another. This arrangement of the support rollers is comparable to the arrangement of the support rollers 121 and 122 in FIG. 1. The two support rollers 112o and 112u that follow them are likewise facing one another in a plane 126, as can be seen from FIG. 4b. Once again, the wheel flanges 16 rest from opposite sides on the traversing rod 11, and the shafts 24 are perpendicular to the plane 126, as can be seen from the angles 128 and 129. This arrangement of the support rollers is comparable to the arrangement of the support rollers 123 and 124 in FIG. 1.
The two planes 26 and 126 enclose an angle 65, which in this case is 60° but may also be expanded to 90°. In the present exemplary embodiment, the sequential arrangement of the support rollers is equivalent in each case to a folding mirroring at the angle bisector 66 of the angle 65 between the two planes 26 and 126.
If the support plate 13 known from FIG. 2 is rotated by 180°, so that the tab 21 at the securing point 14 and the tab 20 at the securing point 15 is rotated, then the support roller located at the top is rotated by 180° about the traversing rod 11. The support roller then rests with its wheel flange on the traversing rod 11 in the opposite direction from that of the upper support roller.
FIG. 4a is a view of two support rollers disposed one after the other on the traversing rod 11. The machine frame 3 has not been shown here. As to how the support rollers 12o and 12u disposed one above the other look, in reality the support of the traversing rod is spaced apart by the width of one work station. The center line 27 of the traversing rod 11 is located in a plane 26, and the tangents t to the circumference of the traversing rod 11 at the respective contact point B of the traversing rod 11 and the support roller 12o and 12u, respectively, are perpendicular to the plane 26.
If as in the present exemplary embodiment shown in FIG. 4a the shafts 24 of the support rollers 12o and 12u are perpendicular to the plane 26, as represented by the right angles 28 and 29, then optimal guidance of the traversing rod 11 is accomplished by the circumferential faces of the support rollers with their respective wheel flanges 16.
To attain calm shogging of the traversing rod 11, the traversing rod is put under tension by the support rollers 12o and 12u. To that end, for instance when the support plates 13 of the support rollers 12o and 12u are installed, the support plates are each pivoted slightly about their respective fastening point 15 and 14, making the spacing between two adjacent support rollers 12o and 12u less, by a few tenths of a millimeter, than the sum of the radii ro and ru of the two support rollers 12o and 12u and the diameter d of the traversing rod 11.
FIG. 5 shows an example for a support plate that can be pivotally mounted about a securing point so as to guide the traversing rod with tension by means of the support roller. The support plate 13 for an upper support roller 12o is pivotable about the securing point 15, as indicated by the arrow 30. The pivoting is made possible by an oblong slot 31 in the tab 20, which allows a change of position relative to the securing point 14. Pivoting the support plate 3 in the direction of the arrow 30 presses the support roller 12o against the traversing rod 11 in the direction of the arrow 32. This causes a hardly perceptible sagging, which brings about the tension in the traversing rod.
An arrangement of support rollers and traversing rod to one another in such a way that the traversing rod is guided with tension is shown in FIG. 6. For the sake of simplicity, of the traversing rod 11 shown in section, only the circumferential profile u is shown, in dashed lines. From the contours of the support rollers 121, 122, 123 and 124, as arranged in accordance with FIG. 3, it can be seen that the diameter of a circular arc u' enclosed by the contact lines, formed by the wheel flange contour, of the successive support rollers and the traversing rod 11 is smaller than the traversing rod diameter ds itself. The decrease in diameter is 10% at maximum and as a rule is between 1% and 3%, referred to an actual traversing rod diameter of about 10 mm.
FIG. 7 schematically shows an embodiment of the invention in which three cylindrical support rollers 221, 222 and 223 are disposed one after the other, distributed uniformly over the circumference of the traversing rod 11. The center line 27 of the traversing rod 11 passes through the intersection of the planes 71, 72 and 73 in which the support rollers 221, 222 and 223, respectively, are located and to which planes the axes 74 of these support rollers are respectively perpendicular. The angles 75 between the planes 71, 72 and 73 are equal, in the present exemplary embodiment, and thus are 120 each. Because of their cylindrical circumferential faces 76, the support rollers 221, 222 and 223, in the ideal case, rest only pointwise at the points 77 on the circumferential face u of the traversing rod 11, at which points the respective planes 71, 72 and 73 intersect the traversing rod 11. By this type and arrangement of support rollers as well, rectilinear guidance of the traversing rod is attained.
The helical succession of the arrangement of support rollers can either be repeated continuously or be rotated after a sequence of three support rollers each, for instance by 180° each time. An arrangement of four support rollers, for instance as in the preceding exemplary embodiments, would also be conceivable.
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In textile machines that produce cross-wound bobbins, especially open-end spinning machines, the yarn is laid onto the cross-wound bobbins with yarn guides. The yarn guides are commonly reciprocated with a driven traversing rod. All the yarn guides of the work stations located next to one another are driven simultaneously by this traversing rod. For the sake of uniform laying of the yarn and so that the traversing rod will not sag under tensile and compressive strain, careful rectilinear guidance of the traversing rod is required. Four successive support rollers each are angularly distributed about the circumference of the traversing rod in such a way that, viewed in the circumferential direction of the traversing rod, mutually identical wheel flanges are always adjacent to one another. Those support rollers which are adjacent with respect to the circumference of the traversing rod and whose wheel flanges are toward one another each have the same angular spacing relative to the other two support rollers.
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BACKGROUND OF THE INVENTION
Lyotropic liquid crystalline polyamides, such as poly(p-phenylene terephthalamide), which are exemplified by such commercially available products as TWARON polyamide and KEVLAR polyamide, exhibit liquid crystalline properties in solution.
Polymers which demonstrate liquid crystalline properties in the melt, and which are referred to as thermotropic liquid crystalline polymers, have been limited chiefly to poly(esters) such as VECTRA brand polyester. In general, aromatic polyamides have not demonstrated thermotropic behavior due to their extremely high melting points as a result of intermolecular hydrogen bonding and the rigidity of the aromatic mesogen which is necessary to convey liquid crystalline properties. Consequently decomposition occurs before melting. There have been a few examples of amide-containing thermotropic liquid crystalline polymers in the literature which have either large flexible spacers or have large substituents to lower the melting temperature of the polymer. Some examples of such polymers include:
1. J. M. G. Cowie et al., in British Polymer Journal, 20, 515-519 (1988) shows thermotropic liquid crystalline main chain polyamides containing diaza-18-crown-6-ether units.
2. M. Schmucki et al., in Makromol. Chem. 190, 1303-1308 (1989) show polyamides with stiff and flexible chain segments which are formed by reaction of a dicarbonyl dichloride, optionally containing a short alkylene bridge group between the phenyl rings with an ortho-substituted α,ω-bis(4-aminophenyl) alkylene monomer.
3. A. C. Griffin et al., in Mol. Cryst. Liq. Cryst. Vol. 82 (Letters), pp. 145-150, shows thermotropic polyamide liquid crystalline materials formed from the polymerization of 4,4'-dichloroformyl-1,10-diphenoxydecane and a 3,3'-disubstituted-4,4'-diaminobiphenyl monomer.
4. Uryu et al., polymer Journal, Vol. 21, No. 12, pp. 977-986 (1989), describes thermotropic liquid crystalline copoly(ester-amides) which are formed from 4,4'-diacetoamido-3,3'-dimethoxybiphenyl or 4,4'-diacetoamido-3,3'-dichlorobiphenyl and diacetylated p-phenylenediamine, in combination.
5. H. Ringsdorf et al., in Makromol. Chem. 188, 1431-1445 (1987), illustrate liquid crystalline rigid-rod polyesters and polyamides containing disk-like mesogens in the main chain which are derived from discoid 1,4-hydroquinone derivatives.
U.S. Pat. No. 5,070,155 to M. Liu et al. describes semi-aromatic copolyamide or copolyesteramides which are prepared from an aliphatic polyamide and an aromatic hydroxyacid or aminoacid.
D. Liu et al. in Polymer Preprints, Vol. 33, No. 2 (August 1992), indicate that thermotropic aromatic-aliphatic polyesteramides can be formed based on p-terephthaloyl chloride, dimethylbenzidine, and hexylene glycol.
SUMMARY OF THE INVENTION
The present invention relates to thermotropic poly(ester-amides) which comprise a bis(4-carbonyl phenylene) terephthalate unit and a unit derived from an N-substituted alkylenediamine, e.g., one derived from an N,N-dialkylalkylenediamine.
DETAILED DESCRIPTION OF THE INVENTION
The bis(4-carbonyl phenylene) terephthalate unit for the thermotropic poly(ester-amide) of the present invention has the formula ##STR1## where Ar are phenylene and the bonding is para-. This unit is derived from reaction of the corresponding diacid chloride or dicarboxylic acid of the terephthalate with an aliphatic diamine.
The aliphatic diamines which are intended to serve as the other reagent are of the formula ##STR2## where B is hydrocarbylene, such as alkylene, --(CH 2 ) x -- for example, ethylene, where x is an integer which varies from 2 to 12, or arylene (e.g., phenylene, naphthylene, and the like), R is alkyl such as lower alkyl, and A is a group or atom which reacts with the acid or chloride group of the terephthalate, e.g., hydrogen or trimethylsilyl. These diamines preclude strong hydrogen bonding within the resulting polymer.
One possible preferred synthetic route involves the direct condensation of the terephthalic acid chloride with diamine (A=hydrogen) using an external base (e.g., potassium hydroxide) to neutralize the hydrochloric acid by-product formed during the reaction.
A second preferred route involves the use of the disilamines (A=trimethylsilyl) with the acid chlorides without the need for an external base. This second route has certain advantages: (1) the disilamines can be readily distilled to yield the monomer in high purity; (2) there is no need to use an external base, thereby avoiding side reactions between the external base and the diacid chloride; (3) the reaction of a disilamine with an acid chloride can be carried out in a variety of solvents; and (4) the product which is eliminated during the condensation is trimethylchlorosilane which can be recycled for further use for the conversion of diamines to disilamines as described by Y. Imai in Macromolecules, Vol. 21, No. 3, March 1988.
The present invention is further illustrated by the Examples which follow.
EXAMPLES
Monomer Synthesis
The triad acid chloride (namely, bis(4-carbonylchloride phenylene) terephthalate) used in the Examples which follow was prepared according to the procedure described by Bilibin, et al., in Makromol. Chem. Rapid Commun. 6, 209-211 (1985).
The N,N-dimethylalkylenediamines that were used were prepared using the method described by Devinsky et al., in Synthesis (Communications), April 1980, pp. 303-305.
The disilamines were prepared according to the following general procedure (the synthesis of a disilamine having a spacer of twelve methylene units being given for illustration): N,N'-dimethyldodecamethylenediamine (52.37 gm, 0.229 mol), prepared according to the previously noted method of Devinsky, was placed in a flame and oven-dried glass 1,000 ml three neck round bottom flask equipped with a reflux condenser, an addition funnel, and a large magnetic stirrer. All manipulations were carried out under an argon atmosphere. To the flask was added 600 ml of dry benzene, followed by the slow addition of chlorotrimethylsilane (66.68 ml, 0.525 mol), after which the reaction vessel was heated at reflux temperature for ninety minutes. A white gel-like precipitate was formed. The reaction vessel was cooled to room temperature. To this product was then added triethylamine (97.4 ml, 0.70 mol.), and the reaction was allowed to continue at reflux for one additional day. Triethylaminehydrochloride readily precipitated from the reaction mixture. The vessel was allowed to cool to room temperature. The solution was filtered through a cannula equipped with a filter under argon pressure. To the triethylaminehydrochloride residue was added 400 ml of dry benzene. This solution was also cannulated into a 2000 ml distillation apparatus. The distillation apparatus was heated to 1000° C. to remove solvent and other volatiles at atmospheric pressure. The liquid residue was cannulated into an oven-dried, 200 ml single-neck flask equipped with an insulated eight inch Vigreux column and a short path distillation head. The desired product was distilled at 129° C. and 0.1 mm of mercury and was obtained in 81% yield. The disilamine product had the following elemental analysis, which was consistent with the calculated values: carbon--64.44 (calc.), 64.33 obtained); hydrogen--12.98 (calc.), 12.84 (obtained); and nitrogen--7.52 (calc.), 7.65 (obtained).
Analogous disilamines having alkylene spacer lengths of six and eight carbon atoms, respectively, were also prepared using this procedure.
EXAMPLES OF POLYMER PREPARATION
EXAMPLE 1
This Example relates to the synthesis of "Polymer 1A" in the Table given below.
N,N'-dimethyldodecamethylenediamine (0.88 gms, 3.8 mmol) was dissolved in 100 ml of dry chloroform and 1.71 gm (3.8 mmol) of diacid chloride was dissolved in 200 ml of dry chloroform. Then, 0.426 gm (7.6 mmol) of potassium hydroxide was dissolved in 200 ml of distilled water. The aqueous solution was first placed in a Waring blender. The two chloroform solutions were simultaneously added to one another. The resulting mixture was blended at high speed with a nitrogen purge for forty minutes. The product was precipitated in methanol and was suction filtered. The resulting polymer was extracted in a Soxhlet for one day with methanol. The polymer was then dried under vacuum.
EXAMPLE 2
This is the synthesis procedure for "Polymer 7A".
N,N'-dimethyloctamethylenediamine (0.47 gm, 2.73 mmol) was added to 5.45 ml of 1N HCL until it dissolved. This solution was further diluted with 70 ml of distilled water. An equimolar amount (1.22 gm) of diacid chloride was dissolved in 200 ml of chloroform, and 0.673 gm of potassium hydroxide was dissolved in 100 ml of distilled water. The base solution was first added to a Waring blender followed by the diamine and diacid chloride solutions, which were added simultaneously. The reaction mixture was stirred at high speed in the Waring blender for one hour under an argon purge. The polymer was precipitated in methanol, collected by filtration, extracted in a Soxhlet with methanol for one day, and then vacuum dried for one day.
EXAMPLE 3
This is the synthesis procedure for "Polymer 7B".
All manipulations had to be carried out in thoroughly dried glassware because of the sensitivity of the disilamines to moisture. A 500 ml three-neck round bottom flask was equipped with a magnetic stirrer and an addition flask. Disilamine (20.125 gm, 69.7 mmol) was weighed into the addition flask under argon. An equimolar amount (30.90 gm, 69.7 mmol) of diacid chloride was weighed and placed into the round bottom flask which had been purged with nitrogen. Two hundred milliliters of dry tetrachloroethane were added to the acid chloride solid. The tetrachloroethane did not dissolve the solid. The mixture was cooled to -300° C. The disilamine was slowly added to the round bottom flask through an addition funnel. The reaction was allowed to continue between -100° C. and -30° C. for four hours. The acid chloride had a very low solubility of approximately one gram in 100 ml in halogenated solvents at reflux. However, the acid chloride very gradually dissolved in the tetrachloroethane as it was reacted and was converted to polymer. Alter four hours, the solution was allowed to warm to room temperature. The reaction was stirred further for two days at room temperature to yield a very viscous solution. The solution was precipitated in methanol to yield a fibrous polymer. The polymer was extracted in a Soxhlet with methanol for one day and was vacuum dried. The syntheses of the polymers by the disilamine route yielded the best results at very low temperature. In most condensation polymerization reactions, the monomers, rather than the resulting polymer, have the greater solubility in the reaction medium. The polymer then precipitates as the molecular weight increases. The reaction which occurs in the present invention is unique in that the solubility behavior was opposite from what one would expect. The diacid chloride has very low solubility in the reaction solvent. As the monomer is slowly converted to polymer, all of the diacid chloride slowly enters into solution by reaction because the polymer has excellent solubility in halogenated solvents. These polymers are also soluble In polar solvents at elevated temperatures. For example, polymer obtained from Example 3 dissolved in tetrachloroethane at a ratio of 1 gm of polymer to four milliliters of solvent.
__________________________________________________________________________SUMMARY OF POLYMERIZATIONSPolymerDesignation Spacer Temp. Base Solvent* Yield [η]** inh.__________________________________________________________________________1A 12 RT KOH/H.sub.2 O Chloroform 42% 0.362A 10 RT KOH/H.sub.2 O Chloroform 64% 0.383A (75% 12, 25% 6) RT KOH/H.sub.2 O Chloroform 64% 0.394A (50% 12, 50% 6) RT KOH/H.sub.2 O Chloroform 56% 0.385A (25% 12, 75% 6) RT KOH/H.sub.2 O Chloroform 46% 0.346A 6 RT KOH/H.sub.2 O Chloroform 39% 0.317A 8 RT KOH/H.sub.2 O Chloroform/H.sub.2 O 40% 0.241B 8 100° C. -- HMPA/NMP 28% 0.252B 8 RT to 70° C. -- Chloroform 76% 0.353B 8 RT to 100° C. -- NMP 65% 0.494B 8 RT to 150° C. -- Tetrachloroethane 81% 0.545B 6 RT to 150° C. -- Tetrachloroethane 78% 0.456B 6 RT to 150° C. -- Tetrachloroethane 79% 0.537B 6 -10 to -30° C. -- Tetrachloroethane 99% 0.848B (50% 12, 50% 6) -10 to -30° C. -- Tetrachloroethane 98% 1.23__________________________________________________________________________ *All polymerizations were solution polymerizations with the exception of that for polymer 7A which was an interfacial polymerization. **Inherent viscosities were measured in TFA at 29.5° C. at 0.125 g/.25 dL. Infrared spectra were obtained on a PerkinElmer 1600 Series FTIR and Varian XL200 and XL300 NMR spectrometers were used to obtain carbon and proton spectra for polymer characterization.
BLEND PREPARATION
Blends of nylon 6,6 and the liquid crystalline polymers previously described were made by first dissolving nylon 6,6 in trifluoroacetic acid (TFA), which had been previously dried over molecular sieves for one week to minimize hydrolysis. Blends were made in compositions ranging from 5 weight % to 50 weight % LCP. A typical procedure, which is illustrative of the general blending technique employed, is as follows: nylon 6,6 (11.25 gms) was dissolved in TFA. The LCP was then added to this solution to form a homogeneous solution. After dissolution, the solution was precipitated in methanol, and the polymer blend was collected by filtration. The polymer blend was washed with copious amounts of an aqueous sodium carbonate solution to neutralize any remaining acid and was subsequently extracted in a Soxhlet apparatus with methanol for eight hours. The blend was then extracted in a Soxhlet apparatus with water for six hours. The extracted blend was then dried in a vacuum oven for one day at 130° C., ground, and dried for an additional day.
BLEND CHARACTERIZATION
The blends were characterized by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and mechanical testing. The DSC and TGA data were obtained on a Perkin-Elmer 7 Series instrument equipped with a DSC and TGA.
The DSC data for a blend of 50% nylon 6,6 and 50% LCP (Polymer 7A) indicated the melting of nylon 6,6 at 265° C. and the melting of the LCP between 300° C. and 310° C. This blend showed two different melting transitions, indicative of an immiscible blend. However, a thermogram of the second heating cycle contained only one broad melting transition between 190° C. and 225° C., which may be indicative of a miscible blend. The third melting cycle also revealed one melting transition which began at 180° C. In each of the three cooling cycle thermograms there was only one thermal transition for recrystallization. Because the time scale of the experiment used was short, it might be possible that the recrystallization of the LCP is slower than the time permitted in the experiment. A fourth heating-cooling cycle, was performed two months after the initial experiment using the original DSC sample. There was only one broad melting point peak between 150° C. and 200° C. It appears that when the LCP and nylon 6,6 are heated together at elevated temperatures, there was a molecular reorganization which took place, a transamidation reaction, in which the two polymers reacted to form copolymers. It is another aspect of this invention that the simple heating of an amide-containing LCP and a linear nylon can be a viable route to develop copolymers. During the first heating and cooling at 10° C./minute, the sample remained above 250° C. for ten minutes, so if this conclusion is correct, very little time was required to permit this copolymer formation. Preliminary investigation of this phenomena was described by Brubaker, et. al., in U.S. Pat. No. 2,339,237 and Beste, et. al., Journal of Polymer Science, Vol. 8, No. 4, pp. 395-407(1952). Brubaker et. al. investigated the melting of a water-soluble polyamide (polytriglycol adipamide) with a water-insoluble polyamide (polyhexamethylene adipamide) at 287° C. to yield a polymer having properties intermediate between the two homopolymers. Their data support the present concept that heating a mixture of an amide-containing LCP and a commercial nylon will yield copolymers.
MECHANICAL TESTING
The blends of this invention produced an enhancement in the mechanical properties of blends of the LCP and nylon 6,6. Such blends were prepared from solution, and a fiber was obtained by extrusion of polymer chips through a Randcastle microextruder equipped with a 1575 micron single hole die. These polymer chips were obtained from the polymer blend which was precipitated in methanol, vacuum dried for one day at 130° C., and ground in a mill. The Randcastle microextruder contained the following three temperature settings in the screw and a fourth temperature setting in the die zone.
______________________________________ Zone 1 Zone 2 Zone 3 Die block______________________________________Temperature: 230° C. 270° C. 300° C. 262° C.______________________________________
After take-up, the blended fiber was cold drawn at 100° C. and was subsequently hot drawn at 170° C. The following data describe the mechanical properties of these blends:
______________________________________BLENDS OF LCP (POLYMER 7B) WITH NYLON 6,6Draw Ratios*LCP (%) Cold Hot Total σ.sub.b (MPa) E (GPa) e.sub.b (%)______________________________________ 0 -- -- -- 490 4.00 57.0 5 1.12 1.98 2.22 307 8.51 8.615 1.38 1.86 2.57 348 14.1 5.820 2.18 1.40 3.05 362 15.5 3.725 2.33 2.14 4.99 352 21.0 3.0______________________________________ *The draw ratio is the ratio of the final length divided by the initial length σ.sub.b : breaking tenacity E: modulus e.sub.b : elongation at break
With increasing LCP content, the blends can be increasingly drawn. High draw ratios resulted in significantly higher values for the modulus. The values for tensile strength were apparently independent of the liquid crystalline content. The value of 21.0 GPa for the modulus for the 25% blend was three times the value of moduli typically obtained for commercial grade nylon 6,6. Polarizing optical micrographs, using a Zeiss optical microscope equipped with a hot stage and, for birefringence, an Olympus Bh-2 polarizing optical microscope, for the drawn samples were highly birefringent and indicated the presence of a one phase system. Similar micrographs of the extruded fibers support the conclusion that amide interchange took place quite rapidly, resulting in a one phase system after melt processing. A DSC scan of an extruded fiber supported the presence of a one phase system resulting from copolymerization. Before extrusion, there was a clear melting of the liquid crystalline phase in the first melting cycle in. After extrusion there remained only one melting transition which occurred below that of nylon 6,6. The melting transitions of both the LCP and the nylon 6,6 were replaced after extrusion by a single melting transition below that of nylon 6,6.
The foregoing Examples and data should not be construed in a limiting sense since it is intended to set forth only certain embodiments of the present invention. The scope of protection sought is set forth in the claims which follow.
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Thermotropic liquid crystalline poly(ester-amide) compositions are disclosed which comprise a bis(4-carbonyl phenylene) terephthalate unit and a unit derived from an N-substituted hydrocarbylenediamine (e.g., one derived from an N,N-dialkylalkylene).
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[0001] The present invention relates to the chemical synthesis of alkaloid glycosides, in particular to the synthesis of steroid modified chacotrioses and solatrioses. Furthermore, the present invention relates to intermediate compounds useful for the preparation of steroid modified chacotrioses and solatrioses and to novel steroid modified chacotrioses.
[0002] The aglycon solasodine is a source for synthetic cortisone and progesterone. Solasodine and its glycosides are of considerable interest commercially and clinically. They are widely used as starting products for the synthesis of various steroidal drugs.
[0003] It is moreover well established that certain naturally occurring conjugate solasodine glycosides have potent antineoplastic properties. Of particular interest is the chacotriose type triglycoside solamargine (22R, 25R)-spiro-5-en-3β-yl-α-L-rhamnopyranosyl-(1->2 glu)-α-L-rhamnopyranosyl- (1->4 glu)-β-D-gluco-pyranose. The structure of this triglycoside is as follows:
[0004] Another naturally occurring conjugate solasodine glycoside of particular interest is the solatriose type triglycoside solasonine (22R, 25R)-spiro-5-en-3β-yl-α-L-rhamno-pyranosyl-(1->2 gal)-O-p-D-glucopyranosyl-(1->3 gal)-β-D-galactopyranose. The structure of this triglycoside is as follows:
[0005] The above triglycosides are conventionally obtained by extraction from a plant source. A commercially available extract of S. sodomaeum, commonly referred to as BEC (Drug Future, 1988, vol. 13.8, pages 714-716) is a crude mixture of solamargine, solasonine and their isomeric diglycosides. The extraction process for making BEC involves homogenizing the fruits of S. sodomaeum in a large volume of acetic acid, filtering off the liquid through muslin followed by precipitation of the glycosides with ammonia (Drugs of today (1990), Vol. 26 No. 1, p. 55-58, cancer letters (1991), Vol. 59, p. 183-192). The yield of the solasodine glycoside mixture is very low (approx. 1%). Moreover the individual process steps are not defined to GMP in terms of scale up, definition of yield, composition and product quality.
[0006] There is a great need for a cost efficient process that provides the antineoplastically active triglycosides such as solamargine and solasonine as well as analogues thereof at high yield with little or no impurities.
[0007] Contrary to other steroid ring systems, the steroid skeleton of solasodine contains a very labile nitrogen-containing ring. The same hold true for the steroid ring systems of other alkaloids, notably tomatidine, demissidine or solanidine. These aglycons cannot readily be chemically modified while keeping the steroid skeleton intact. In spite of the fact that the aglycon solasodine is readily available, the prior art does not disclose the synthesis of the solamargine or solasonine using the aglycon as starting material.
[0008] The problem underlying the present invention is to provide a cost effective method for the preparation of steroid modified chacotrioses and solatrioses such as solamargine and solasonine or analogues thereof in high yields.
[0009] Such compounds exhibit cytotoxic activity and may be employed as anticancer agents. Furthermore, such compounds exhibit anti bacterial, anti fungal or anti viral activity.
[0010] Accordingly, the present invention provides a method for the preparation of a steroid modified chacotriose of general formula (Ia) or a steroid modified solatriose of general formula (Ib):
[0011] wherein R 1 represents a steroid or a derivative thereof having a hydroxyl group in the 3-position and no further unprotected hydroxyl groups; and each R 2 independently represents a straight or branched C 1-14 alkyl group, a C 5-12 aryl or heteroaryl group optionally substituted by one or more halogen atoms or C 1-4 alkyl groups, or a hydroxyl group.
[0012] The method comprises the step of: reacting a compound of general formula (IIa) or (IIb):
[0013] wherein R 3 represents a halogen atom, an ethylsulfide or a phenyl sulfide group; and each R 4 independently represents a benzoyl, substituted benzoyl, whereby the substituents are selected from C 1-4 alkyl groups, halogen atoms and NO 2 , acetyl or pivolyl protecting group; with a compound of general formula (III):
HO—R 1 Formula (III)
[0014] wherein R 1 is defined as above; to yield a compound of general formula (IVa) or (IVb):
[0015] wherein R 1 and R 4 are defined as above.
[0016] The compounds of the above general formulae (IVa) and (IVb) may be transformed to the desired steroid-modified chacotriose of general formula (Ia) or the steroid-modified solatriose of general formula (Ib) by any suitable method known in the art. A particular preferred procedure is described in detail below.
[0017] Furthermore, the present application provides steroid modified chacotriose compounds of general formula (Ia) as defined above, wherein R 1 represents a tomatidin-3-yl, demissidin-3-yl group, solanidin-3-yl or solasodin-3-yl group.
[0018] A further object of the present application is the provision of intermediate compounds useful for the synthesis of the steroid modified chacotriose of general formula (Ia) defined above, namely:
[0019] A compound of general formula (IVa) or (IVb) as defined above;
[0020] A compound of general formula (Va) or (Vb):
[0021] wherein R 1 is defined as above;
[0022] A compound of general formula (VIa) or (VIb):
[0023] wherein R 1 is as defined above, R 5 represents a pivolyl protecting group, and R 6 represents a ketal or acetal type protecting group selected from benzylidene, 4-nitrobenzylidene, 4-methoxybenzylidene or isopropylidene.
[0024] A compound of general formula (VIIIa) or (VIIIb):
[0025] wherein R 1 , R 2 , R 4 , R 5 and R 6 are as defined above.
[0026] A compound of general formula (IXb):
[0027] wherein R 1 , R 2 , R 4 and R 6 are as defined above.
[0028] Further embodiments of the present application are described in the dependent claims.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In the following, the present invention will be explained in more detail with reference to preferred embodiments.
[0030] The steroid residue constituting substituent R 1 is a steroid or a derivative thereof having a hydroxyl group in the 3-position that serves as the α-glycosidic hydroxyl group, which binds the steroid residue to the compound of formula (II) defined above. The steroid residue bears no further unprotected hydroxyl groups and preferably has no further hydroxyl groups at all, in order not to compromise subsequent reaction steps. In a preferred embodiment of the present invention R 1 is selected from a tomatidin-3-yl, demissidin-3-yl, solanidin-3-yl and solasodin-3-yl group.
[0031] All of those steroid groups contain a labile nitrogen-containing ring and, therefore, cannot be chemically modified by means of conventional methods. Moreover, all of the above steroid groups represent substituents for cyctotoxic, anti bacterial, anti fungal or anti viral compounds.
[0032] In the above general formulae (Ia) and (Ib) each R 2 independently represents a straight or branched C 1-14 alkyl group, a C 5-12 aryl or heteroaryl group optionally substituted by one or more halogen atoms or C 1-4 alkyl groups, or a hydroxyl group. In a preferred embodiment R 2 represents a C 1-14 alkyl group selected from methyl, ethyl and propyl; an aryl group selected from phenyl, p-methylphenyl and p-chlorophenyl; or an heteroaryl group selected from pyridinyl, pyrimidinyl, furanyl, pyrrolyl, thiophenyl, indolyl, pyrazolyl and imidazolylmethyl; methyl, ethyl and propyl are more preferred.
[0033] In a particular preferred embodiment R 2 represents a methyl group.
[0034] The method of the present invention for preparing a steroid-modified chacotriose of general formula (Ia) comprises reacting a compound of general formula (IIa):
[0035] with a compound of general formula (III):
HO—R 1 Formula (Ill)
[0036] to yield a compound of general formula (IVa):
[0037] In the above general formula (IIa) R 3 represents a halogen atom, an ethylsulfide or a phenyl sulfide group. Preferably, R 3 represents a bromine atom or a chlorine atom. Most preferably R 3 is a bromine atom. Furthermore, in general formulae (IIa) and (IVa), each R 4 independently represents a benzoyl, substituted benzoyl, whereby the substituents are selected from C 1-4 alkyl groups, halogen atoms and NO 2 , acetyl or pivolyl protecting group, preferably a benzoyl or p-toluoyl protecting group, most preferably a benzoyl protecting group.
[0038] The above step is preferably conducted in an inert organic solvent such dichloromethane, tetrahydrofuran or dichloroethane. A preferred solvent is dichloromethane.
[0039] Preferably the reaction is carried out in the presence of a promoter. Any conventional promoter used in carbohydrate chemistry may be employed. Particular preferred promoters include silver triflate, boron trifluoride diethyl etherate (−10° C.), trimethylsilyl triflate bromide, N-iodosuccinimide and dimethyl thiomethyl sulfonium triflate. The most preferred promoter is silver triflate.
[0040] The reaction may preferably be carried out under anhydrous conditions in the presence of a water detracting means such as 4 Å mol sieves.
[0041] In a preferred embodiment the reaction is carried out at low temperature such as 0° C. or lower, more preferably −10° C. or lower. The most preferred reaction temperature is −20° C.
[0042] Subsequently, the above-obtained compound of general formula (IVa) may be further modified as described below.
[0043] In a preferred embodiment of the method of the present application, the compound of general formula (IVa) is deprotected by removing substituent R 4 to obtain a compound of general formula (Va):
[0044] wherein R 1 is defined as above.
[0045] Any suitable deprotection condition conventionally employed in the chemistry of protecting groups may be used. Deprotection is preferably carried out in an inert organic solvent such as dichloromethane or tetrahydrofuran in the presence of an alkali metal alkoxide having 1 to 4 carbon atoms and a C 1-4 alcohol, or in the presence of water, an alkali metal hydroxide and a C 1-4 alcohol. In a particular preferred embodiment deprotection is carried out in dichloromethane in the presence of methanol and sodium methoxide.
[0046] The thus obtained compound of general formula (Va) may be selectively protected in 3-OH and 6-OH position using pivolyl chloride in the presence of an amine base to yield compound of general formula (VIa):
Formula (VIa)
[0047] wherein R 1 is as defined above, and R 5 represents a pivolyl group. Suitable amine bases include pyridine, triethylamine, collidine, or lutidine. A preferred amine base is pyridine.
[0048] The reaction may be carried out in an inert organic solvent. Examples of suitable solvents include tetrahydrofuran, dichloroethane, or dimethylformamide.
[0049] The compound of formula (VIa) may be then reacted with a compound of general formula (VIIa):
[0050] under substantially the same conditions as described above for the preparation of the compound of formula (IVa). In general formula (VIIa) R 2 , R 3 and R 4 are as defined above.
[0051] Resulting compound of general formula (VIIIa):
[0052] wherein R 1 , R 2 , R 4 and R 5 are as defined above, may be subsequently deprotected to yield the compound of general formula (la) under substantially the same conditions as described above for the preparation of the compound of formula (Va). In a preferred this deprotection step is carried out in tetrahydrofuran in the presence of water, sodium hydroxide and methanol.
[0053] In another embodiment, the present invention provides a method for preparing a steroid-modified solatriose of general formula (Ib). According to a preferred embodiment of the method for preparing a steroid-modified solatriose of general formula (Ib), galactose is reacted to yield a compound of general formula (IIb):
[0054] wherein R 3 and R 4 are as defined above.
[0055] The preparation of the compound of formula (IIb) may be carried out using either acetic anhydride, acetyl chloride, benzoyl chloride, benzoic anhydride, or pivolyl chloride in the presence of a base such as, e.g., pyridine, triethylamine, or collidine, to give fully esterified galactose. Esterified-D-galactopyranose may be treated with hydrogenbromide or hydrogenchloride in glacial acetic acid to yield the above compound of general formula (IIb).
[0056] In a particularly preferred embodiment galactose is suspended in organic base such as pyridine and cooled to 0° C., to this solution is added dropwise either acetic anhydride, benzoic anhydride or acid chloride. Upon complete addition the solution is warmed to +25° C. (room temperature) and stirred for about 16 hours. The reaction is quenched by addition of alcohol. The solution is diluted with organic solvent such as tert-butylmethyl ether, or dichloromethane, or toluene and washed with cold 1N HCl, water, saturated sodium bicarbonate, water and brine then the product is dried over magnesium sulfate and concentrated under reduced pressure to dryness. The product can be used without further purification or it can be recrystallised.
[0057] The fully esterified galactopyranose in dry solvent such as dichloromethane is cooled to 0° C. under an inert atmosphere. To this solution is added hydrogen bromide in glacial acetic acid, typically 30% HBr content. The solution is allowed to warm to +25° C. (room temperature) and stirred for around 16 hours. The solution is diluted with organic solvent such as dichloromethane and then quickly washed with ice cold water, saturated aqueous sodium bicarbonate, and brine. The product is dried over magnesium sulfate filtered and the solvent is removed under reduced pressure. The product is crystallized from petrol (40-60) and diethyl ether.
[0058] Furthermore, the method for preparing a steroid-modified solatriose of general formula (Ib) comprises reacting the compound of general formula (IIb) as defined above with a compound of general formula (III) as defined above to yield a compound of general formula (IVb):
[0059] in which R 3 and R 4 are as defined above.
[0060] The step for preparing the compound of formula (IVb) is preferably conducted under substantially the same conditions as the reaction for preparing the compound of formula (IVa) above.
[0061] Alternatively, the reaction may be carried out by reacting the compound of formula (III) as defined above with intermediate (A):
[0062] wherein R 4 is defined above, and R 7 represents any alkyl or aryl residue, e.g., a straight or branched C 1-14 alkyl group or a phenyl group optionally substituted with one or more C 1-4 alkyl groups; whereby the C 1-14 alkyl group is preferably selected from methyl, ethyl and propyl and the phenyl group is preferably selected form phenyl, p-methylphenyl and p-chlorophenyl. The reaction can be carried out in a suitable solvent such as dichloromethane or a combination of dichloromethane and an ether such as diethylether. The reaction is preferably carried out in the presence of a promoter as defined above, e.g., triflic anhydride, and a sterically hindered base such as 2,6-lutidine, 2,4,6-collidine or 2,6-di-tertbutyl-4-methyl pyridine, preferably 2,6-di-t-butylpyridine, at low temperature (below −10° C., preferably below −20° C.).
[0063] In this embodiment, intermediate (A) may be obtained by oxidizing intermediate (B):
[0064] wherein R 4 and R 7 are as defined above, to yield the corresponding sulfoxide (i.e., intermediate (A)). Oxidation of intermediate (B) may be effected using a suitable oxidation means, e.g., m-chloroperbenzoic acid. The reaction may be carried out in a solvent such as dichloromethan at low temprature (−20° C., preferably −40° C.).
[0065] Intermediate (B) may be formed by the treatment of the compound of formula (IIb) with an alkali metal salt of an alkyl or aryl thiol (R 7 —SH), e.g., the potassium or sodium salt of R 7 —SH, in a suitable solvent such as ethanol or methanol.
[0066] Subsequently, the above-obtained compound of general formula (IVb) may deprotected by removing substituent R 4 to obtain a compound of general formula (Vb):
[0067] wherein R 1 is defined as above.
[0068] Any suitable deprotection condition conventionally employed in the chemistry of protecting groups may be used. In particular, deprotection may preferably be carried out as described above for the preparation of the compound of formula (Va).
[0069] The thus obtained compound of general formula (Va) may be selectively protected in 4-OH and 6-OH position with a ketal or acetal protecting group using standard conditions to yield a compound of general formula (VIb):
[0070] wherein R 6 represents a ketal or acetal type protecting group selected from benzylidene, 4-nitrobenzylidene, 4-methoxybenzylidene or isopropylidene. In a preferred embodiment R 7 represents a benzylidene protecting group.
[0071] The reaction is preferably carried out in a dipolar aprotic solvent such as dimethyl formamide (DMF) or acetone in the presence of acid catalysts such as p-toluene sulfonic acid or camphorsulfonic acid using a 2,2-dialkyloxypropane or an optionally substituted dialkyloxybenzylidene such as preferably benzaldehyde dimethyl acetal.
[0072] Suitable reaction temperatures range from ambient temperature to eievated temperatures. Preferably the reaction is carried out at a temperature of 25° C.
[0073] The compound of formula (VIb) may be then reacted with a compound of general formula (VIIb):
[0074] under substantially the same conditions as described above for the preparation of the compound of formula (IVa). In general formula (VIIb) R 3 and R 4 are as defined above. Selective glycosylation at the more reactive 3-position of the galactose may be achieved at reduced temperature such as 0° C. or lower, more preferably −10° C. or lower. Most preferably the reaction is carried out at about −20° C.
[0075] Resulting compound of general formula (VIIIb):
[0076] wherein R 1 , R 4 and R 6 are as defined above, may subsequently be reacted with a compound of formula (VIIa) as defined above under substantially the same conditions as described above for the preparation of the compound of formula (IVa) to yield a compound of general formula (IXb):
[0077] wherein R 1 , R 2 , R 4 and R 6 are as defined above.
[0078] Subsequently, the compound of formula (IXb) may be deprotected to yield the compound of formula (Ib). For example, the ester type protecting group R 4 may be removed at pH 10-11 under substantially the same conditions as described above for the preparation of the compound of formula (Va). The reaction may then be neutralized by addition of solid carbon dioxide. On the other hand, R 6 may be removed by using catalytic hydrogenation over palladium on carbon and hydrogen in an appropriate solvent such as ethanol or methanol. It should be understood that the removal of R 4 and the removal of R 6 are reversable.
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The present invention relates to steroid modified chacotrioses and the synthesis thereof as well as to intermediate compounds useful for the synthesis of the steroid modified chacotrioses and solatrioses. Moreover, the present inventions relates to a method for the preparation of steroid-modified solatrioses.
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REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation-in-part of the patent application entitled “Sclerostin and the Inhibition on Wnt Signaling and Bone Formation,” filed on Mar. 18, 2005 (Dan Wu, et al.). This application is related to the patent application entitled “Compositions and Methods for the Stimulation or Enhancement of Bone Formation and the Self-Renewal of Cells,” application Ser. No. 10/849,643, filed on May 19, 2004, and its contents is hereby incorporated by reference, in its entirety. This application is also related to the patent application entitled “Compositions and Methods for Bone Formation and Remodeling,” application Ser. No. 10/849/067, filed on May 19, 2004, and its contents is hereby incorporated by reference, in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the Dishevelled proteins, which translate Wnt signals from the transmembrane receptor Frizzled to downstream components in canonical and non-canonical Wnt signaling pathways. The invention relates to the field of therapeutic methods, compositions and uses thereof, in the treatment of various diseases which are caused by Wnt signaling involved in pathogenesis. More particularly, the compositions and methods are directed to compounds that interrupt the Frizzled-Dishevelled interaction. The compounds were identified from libraries of compounds using screening methods. These compounds may also be modified to create derivatives or analogues not found in the libraries or in nature, which also function effectively.
[0003] All patents, patent applications, patent publications, scientific articles, and the like, cited or identified in this application are hereby incorporated by reference in their entirety in order to describe more fully the state of the art to which the invention pertains.
BACKGROUND OF THE INVENTION
[0004] Wnt signaling pathways play important roles in embryonic and postembryonic development and have been implicated in tumorigenesis. In the canonical Wnt-β-catenin pathway, secreted Wnt glycoproteins bind to seven-transmembrane domain Frizzled (Fz) receptors and activate intracellular Dishevelled (Dvl) proteins. Activated Dvl proteins then inhibit glycogen synthase kinase-3β (GSK-3β); this inhibition causes destabilization of a molecular complex formed by GSK3β, adenomatous polyposis coli (APC), axin, and β-catenin and reduces the capability of GSK-3β to phosphorylate β-catenin. Unphosphorylated β-catenin proteins escape from ubiquination and degradation and accumulate in the cytoplasm. This accumulation leads to the translocation of β-catenin into the nucleus, where it stimulates transcription of Wnt target genes, such as the gene encoding the T cell factor/lymphoid enhancer factor (Tcf/Lef). Numerous reports address mutations of Wnt-β-catenin signaling pathway components that are involved in the development of neoplasia.
[0005] The link between the Wnt pathway and cancer dates back to the initial discovery of Wnt signaling: the first vertebrate Wnt growth factor was identified as the product of a cellular oncogene (Wnt-1), which is activated by proviral insertion in murine mammary carcinomas. Perhaps the most compelling evidence supporting the role of Wnt signaling in oncogenesis is the finding that approximately 85% of colorectal cancers are characterized by mutations in APC, one of the key components of the Wnt pathway. Members of the Wnt signaling pathway also have been implicated in the pathogenesis of various pediatric cancers such as Burkitt lymphoma, 4 medulloblastoma, Wilms' tumor, and neuroblastoma. Furthermore, aberrant Wnt signaling is involved in other diseases, such as osteoporosis and diabetes.
[0006] Dvl relays the Wnt signals from membrane-bound receptors to downstream components and thereby plays an essential role in the Wnt signaling pathway. Dvl proteins are highly conserved throughout the animal kingdom. Three Dvl homologs, Dvl-1, -2, and -3, have been identified in mammalian systems. All three human Dvl genes are widely expressed in fetal and adult tissues including brain, lung, kidney, skeletal muscle, and heart. The Dvl proteins are composed of an N-terminal DIX domain, a central PDZ motif, and a C-terminal DEP domain. Of these three, the PDZ domain appears to play an important role in both the canonical and non-canonical Wnt pathways. Indeed, the PDZ domain of Dvl may be involved not only in distinguishing roles between the two pathways but also in nuclear localization. Recently, the interactions between the PDZ domain (residues 247 through 341) of mouse Dvl-1 (mDvl1) and its binding partners were investigated by using nuclear magnetic resonance (NMR) spectroscopy. The peptide-interacting site of the mDvl1 PDZ domain interacts with various molecules whose sequences have no obvious homology. Although it is not a typical PDZ-binding motif, one peptide that binds to the mDvl1 PDZ domain is the conserved motif (KTXXXW) of Fz, which begins two amino acids after the seventh transmembrane domain. This finding showed that there is a direct interaction between Fz and Dvl and revealed a previously unknown connection between the membrane-bound receptor and downstream components of the Wnt signaling pathways. Therefore, an inhibitor of the Dvl PDZ domain is likely to effectively block the Wnt signaling pathway at the Dvl level.
[0007] The special role of the Dvl PDZ domain in the Wnt-β-catenin pathway makes it an ideal pharmaceutical target. Small organic inhibitors of the PDZ domain in Dvl might be useful in dissecting molecular mechanisms and formulating pharmaceutical agents that target tumors or other diseases in which the Wnt signaling is involved in pathogenesis. In light of the structure of the Dvl PDZ domain, virtual ligand screening was used to identify a non-peptide compound, NCI668036, that binds to the Dvl PDZ domain. Further NMR experiments validated that the compound binds to the peptide-binding site on the surface of the PDZ domain; the binding affinity (dissociation constant, K D ) of the compound was measured by fluorescence spectroscopy. In addition, we carried out molecular dynamics (MD) simulations of the interaction between this compound and the PDZ domain as well as that between the C-terminal region of a known PDZ domain inhibitor (Dapper) and the PDZ domain, and we compared the binding free energies of these interactions, which were calculated via the molecular mechanics Poisson-Boltzman surface area (MM-PBSA) method.
SUMMARY OF THE INVENTION
[0008] The present invention is based on the activation or inactivation of the intracellular Dishevelled (Dvl) proteins, or homologs of said proteins, which are involved in Wnt signaling pathways.
[0009] In one aspect, the present invention provided methods for identifying compounds using virtual screenings.
[0010] In a preferred embodiment, the present invention provides methods for conducting NMR-assisted virtual screening.
[0011] In another aspect, the present invention provides compounds which bind to the Dishevelled proteins or homologs of said Dishevelled proteins to interrupt the interaction of these proteins with Frizzled receptors, or homologs of Frizzled receptors.
[0012] In still another aspect, the invention provides compounds which bind to the PDZ domain of the Dishevelled proteins to interrupt interactions with transmembrane receptors, such as the Frizzled receptor.
[0013] Other aspects of the present invention will be apparent to one of ordinary skill in the art from the following detailed description relating to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Structure-Based Ligand Screening
[0014] A search was conducted for potential inhibitors of the PDZ domain of Dvl by the use of structure-based virtual screening. PDZ is a modular protein-interaction domain that has two α helices and six β sheets. The αB helix and βB sheet, together with the loop that proceeds, followed by βB, form a peptide-binding cleft. In their crystal-complex structure, the Dapper peptide (derived from one of the binding partners of the Dvl PDZ domain) forms hydrogen bonds with residues Leu265, Gly266, Ile267, and Ile269 in the βB sheet of the PDZ domain.
[0015] To identify small organic compounds that can bind to this groove and interrupt interactions between the PDZ domain and its binding partners, a query was designed by using the program UNITY™, a module in the software package SYBYL™ (Tripos, Inc.). The query consisted of two hydrogen-bond donors (backbone amide nitrogens of Gly266 and Ile269) and two hydrogen-bond acceptors (carbonyl oxygens of Ile267 and Ile269) on the PDZ domain, with 0.3-Å tolerances for spatial constraints. The Flex™ search module of UNITY™ was then used to explore the three-dimensional (3D) small-molecule database of the National Cancer Institute (NCI) to identify compounds that met the requirements of the query. The 3D database is available from NCI at no cost, and it includes the coordinates of more than 250,000 drug-like chemical compounds. The Flex™ search option of UNITY™ considers the flexibility of compounds, and it uses the Directed Tweak algorithm to conduct a rapid and conformationally flexible 3D search. The search yielded 108 organic compounds as the initial hits.
[0016] These 108 hits then were “docked” into the binding site of the PDZ domain using the FlexX™ program of SYBYL™. FlexX™ is energy minimization-modeling software that varies the conformation of the ligand to fit it into the protein-binding site. As a control, we also docked the Dapper peptide into the PDZ domain. The receptor's binding site was defined by residues Gly266, Ile269, and Arg325 with a selection radius of 5.9 Å, and a core sub-pocket was defined by Gly266 with a selection radius of 5.9 Å. Under this condition, the docked Dapper peptide had a similar conformation to that found in crystal structure of the complex with a backbone root mean square deviation (RMSD) of 2.04 Å. In particular, the backbone RMSD for the six C-terminal amino acids is 1.22 Å, indicating that the docking procedure was able to dock ligand into the binding site of the PDZ domain with reasonable accuracy. The results of the docking procedure were evaluated and the compounds that were not docked into the binding pocket of the PDZ domain were manually removed. The Cscore™ program of the SYBYL™ package was used to rank the remaining compounds on the basis of their predicted ability to bind to the binding pocket. Cscore™ generates a relative, consensus score, based on the individual scoring functions of the protein-ligand complex. One of the score functions in Cscore™, the Fscore™, is particularly useful. Fscore™ considers polar and nonpolar interactions to calculate the binding free energy of ligand, including proteins identified through the FlexX™ scoring function. The nine available chemicals whose Fscores™ were better than that of the control Dapper—PDZ interaction were further characterized; these compounds were obtained from the Developmental Therapeutics Program (DTP) of the NCI.
Binding of NCI668036 to the PDZ Domain
[0017] The abilities of the nine compounds obtained from DTP to bind to the PDZ domain were tested using NMR spectroscopy, mainly the chemical-shift perturbation experiment. Of these nine compounds, NCI668036 (MW, 461 Da; FIG. 1 ) generated chemical-shift perturbations to the resonances of the Dvl PDZ domain when added to a solution of the 15 N-labeled Dvl PDZ domain (residues 247 through 341 of mouse Dvl1): the series of 1 H- 15 N correlation spectra showed prominent chemical-shift perturbations of Ile260, Ser261, Val285, Ala286, Arg318, and Val321 in the PDZ domain ( FIG. 2 ). Residues Ile260 and Ser261 are in the αA helix of the PDZ domain, whereas Arg318 and Val321 are in the βB sheet. The binding site of compound NCI668036 on the mDvl1 PDZ domain can be further illustrated by a “backbone worm” representation of the PDZ domain ( FIG. 2 ). The thickness of the worm is proportional to the weighted sum of the 1 H and 15 N chemical-shift perturbations (colored from blue [low] to red [high]) induced by the binding of NCI668036. These chemical-shift perturbations were similar to those caused by binding of the Dapper peptide and Fz7 peptide, which was derived from a Fz membrane receptor. This result suggests that compound NCI668036 binds to the same binding site as native PDZ domain-binding partners such as Dapper and Fz. Therefore, NCI668036 may be able to disrupt functional interactions of the PDZ domain and thereby inhibit Wnt-Fz signaling pathways.
[0018] To determine the binding affinity of NCI668036, we conducted fluorescence spectroscopy experiments by using fluorophore-labeled PDZ domain (TMR-PDZ). We followed the quenching of fluorescence emission of TMR-PDZ at 579 nm (with the excitation at 552 nm) as we titrated NCI668036 into the TMR-PDZ solution. The fluorescence emission of TMR was quenched because of the binding of NCI668036 to the PDZ domain. A double reciprocal plot of the fluorescence changes against the concentrations of NCI668036 gave a linear correlation. Linear fitting using Origin (Microcal Software, Inc.) calculated a K D (mean±standard deviation) of 237±31 μM ( FIG. 3 ).
Molecular Dynamics Simulations of the Complex Between the Dvl PDZ Domain and NCI668036
[0019] To further investigate the interaction between the PDZ domain and NCI668036, the AMBER™ software suite was used to conduct a molecular dynamics (MD) simulation study of the NCI668030-PDZ domain complex. MD simulations were performed in explicit water for 5 ns after equilibration with the particle mesh Ewald (PME) method. The MM-PBSA algorithm was then used to calculate the binding free energy of the interaction between the PDZ domain and NCI668036.
[0020] To sample sufficient possible binding modes during the MD simulation, we re-examined the entire output of the initial FlexX™ docking results were re-examined. The default settings of the FlexX™ docking algorithm yielded 30 possible docking conformations ( FIG. 4 ), and the conformer which had the best docking scores were selected. Although the conformations of the 30 docked NCI668036 were very similar overall, there were distinct variations. These 30 bound conformers can be clustered into three main groups. Group I comprises 5 conformers (in red), and the RMSDs of all the atoms in NCI668036 are between 0.46 and 0.77 Å for this group of conformers; group II has 13 conformers (in yellow) with RMSDs between 1.44 and 1.7 Å; and group III has 12 conformers (in blue) with RMSD between 2.31 to 2.86 Å ( FIG. 3A ). Manual inspection of these docking conformers led to the selection of 10 conformers as starting points for the MD simulations (see Table 1 for the list of the parameters used in the MD simulations). Of these 10 conformers, one was from group I (conformer 6), five were from group II (conformers 4, 7, 10, 14, and 15), and four were from group III (conformers 12, 22, 26, and 27). During the 10 MD simulation runs, the simulation that started with conformer 22 (group III) had the lowest and most stable binding free energy, suggesting that this conformer represents the true PDZ domain-bound conformation of NCI668036 in solution.
Structure of the NCI668036-Bound Dvl PDZ Domain
[0021] The MD simulation that started with conformer 22 was analyzed in detail. During the 5-ns MD production run, the total energy of the MD system (waterbox included) fluctuated between −44552.6 kcal mol −1 and −44344.2 kcal mol −1 (mean, −44450.8 kcal mol −1 ) with a root mean square (rms) of 32.6 kcal mol −1 ( FIGS. 5A and 5C ). The lowest energy occurs at 4.905 ns; the structure of mDvl1 bound with NCI668036 at this point is shown in FIG. 6A . In the complex, NCI668036 formed hydrogen bonds with residues Leu258, Gly259, Ile260, Ile262, and Arg318 of the Dvl PDZ domain ( FIG. 6B ); close hydrophobic contacts between the ligand and the residues in the PDZ domain were also observed. For example, the valyl group that is connected to carbon C1 was within 3.5 Å of the hydrophobic side chains of residues Leu258, Ile260, Ile262, Leu317, and Val314 as well as the C á side chain of Arg318. In addition, the C17 methyl group was within 3.5 Å of Phe257, and the “C”-terminal t-butyl group had hydrophobic contacts with Val263 and Val314 (within 3.5 Å of the hydrophobic side chains of the two residues).
Bound NCI668036 Adopts a Conformation Similar to That of Bound Dapper Peptide
[0022] A comparison between the crystal structure of the PDZ domain bound with the Dapper peptide and the simulated NCI668036-PDZ domain complex revealed that both ligands adopt similar conformations when bound to the PDZ domain ( FIGS. 5C and 5D ). The mass-weighted backbone RMSD (only the 4 C-terminal amino acids, MTTV, were included in the RMSD calculation) for both the PDZ domain-NCI668036 and the PDZ domain-Dapper peptide was 1.49 Å. The backbone of NCI668036 was defined as the atoms in the main chain between and including the carbonyl carbon of the carboxylate group (C) and the carbonyl carbon at the other end of NCI668036 (C8), (a total of 13 atoms; FIG. 1 ).
[0023] To conduct a further detailed comparison, similar to the MD simulation conducted with the PDZ domain-NCI668036 complex, we first carried out a 5-ns MD simulation for the complex was first carried out which consisted of the PDZ domain and Dapper peptide. For each MD simulation, 1000 “snapshots” were saved and analyzed in detail ( FIG. 5 ). The MD simulations allowed the comparison the hydrogen bonds within the two complexes in depth, and those hydrogen bonds, together with their percentage occupancies in the 1000 snapshots, are listed in Table 5. The most striking difference between the two complexes was within the hydrogen-bond network between the “carboxylate binding loop” formed by the conserved motif of Gly-Leu-Gly-Phe (Phe257-Leu258-Gly259-Ile260 in the mDvl1 PDZ domain) and the C-terminal residue of the bound peptide. This hydrogen-bond network is the hallmark of the structure of a C-terminal peptide complex of a PDZ domain; and in the structure of the Dapper-PDZ domain complex, the amide groups of Leu258, Gly259, and Ile260 donated hydrogen bonds to the carboxylate group of the Dapper peptide. In the NCI668036-PDZ domain complex, because of the flexibility of the ether bond, the C-terminal carboxylate group and oxygen O3 were in cis conformation. This conformation allowed both oxygen O3 and the C-terminal carboxylate group to be involved in the “hydrogen network”; the amide groups of Gly259 and Ile260 form hydrogen bonds with oxygen O3, and the C-terminal carboxylate group of NCI668036 forms a hydrogen bond with the amide group of Leu258. Outside the “carboxylate binding network”, the two bound ligands had very similar hydrogen bonds and hydrophobic contacts with the host PDZ domain. Therefore, the increased binding affinity of the Dapper peptide likely is due to the extra length of the peptide-residues Lys5, Leu6, and Ser7 of the bound Dapper peptide form multiple hydrogen bonds and hydrophobic contacts with the host PDZ domain.
[0024] To further compare the binding events of the Dapper peptide and NCI668036 to the PDZ domain, the binding free energies of the complexes were examined. The absolute binding free energies for both systems were calculated by using the MM-PBSA approach in combination with the normal mode analysis. The binding free energy was −1.88 kcal mol −1 for the PDZ-NCI668036 complex and −7.48 kcal mol −1 for the PDZ-Dapper peptide complex (see Tables 2, 3, and 4 for all the energy elements obtained from the MM-PBSA free binding energy calculations). The relative ranking of binding free energies was consistent with experimental data. Indeed, as the dissociation constants for NCI668036 and the Dapper peptide were 237 μM and 10 μM, respectively, at 25° C., the binding free energies (G=−RTlnK D ) were −4.94 kcal mol − 1 for NCI668036 and −6.82 kcal mol − 1 for the Dapper peptide.
Inhibition of the Wnt Signaling Pathway By NCI668036
[0025] In an earlier study, it was demonstrated that the PDZ domain of Dvl interacts directly with the conserved sequence that is C terminal to the seventh transmembrane helix of the Wnt receptor Fz. This interaction is essential in transduction of the Wnt signal from Fz to the downstream component of Dvl. Therefore, an inhibitor of the Dvl PDZ domain should modulate Wnt signaling by acting as an antagonist. To test whether NCI668036 can indeed inhibit Wnt signaling pathways, NCI668036 was co-injected with various activators of the canonical Wnt pathway into the animal-pole region of Xenopus embryos at the two-cell stage. RT-PCR was then performed to analyze expression of the Wnt target gene Siamois in ectodermal explants that were dissected from blastulae and cultured until their development reached the early gastrula stage. In the RT-PCR experiments, expression of ornithine decarboxylase (ODC) was used as the loading control. Although NCI668036 had little effect on Siamois expression induced by β-catenin, a component of Wnt signaling that is downstream of Dvl, NCI668036 inhibited Siamois expression induced by Wnt3A ( FIG. 7A ). These results are consistent with the notion that binding of NCI668036 to the PDZ domain of Dvl blocks signaling in the canonical Wnt pathway at the Dvl level.
[0026] Whether NCI668036 affected the well-known ability of Wnt to induce secondary axis formation was then tested. Wnt3A injected into the ventro-vegetal region of a Xenopus ectodermal explant induced the formation of a complete secondary axis ( FIGS. 7B and 7C ). However, when co-injected with Wnt3A, NCI668036 substantially reduced the secondary axis formation induced by Wnt3A ( FIG. 7D ). This reduction resulted in embryos with a partial secondary axis or only a single axis (see Table 6). Therefore, it may be concluded that NCI668036 specifically blocks signaling in the canonical Wnt pathway.
[0027] By using a UNITY™ search for compounds with the potential to bind to the PDZ domain, FlexX™ docking of candidates into the binding site, Cscore™ ranking of binding modes, and chemical-shift perturbation NMR experiments, we identified a non peptidic small organic molecule (NCI668036) was identified, which could bind to the mDvl1 PDZ domain. This shows that NMR-assisted virtual ligand screening is a feasible approach to identify small molecules that, on the basis of their structural features, are predicted to bind to the target.
[0028] To build the search query for the virtual-screening stage, the crystal structure of the PDZ domain of Xenopus Dvl bound with the Dapper peptide was used instead of the NMR solution structure of the apo-PDZ domain of mouse Dvl. The two PDZ domains share high homology, especially around the peptide-binding sites; near the binding sites, there is only a single amino acid difference between the two PDZ domains (Glu319 in the PDZ domain of mDvl1 versus Asp326 in the PDZ domain of Xenopus Dvl), and the side chain of this residue points away from the peptide-binding cleft. The peptide-binding cavity of the domain is smaller in the apo-form of the solution structure than in the crystal structure of the Dapper-bound PDZ domain of Xenopus Dvl. This difference is consistent with the classic “induce-and-fit” mechanism, in which, upon the binding of a peptide or a small organic molecule, the binding sites in the PDZ domain undergo conformational change to accommodate the bound ligand. However, this flexibility cannot be fully explored through UNITY™ search and the FlexX™ docking protocols. Therefore, although the PDZ domain of mouse Dvl was used in the experimental studies, the crystal structure of the PDZ domain of Xenopus Dvl provides a better template for the virtual screening steps. Indeed, the binding free energies calculated from MD simulation of the PDZ domain-NCI668036 and PDZ domain-Dapper peptide complexes fit well with the experimental binding data.
[0029] NCI668036 is a peptide mimetic in which two peptide bonds are substituted by two ether bonds. Therefore NCI668036 is expected to be more stable than the corresponding peptide in vivo. Although it binds the PDZ domain relatively weakly, NCI668036 can be used as a template for further modifications. Indeed, NCI668036 has a very simple structure, and it is very stable and highly soluble. In addition, MD simulation showed that, compared with the complex of the PDZ domain and Dapper peptide, which has higher binding affinity (K d =10 μM), the complex formed by the PDZ domain and NCI668036 does not fully utilize all possible interactions to maximize binding affinity. For example, the binding affinity is expected to increase if the branching of a hydrophobic group from the backbone of NCI668036 contacts the side chain of Phe257 in the PDZ domain.
[0030] NCI668036 interacts with the Dvl PDZ domain specifically. We tested two other PDZ domains: the first PDZ domain of PSD-95, PSD95a (PDB code: 1IU0, 1IU2), which belongs to the class I PDZ domains, and the PD Z7 domain of the glutamate receptor-interacting protein (PDB code: 1M5Z), a member of class II PDZ domains ( FIG. 12 shows the structure-based sequence alignment of different PDZ domains). NCI668036 binds to both of these PDZ domains extremely weakly. The specificity of NCI668036 for the Dvl PDZ domain likely is due to a unique feature of the domain. The Dvl PDZ domain belongs to neither class I nor class II PDZ domains ( FIG. 12 ). In particular, the Dvl PDZ domain has two loops: one is between the first and second β-strands (the βA-βB loop), and the other is between the second α-helix and the last β-strand (the βB-βF loop). These two loops of the Dvl PDZ domain are longer than that in a typical PDZ domain. In the structure of a typical PDZ domain bound with a C-terminal peptide, the carboxylate group of the bound peptide is also linked through a bound water molecule to the guanidinium group of an arginine in the βA-βB loop. The side chain of the same arginine also forms a hydrogen bond with the amide ground of a glycine in the βB-βF loop. However, the Dvl PDZ domain lacks both the arginine and glycine, and the cavity that holds the bound water molecule in a typical PDZ domain is much smaller in the Dvl PDZ. Indeed, there is no bound water molecule in the crystal structure of the Dvl PDZ domain in a complex with the Dapper peptide. However, when NCI668036 bound to the Dvl PDZ domain, oxygen O3 participated in two hydrogen-bond connections with the “carboxylate binding loop” of the PDZ domain, and the carboxylate group of the bound NCI668036 was pushed into the empty space and stayed in the narrow cavity. We speculate that this binding feature of NCI668036 may explain the specificity of the molecule for the Dvl PDZ domain; in other words, NCI668036 achieves its specificity by using its unique binding mode. This notion is supported by results from one of our MD simulation studies. In the MD simulation run, the starting conformation of the PDZ domain-NCI668036 complex was created by superimposing NCI668036 over the bound Dapper peptide, so that the carboxylate group of the compound formed all three hydrogen bonds with the host PDZ domain. After a 200-ps production run, the system was no longer stable.
[0031] Using the screening methods described, additional compounds were identified which were found to bind to a domain of the Dishevelled proteins. FIG. 8 shows the structures of molecular compounds which were all found capable of binding to the Dishevelled proteins. FIG. 9 and FIG. 10 show structures of compounds that bind to Dishevelled, and they also show compounds which were found to be non-binding. All of the compound structures in FIG. 11 were found to bind to the PDZ domain of the Dishevelled protein. These compounds were NCI compounds, Sigma Aldrich compounds and Chem Div compounds.
[0032] Considering that Dvl is at the crossroad of the Wnt signaling pathways and that the typical binding events in which the molecule is involved are relatively weak but finely tuned and well balanced, an effective Dvl antagonist might be very useful in analyses of Wnt signaling and in dissecting various pathways. Functional studies of NCI668036 strongly support this theory. Besides being a powerful tool for biological studies of Wnt signaling pathways, a strong inhibitor of Dvl serves as a leading compound for further development of pharmaceutical agents useful in the treatment of cancer and other human diseases in which the Wnt signaling pathway has a crucial role in pathogenesis.
MATERIALS AND METHODS
Purification of 15 N-labeled mDvl1 PDZ Domain.
[0033] The 15 N-labeled mouse Dvl1 PDZ domain (residue 247 to residue 341 of mDvl1) was prepared as described previously. To increase the solubility of the protein, Cys334, which is located outside the ligand binding site, was mutated to alanine in the PDZ domain construct.
Preparation of 2-((5(6)-Tetramethylrhodamine)carboxylamino)ethyl Methanethiosulfonate (TMR)-Linked mDvl1 PDZ Domain.
[0034] Wild-type PDZ domain protein (without the Cys334Ala mutation) was produced using the standard procedure. Cys334 is the only cysteine in the protein. Purified PDZ (40 μM) was dialyzed against 100 mM potassium phosphate buffer (pH 7.5) at 4° C. overnight to remove DTT, which was added during protein purification steps to prevent disulfide bond formation. We then dropwise added a 10-fold molar excess of TMR dissolved in DMSO to the solution of the PDZ domain while it was being stirred. After 2 hours of reaction at room temperature, excess TMR and other reactants were removed by extensive dialysis against 100 mM potassium phosphate buffer pH 7.5) at 4° C.
Structure-based Ligand Screening of Small Compounds Binding to the PDZ Domain.
[0035] The UNITY™ module of the SYBYL™ software package (Tripos, Inc.) was used to screen the NCI small-molecule 3D database for chemical compounds that could fit into the peptide-binding groove of the Dvl PDZ domain (PDB code: IL6O). The candidate compounds then were docked into the binding groove by using the FlexX™ module of SYBYL™ (Tripos, Inc.). The compounds that displayed the highest consensus binding scores were acquired from the Drug Synthesis and Chemistry Branch, Developmental Therapeutics Program, Division of Cancer Treatment and Diagnosis, National Cancer Institute (http://129.43.27.140/ncidb2/) for further tests.
NMR Spectroscopy.
[0036] NMR 15 N-HSQC experiments were performed by using a Varian Inova 600-MHz NMR spectrometer at 25° C. Samples consisted of the Dvl PDZ domain (concentration, ˜0.3 mM) in 100 mM potassium phosphate buffer (pH 7.5), 10% D 2 O, and 0.5 mM EDTA. NMR spectra were processed with NMRpipe software and analyzed by using the program Sparky™.
Fluorescence Spectroscopy.
[0037] We used a Fluorolog-3 spectrofluorometer (Jobin-Yvon, Inc.) was used to obtain the fluorescence measurements of the interaction between the TMP-linked PDZ domain and the NCI668036 compound. Titration experiments were performed at 25° C. in 100 mM potassium phosphate buffer (pH 7.5). The solution of NCI668036 (concentration, 1 mM) was sequentially injected into a fluorescence sample cell that contained 2 ml 30 μM TMR-labeled PDZ domain in 100 mM potassium phosphate buffer (pH 7.5). During the fluorescence measurement, the excitation wavelength was 552 nm, and the emission wavelength was 579 nm. The fluorescence data were analyzed by using the ORIGIN™ program (Microcal Software, Inc.). The K D values were determined by using a double reciprocal plot of fluorescence changes against increasing compound concentrations.
Molecular Dynamics Simulation.
[0038] MD simulation was performed by using the sander program in the software package AMBER 8™ with the parm99 force field. AM1-BCC charges were assigned to NCI668036 by using the Antechamber module 47 in AMBER 8.™ The starting structures of ligand-protein complexes were prepared by using the output from the FlexX™ docking studies. After neutralization, complexes were dissolved in a periodic rectangular TIP3P water box, with each side 10 Å away from the edge of the system. The components of these MD systems are. summarized in Table 1 Systems were minimized by 1000-step steepest descent minimization followed by 9000-step conjugated gradient minimization. The MD simulations were performed with time step of 2 ps and non-bonded cutoff being set to 9.0 Å. Both constant volume (NTV) and constant pressure (NTP) periodic boundary conditions were applied to gradually relax the system. In detail, the MD production run was carried out under the NPT condition for 5 ns after a 50-ps NVT ensemble in which the temperature was increased from 100 K to 300 K, a 50-ps NPT ensemble in which solvent density was adjusted, and another 100-ps NPT ensemble in which harmonic restraints were gradually reduced from 5.0 kcal mol −1 Å −2 to 0. Snapshots were saved every 5 ps during the production run. Other simulation parameters were set similarly to those described in the work by Gohlke et al.
Binding Free Energy Calculation.
[0039] Binding free energy was calculated by (1) for which the MM-PBSA approach was implemented by using the mm_pbsa.pl module of AMBER 8™.
[0000] Δ G total =G complex −G protein −G ligand (1)
[0000] where
[0000] G=H gas +H trans/rot +G solvation −TS (2)
[0000] G solvation =G polar solvation +G nonpolar solvation (3)
[0000] G nonpolar solvation = yA+b (4)
[0000] Where gas phase energy, H gas , is the sum of internal (bond, angle, and torsion), van der Waals, and electrostatic energy in the molecular mechanical force field with no cutoff, as calculated by molecular mechanics. H trans/rot is 3RT (R is the gas constant) because of six translational and rotational degrees of freedom. Solvation free energy, G solvation , was calculated by using the PB model. In PB calculations, the polar salvation energy, G polar solvation , was obtained by solving the PD equation by with the Delphi software using parse radius, parm94 charges (for the PDZ domain and the Dapper peptide), and AM1-BCC charges (for the compound). The nonpolar contribution was calculated by (4). In the equation, A is the solvent accessible area calculated by the Molsurf module in Amber 8™, and y (surface tension) and b (a constant) were 0.00542 kcal mol −1 Å −2 and 0.92 kcal mol −1 respectively. All of the above energy terms were averaged from 150 snapshots extracted every 20 ps, and entropy TS was estimated by normal mode analysis using 15 snapshots extracted every 200 ps during the last 3-ns production run.
DETAILED DESCRIPTION OF THE FIGURES
[0040] FIG. 1 . Structure of compound NCI668036
The chemical structure of NCI668036 was sketched by using ISIS/Draw (MDL Information Systems, Inc.). Some atoms (which are mentioned previously) are labeled with the atom name assigned by the Antechamber module of AMBER 8™.
[0041] FIG. 2 . Interaction between the mDvl1 PDZ domain and NCI668036.
[0000] 15 N-HSQC spectra of free NCI668036 (red contour lines) and of NCI668036 bound to the PDZ domain of mdvl1 (blue contour lines) are shown. The concentration of the PDZ domain was 0.3 mM. The concentrations of NCI668036 was 7.8 mM (bound form). In the upper inset, the signals from the same region with enlarged spectra were placed in smaller boxes. The inset also contains an additional spectrum (green lines) from a different concentration of NCI668036 (2.4 mM). In the worm representation of the backbone structure of the mDvl1 PDZ domain (lower inset), the thickness of the worm is proportional to the weighted sum (in Hz) of the 1 H and 15 N shifts upon binding by NCI668036; increasing chemical-shift perturbation is shown (blue, low; red, high). The figure was prepared by using the software Insight II™ (Accelrys, Inc.).
[0042] FIG. 3 . Binding affinity between mDvl1 PDZ and NCI668036 as determined from a double reciprocal plot of fluorescence intensity quenching (F) against the concentration of NCI668036.
[0000] Fluorescence measurements were obtained by titrating NCI668036 into a solution of the TMR-PDZ domain. The KD value of the complex formed by NCI668036 and the PDZ domain of mdvl1 was 237±31 μM as extracted after linear fitting.
[0043] FIG. 4 . The 30 docking conformations of compound NCI668036 generated by using the FlexX™ program were clustered into three groups.
Group I comprised 5 conformations (red) with RMSDs between 0.46 and 0.77 Å, group II had 13 conformations (yellow) with RMSDs between 1.44 and 1.73 Å, and group III had 12 conformations (blue) with RMSDs between 2.31 and 2.86 Å.
[0044] FIG. 5 . Backbone root mean square deviations (RMSDs, Å) of the mDvl1 PDZ domain bound to NCI668036, the mDvl1 PDZ domain bound to the Dapper peptide, and the starting structure and total potential energies of the MD systems for 5-ns explicit simulations.
The 200-ps equilibration phase is not included.
[0000]
A. Backbone RMSDs of the mDvl1 PDZ domain (purple) and NCI668036 (green) for a 5-ns simulation.
B. Backbone RMSDs of the Dvl1 PDZ domain (purple) and Dapper peptide (green) for a 5-ns simulation.
C. The total potential energy (ETOT) of the mDvl1 PDZ domain and NCI668036 (water molecules included) during a 5-ns simulation fluctuated between −44552.6 kcal mol −1 and −44344.2 kcal mol −1 . The total potential energy (mean±standard deviation) was −44450.8±32.6 kcal mol −1 .
D. The total potential energy of the Dvl1 PDZ domain (water molecules included) and Dapper peptide during a 5-ns simulation fluctuated between −44349.8 kcal mol −1 and −44122.3 kcal mol −1 . The total potential energy (mean±standard deviation) was −44233.8±31.3 kcal mol −1 .
[0049] FIG. 6 . Conformation of NCI668036 docked into the PDZ domain and of the NCI668036-mDvl1 PDZ domain complex.
[0050] A. NCI668036 and the Dapper peptide bound to the PDZ domain in similar conformations. NCI668036 (blue) was docked into the Dvl PDZ domain (ribbons and tubes in gray) by using FlexX™ (Tripos, Inc.). The Dapper peptide (orange) is in its conformation determined by x-ray crystallography and is in a complex with the PDZ domain. The difference between the backbone root mean square deviation of compound NCI668036 and that of Dapper peptide (only the 4 C-terminal amino acids [MTTV] backbone atoms were used) was 1.49 Å.
[0051] B. The binding conformation of NCI668036 at 4.905 ns during the 5-ns simulation. The PDZ domain is shown as gray ribbons and tubes. NCI668036 is represented according to the bound atom (green, carbon; red, oxygen and blue, nitrogen). Residues that formed a hydrogen bond with the compound are shown in ball-and-stick format (black, carbon; red, oxygen; blue, nitrogen); hydrogen bonds are represented by yellow dashed lines. Residues within 3.5 Å of isopropyl, methyl (those next to nitrogen atoms), and t-butyl groups of compound are in CPK format (gray, carbon; red, oxygen; blue, nitrogen. In addition, Leu258, Ile260, and Ile262 were within 3.5 Å of the isopropyl group next to the carboxylate group. They are in ball-and-stick format for clarity).
[0052] FIG. 7 . Effect of NCI668036 on canonical Wnt signaling in Xenopus embryos.
[0053] A. NCI668036 inhibited the canonical Wnt pathway induced by Wnt3A but not by β-catenin. RT-PCR was conducted to analyze the expression of the Xenopus Wnt target gene Siamois in ectodermal explants. Synthetic mRNA corresponding to Wnt3A (1 pg) and â-catenin (500 ng) were injected alone or with NCI668036 (180 ng) into the animal-pole region at the two-cell stage, and ectodermal explants were cultured until they reached the early gastrula stage, at which time they underwent RT-PCR analysis.
[0054] B. A control embryo that received no injection.
[0055] C. An embryo that received an injection of Wnt3A mRNA developed a complete secondary axis.
[0056] D. An embryo that received coinjections of Wnt3A mRNA and NCI668036 developed a partial secondary axis.
[0057] FIG. 8 . Molecular structures of NCI & Sigma Aldrich compounds which were tested for their ability to bind to the Dishevelled protein.
[0058] Compounds 221120, 107146, 145882 and 161613 were found to weakly bind to Dvl whereas compounds 108123, 339938, v8878 and 579270 were found to not bind at all.
[0059] FIG. 9 . Molecular structures of Chem Div compounds which were tested for their ability to bind to the Dishevelled protein.
[0060] Compounds 3237-0565, 3237-0713, 3237-0430, 8006-2560, 0090-0031 and 2372-2393 were found to bind to Dvl whereas 0136-0181 did not.
[0061] FIG. 10 . Molecular structures of Chem Div compounds which were tested for their ability to bind to the Dishevelled protein.
[0062] Compounds 8004-1312, 3289-8625, 3289-5066, 3237-0719 bound to Dvl. Compounds 8003-2178, C691-0030, 1748-0253, 1108-0424, 2922-0102, 3379-2274 and 8003-4726 did not bind to Dvl.
[0063] FIG. 11 . Molecular structures of compounds which were tested for their ability to bind to the Dishevelled protein.
[0064] Compounds 103673, 145882, 3289-5066, 3289-8625, 337837, 7129, 3237-0719, 12517, p1, 142277, 82569, 39869, p3, 46893, 661075, 661080, 661086, 661092, 661091, 84123 and 668036 were all found to bind to Dvl.
[0065] FIG. 12 . Structure-based alignment of the amino-acid sequences of the PDZ domains of Dvl Homologs and other proteins.
[0066] Secondary structural elements are indicated above the sequences. Residues at the gly-his (GH) positions are in boldface type. The asterisk denotes the binding pocket for the ligand's C terminus. Sequence differences among the PDZ domains are indicated by underlining.
[0067] Table 1. Information about atoms of simulated systems and dimensions of water boxes.
[0068] Table 2. Binding free energy components of compound NCI668036 and PDZ averaged over the last 3 ns of a 5-ns explicit simulation.
[0069] Table 3. Binding free energy components of the PDZ domain and the Dapper peptide averaged over the last 3 ns of a 5-ns explicit simulation.
[0070] Table 4. Binding free energy components of the PDZ domain and NCI668036 and the PDZ domain and the Dapper peptide averaged over the last 3 ns of the 5-ns explicit simulation α .
[0071] Table 5. Hydrogen bonds observed between NCI668036 and the PDZ domain and between the Dapper peptide and the PDZ domain during 5-ns explicit simulation α .
[0072] Table 6. Effect of NCI668036 on formation of the secondary axis induced by Wnt3A and β-catenin a .
[0073] aVentro-vegetal injection of Wnt3A mRNA and β-catenin and of Wnt3A mRNA and NCI668036 at the two-cell stage. Experimental details are shown in FIG. 7B through D. bDefined as the appearance of a second neural plate on the ventral side of early neurulae and ectopic eyes and cement glands. Percentages indicate the proportion of embryos that met the definition. cTotal number of embryos that received injections in two independent experiments.
[0000]
TABLE 1
Atom information of simulated systems and dimensions of water boxes
Complex
PDZ-NCI668036
PDZ-Dapper peptide
No. of atoms in the ligand
67
135
No. of residues in the ligand
1
8
No. of atoms in the protein
1348
1348
No. of residues in the protein
90
90
No. of Na+ atoms
5
3
No. of TIP3P molecules
5399
5372
Total no. of atoms
17617
17602
Box size
62 Å × 67 Å ×
62 Å ×
56 Å
67 Å × 56 Å
[0000]
TABLE 2
Binding free energy components of compound NCI668036 and PDZ averaged
over the last 3 ns of 5 ns explicitly simulation a
PDZ-NCI668036
PDZ
NCI668036
Delta b
Contrib. c
Mean d
SE e
Mean d
SEd e
Mean d
SE e
Mean d
SE e
H elec
−2726.05
49.15
−2738.88
52.64
7.31
2.69
5.52
12.57
H vdw
−306.94
15.67
−272.72
14.71
6.18
2.69
−40.39
2.84
H int
1832.79
27.16
1760.28
25.7
72.51
5.87
0
0
H gas
−1200.2
56.31
−1251.32
59.51
86
6.13
−34.88
12.93
PB sur
31.8
0.5
31.9
0.5
5.17
0.06
−5.27
0.16
PB cal
−1777.12
47.65
−1675.18
51.38
−118.57
2.4
16.63
12.78
PB sol
−1745.32
47.41
−1643.28
51.13
−113.4
2.42
11.36
12.71
PB tot
−2945.52
27.48
−28.94.6
27.13
−27.4
5.38
−23.52
3.36
TS tra
16.03
0
15.99
0
13.27
0
−13.23
0
TS rot
15.83
0.01
15.79
0.01
11.3
0.21
−11.25
0.2
TS vib
1022.07
4.96
973.56
4.65
45.67
1.62
2.84
4.96
TS tot
1053.93
4.96
1005.34
4.65
70.24
1.83
−21.64
5.02
ΔG total
−1.88
a All energies in kcal mol −1 .
b Contribution (PDZ-NCI668036) - Contribution (PDZ) - Contribution (NCI668036).
c H elec , coulombic energy; H vdw , van der Waals energy; H int , internal energy; H gas = H elec + H vdw + H int ; PB sur , non-polar contribution for solvation free energy; PB cal , polar contribution fro salvation free energy; PB sol = PB sur + PB cal ; PB tot = H gas + PB sol ; TS tra /TS rot /TS vib , translational/rotational/vibrational entropy; TS tot = TS tra + TS rot + TS vib; ΔG total = PB tot + H trans/rot − TS tot.
d Average over 150 snapshots and 15 snapshots for entropy contributions.
e Standard error of mean values.
[0000]
TABLE 3
Binding free energy components of the PDZ domain and Dapper peptide
averaged over the last 3ns of 5 ns explicitly simulation a
PDZ-Dapper
Dapper
peptide
PDZ
peptide
Delta
Mean
Std
Mean
Std
Mean
Std
Mean
Std
H elec
−3076.24
56.04
−2759.74
50.83
−127.92
10.73
−188.58
22.76
H vdw
−315.8
17.33
−268.01
16.27
5.66
3.81
−53.46
3.51
H int
1926.1
25.44
1774.73
25.03
151.37
7.34
0
0
H gas
−1465.94
57.68
−1253.02
51.63
29.11
12.13
−242.03
23.04
PB sur
34.03
0.6
32.83
0.57
8.21
0.18
−7.02
0.18
PB cal
−1764.06
55.33
−1660.76
47.57
−318.15
10.32
214.85
22.79
PB sol
−1730.03
55.1
−1627.93
47.34
−309.94
10.3
207.83
22.73
PB tot
−3195.97
25.91
−2880.94
25.17
−280.83
7.24
−34.2
4.13
TS tra
16.07
0
15.99
0
13.86
0
−13.78
0
TS rot
15.9
0.02
15.79
0.01
12.54
0.05
−12.42
0.05
TS vib
1069.73
5.22
969.69
3.62
100.55
0.69
−0.51
6.37
TS tot
1101.7
5.23
1001.47
3.63
126.95
0.71
−26.72
6.37
ΔG total
−7.48
a Abbreviations and equations are the same as those defined for Supplemental Table 2.
[0000]
TABLE 4
Binding free energy components of the PDZ domain and NCI668036, the PDZ and
Dapper peptide averaged over the last 3 ns of 5 ns explicitly simulation a
Contrib. b
ΔH elec
ΔH vdw
ΔH gas
ΔPB cal
ΔPB sur
ΔPB sol
ΔPB tot
TΔS
ΔG total
NCI668036
5.52
−40.39
0
16.63
−5.27
11.36
−23.52
−21.64
−1.88
Dapper peptide
−188.58
−53.46
0
214.85
−7.02
207.83
−34.20
−26.72
−7.48
a All energies are in kcal mol −1 .
b Contribution (PDZ-NCI668036) - Contribution (PDZ) - Contribution (NCI668036) for NCI668036 and Contribution (PDZ-Dapper peptide) - Contribution (PDZ) - Contribution (Dapper peptide) for Dapper peptide.
H elec , coulomic energy;
H vdw , van der Waals energy;
H int , internal energy;
ΔH gas = ΔH elec + ΔH vdw + ΔH int ;
PB sur , non-polar contribution for solvation free energy;
PB cal , polar contribution for solvation free energy;
ΔPB sol = ΔPB sur + ΔPB cal ;
ΔPB tot = ΔH gas + ΔPB sol ;
TΔS = TΔS tra + TΔS rot + TΔS vib ;
ΔG total = ΔPB tot + ΔH trans/rot − TΔS
[0000]
TABLE 5
H-bonds observed between compound NCI668036 and PDZ,
Dapper peptide and PDZ during 5 ns explicitly simulation a
NCI668036 - PDZ
Dapper peptide - PDZ
NCI668036
PDZ
Occupancy b
Dapper peptide
PDZ
Occupancy b
O
Leu258N/H
13.5
Val0OXT
Leu258N/H
27.7
O1
Leu258N/H
85.1
Val0O
Leu258N/H
98.0
O3
Gly259N/H
91.6
Val0OXT
Gly259N/H
98.4
O3
Ile260N/H
32.6
Val0OXT
Ile260N/H
82.3
N/H2
Ile260N/H
99.8
Val0N/H
Ile260N/H
99.1
O6
Ile262N/H
99.5
Thr-2O
Ile262N/H
99.8
N1/H5
Ile262O
65.1
Met-3N/H
Ile262O
99.2
O
Arg318
11.2
Lys-5O
Gly264N/H
99.4
Lys-5N/H
Gly264O
86.9
Ser-7O
Ser266N/H
85.3
a The length and angle cutoffs for H-bond are 3.5 Å and 120° respectively.
b Occupancy is in the units of percentage.
[0000]
TABLE 6
Effect of the compound NCI668036 on the formation of secondary
axis induced by Wnt3A and β-catenin a
Double axis b
Single axis
Total c
No injection
100%
83
Wnt3A
77%
23%
75
Wnt3A/NCI668306
55%
45%
78
β-catenin
51%
49%
78
β-catenin/NCI668306
49%
51%
76
a Ventro-vegetal injections of Wnt3A mRNA and β-catenin, and NCI668036 at two cell stage. Experimental details are shown in FIGS. 7B-7D.
b Defined as the appearance of a second neural plate on the ventral side of early neurulae and ectopic eyes and cement glands. Percentages indicate the proportion of embryos that met the definition.
c Total number of embryos that received injections in two independent experiments
|
The Wnt signaling pathways are involved in embryo development as well as in tumorigenesis. Dishevelled (Dvl) tranduces Wnt signals from the receptor Frizzled (Fz) to downstream components in canonical and non-canonical Wnt signaling pathways, and the Dvl PDZ domain plays an essential role in both pathways, and the Dvl PDZ domain binds directly to Fz receptors. In the present invention using NMR-assisted virtual ligand screening, several compounds were identified and were found to bind to the Dvl PDZ domain. Molecular dynamics simulation was used to analyze the binding between the PDZ domain and these compounds in detail. These compounds provide a basis for rational design of high-affinity inhibitors of the PDZ domain, which can block Wnt signaling by interrupting the Fz-Dvl interaction.
| 2
|
This is a division of copending application Ser. No. 08/068,460, filed May 27, 1993.
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is hereby made to the commonly owned and concurrently filed application of Aslam et al. entitled Process for the Preparation of 1,3,5-tris(4'-hydroxyphenyl)benzene and its Derivatives and Intermediate Compounds Serial No.07/891,167, filed Jan. 08, 1992, and the application of Hilton entitled Epoxidation Products of 1,3,5-(4'-hydroxyphenyl)benzenes, U.S. Ser. No. 07/819,166, filed Jan. 08, 1992.
FIELD OF THE INVENTION
This invention relates to a process for preparing 1,3,5-tris(4'-hydroxyphenyl)benzene (THPB) and related compounds from 4-hydroxyacetophenones (4-HAP). Condensation of three acetophenone molecules produces an aromatic nucleus to provide 1,3,5-trisphenyl benzenes.
BACKGROUND OF THE INVENTION
1,3,5-tris(4'-hydroxyphenyl)benzene falls into the class of compounds known as trisphenyls. Trisphenyls have been recognized as useful intermediates in the preparation of more complex organic structures. For example, resins are readily prepared by a reacting trisphenyls with formaldehyde, acid anhydrides and more importantly with epichlorohydrin. Epoxide resins prepared from such compounds exhibit low shrinkage, extraordinary hardness, chemical inertness, outstanding mechanical strength, and a variety of beneficial features. See, for example, U.S. Pat. No. 4,394,496; and, the above-referenced application of Hilton.
1,3,5-tris(4'-hydroxyphenyl)benzene (THPB) molecules are particularly useful in their ability to stabilize polycarbonates. This is accomplished via a three site rigid D 3h crosslink. THPB molecules may also be used as crosslinking agents in epoxy resins. See, for example, Chem. Abstracts, 66, 3004C.
THPB was reported in Beilstein, E II 6, 1115 (1921). The treatment of 4-methoxyacetophenone (4-MAP) with sulfuric acid produced 1,3,5-tris(4'-methoxyphenyl)benzene (4-MAP trimer or TMPB)(20% yield). This compound was demethylated with concentrated hydrochloric acid to yield THPB.
THPB was also reported in Chimia, 12, 143 (1958) and Chimia, 13, 105 (1959) as formed by the trimerization of 4-haloacetophenone, where the halogen is either bromine or chlorine, in the presence of potassium pyrosulfate and sulfuric acid. This reaction results in 1,3,5-tris(4'-halophenyl)benzenes. These halogen-containing trimers were treated with sodium hydroxide and converted to THPB.
M. H. Karger and Y. Mazur, J. Org. Chem, 36, 540 (1971), reported that anisole and acetyl methanesulfonate, affords 4-MAP (46% yield) and TMPB (41% yield). Subsequent to anisole acetylation, trimerization is catalyzed by methanesulfonic acid.
R. E. Lyle, E. J. DeWitt, N. M. Nichols, and W. Cleland, J. Amer. Chem. Soc., 75, 5959 (1953), report the trimerization of substituted acetophenones, i.e., 4-MAP to TMPB (54% yield), by an alcoholic hydrogen chloride solution, after four months at room temperature.
G. P. Sharnin, I. E. Moisak, E. E. Gryazin, Zhurnal Prikladnoi Khimii, 43, 1642 (1970), report the trimerization of 4-MAP to TMPB (27% yield) using a mixture of potassium pyrosulfate and sulfuric acid. See also, A. F. Odel et al. , J. Amer. Chem. Soc. , 36, 81 (1913).
P. Milart and J. Cioslowski, Synthesis, p. 328-29 (1984) relate to the use of 4-alkoxyacetophenones to prepare 4-alkoxyacetophenone anils which are condensed to form 1,3,5-tris(4-alkoxyphenyl)benzenes. However, the reference does not suggest using 4-hydroxyacetophenone (4-HAP) or substituted 4-hydroxyacetophenones to produce 4-hydroxyacetophenone-anil (4-HAP-anil) or substituted 4-hydroxyacetophenone-anils, which may be then condensed to form 1,3,5-tris (4'-hydroxyphenyl)benzene or substituted 1,3,5-tris (4'-hydroxyphenyl)benzenes. In fact, the reference teaches the conversion of 4-hydroxyacetophenone to 4-alkoxyacetophenone before converting to the corresponding anil and thereafter trimerizing the anil. This is consistent with earlier teachings which describe unsuccessful efforts to trimerize hydroxyacetophenone. See, for example, G. P. Sharnin et al., supra, see also R. E. Lyle et al., supra. Its is also consistent with prior teachings that 1,3,5-tris(4-hydroxyphenyl)benzene is produced by hydrolyzing the corresponding 4'-alkoxy substituted compound which is prepared using 4-alkoxyacetophenone. See, for example, Beilstein, E II 6, 1115 (1921). Moreover, P. Milart et al. fail to teach or suggest a one step process for trimerizing 4-HAP.
U.S. Pat. No. 3,458,473, issued Jul. 29, 1969 to Starnes et al. is directed to the preparation of various hindered trisphenyls prepared by the cyclotrimerization of an acetylphenol precursor.
U.S. Pat. No. 3,644,538 issued Feb. 22, 1972 to W. H. Starnes, discloses that both 3'-alkyl- and 3',5'-dialkyl-4'-hydroxyacetophenones can be trimerized to the corresponding triarylbenzenes with anhydrous HCl and triethyl orthoformate and ethanol. Trimerization of unsubstituted 4-HAP is not suggested or disclosed. Starnes also fails to teach or suggest trimerizing substituted or unsubstituted 4-HAP-anil.
German Patent 258,929 to Zimmerman et al., issued Aug. 10, 1988 is directed to methods for the production of 1,3,5-tris(triarylbenzene) compounds. These compounds are reacted by combining 2,4,6-triaryl pyryliurn salts with carboxylic acid anhydride in the presence of a basic condensing agent. The reaction of Zimmerman utilizes triaryl pyrylium carboxylic anhydride.
Elmorsy et al., "The Direct Production of Tri-and Hexa-Substituted Benzenes from Ketones Under Mild Conditions," Tetrahedron Letters, Vol. 32, No. 33, 4175-4176 (1991) report the treatment of aryl benzenes with tetrachlorosilane in ethanol to yield 1,3,5-triarylbenzenes. However, Elmorsy et al. fail to teach or suggest trimerizing 4-hydroxyacetophenone, a 4-hydroxyacetophenone derivative, or a 4-substituted-oxyacetophenone by contacting such a compound with a halosilane, as in the present invention. Indeed, it is believed that trimerizing a hydroxyacetophenone such as 4-hydroxyacetophenone or a 4-hydroxyacetophenone derivative, is not disclosed or suggested by Elmorsy et al. because of the belief that the hydromy group would interfere with the reaction, for example, react with the tetrachlorosilane. See. e.g., Sharin et al., supra, which illustrate why it was believed, before now, that direct trimerization of hydroxyacetophenone was not feasible. Accordingly, Elmorsy et al. fail to teach or suggest the present invention.
SUMMARY OF THE INVENTION
In accordance with this invention, a process is provided for the preparation of 1,3,5-tris(4'-hydroxyphenyl)benzene (THPB) and related compounds from 4-hydroxyacetophenone (4-HAP) and corresponding substituted 4-hydroxyacetophenones. Until now, the direct trimerization of 4-hydroxyacetophenone (4-HAP) to 1,3,5-tris(4'-hydroxyphenyl)benzene (THPB) was believed to be not feasible.
The inventive reaction provides a novel approach for the large scale synthesis of 1,3,5-tris(4'-hydroxyphenyl)benzene or related compounds. In a broad sense, the present invention provides a process for the production of 1,3,5-tris (4'-hydroxyphenyl)benzene or its related compounds by contacting the corresponding substituted 4-hydroxyacetophenone with aniline or an aniline derivative to form the 4-hydroxyacetophenone-anil, and, contacting the 4-hydroxyacetophenone-anil with a catalytic amount of an acid catalyst, preferably an anilinium salt, such as anilinium hydrochloride, anilinium hydrobromide, anilinium sulfate, anilinium tosylate and the like, to form 1,3,5-tris (4'-hydroxyphenyl)benzene or its related compounds. The term "aniline derivative" refers to substituted aniline wherein the substituents are on the aromatic ring of the aniline and are selected from the group consisting of C 1 -C 6 C 1 -C 6 alkyl, alkoxy, and halo. The scope of the invention also provides for the use of naphthylamine and naphthylamine derivative in place of aniline and aniline derivative respectively, and of naphthylaminium salt in place of the anilinium salt, as is known to those skilled in the art.
More specifically, the process comprises treating 4-hydroxyacetophenone or other substituted 4-hydroxyacetophenones with aniline, preferably by refluxing, and preferably in the presence of a solvent such as toluene to produce 4-hydroxyacetophenone-anil (4-HAP-anil) or the corresponding substituted 4-hydroxyacetophenone-anil. The 4-hydroxyacetophenone-anil or substituted 4-hydroxyacetophenone-anil is trimerized in the presence of an acid catalyst, e.g., HCl, HBr, H 2 SO 4 or the like, preferably an acidic anilinium salt such as anilinium hydrochloride, anilinium hydrobromide, anilinium sulfate or anilinium tosylate to produce 1,3,5-tris(4'-hydroxyphenyl)benzene or the corresponding substituted 1,3,5-tris(4'-hydroxyphenyl)benzene. The present invention also provides a process for the production of 1,3,5-tris(4'-hydroxyphenyl) benzene comprising contacting 4-hydroxyacetophenone-anil with anilinium hydrochloride, under reaction conditions.
The inventive process is based on the following general reaction in which three acetophenone molecules, e.g., 4-hydroxyacetophenone or substituted 4-hydroxyacetophenone molecules, are condensed to provide a 1,3,5-tris(4'-hydroxyphenyl)benzene or substituted 1,3,5-tris(4'-hydroxyphenyl)benzene. ##STR1##
In one embodiment, the reaction can be carried out in one step, without the isolation of 4-hydroxyacetophenone-anil or a substituted 4-hydroxyacetophenone-anil. In the reaction, the 4-hydroxyacetophenone or a substituted 4-hydroxyacetophenone is treated with the aniline in the presence of an acid catalyst to form the 1,3,5-tris(4'-hydroxyphenyl)benzene or a substituted 1,3,5-tris(4'-hydroxyphenyl)benzene. ##STR2##
In each of the above reaction schemes, R 1 is hydrogen, an alkyl group such as an alkyl group having from 1 to about 12 carbon atoms preferably a C 1 -C 5 lower alkyl, such as methyl or ethyl, a cycloalkyl of from about 3 to about 6 carbon atoms, phenyl (including mono or poly-substituted phenyl, e.g., with halogen and/or nitro), halogen, such as Br, Cl, I or F, NO 2 or sulfonyl (alkyl or aromatic). The alkyl group of the alkyl sulfonyl is preferably an alkyl group having from 1 to about 12 carbon atoms, more preferably a C 1 -C 5 lower alkyl, for instance, a C 1 -C 5 lower alkyl substituted by one or more halogen and/or nitro groups. The aromatic of the aromatic sulfonyl is preferably phenyl, or an alkyl substituted aromatic such as an aromatic substituted by one or more lower alkyl groups, for instance, tolyl, xylyl, cumenyl or the like, or an aromatic substituted by one or more halogen and/or nitro groups.
In addition, the acetophenone molecule can have from one to four R 1 substituents on it (e.g., at any or all of the 2, 3, 5 and 6 positions); and, these multiple R 1 substituents can be the same or different. Thus, x can be an integer from 1 to 4, and, when x is greater than 1, the R 1 substituents can be the same or different.
In the inventive process, it has been found, surprisingly, that the 4-hydroxyacetophenone carbonyl group is converted to the aniline imine, which undergoes cyclotrimerization readily in the presence of the acidic, preferably anilinium salt, condensing agent which is regenerated in the process.
A significant advantage of the process of the invention is that the process may be carried out in a single step and provides for the production of THPB and its derivatives, without using a number of reaction steps and reagents which were necessary in the past.
DETAILED DESCRIPTION
An embodiment of the present invention is exemplified by the following general reaction in which three acetophenone molecules are condensed to provide a 1,3,5-trisaryl benzene: ##STR3##
Another embodiment of the present invention is illustrated by the preparation of THPB from 4-HAP by the following reaction scheme: ##STR4##
Yet another embodiment of the present invention is illustrated by the following one step process to prepare THPB from 4-HAP: ##STR5##
In this one step process, the 1,3,5-trisaryl benzene such as THPB is prepared, via a conversion from the corresponding substituted 4-hydroxyacetophenone such as 4-HAP without the isolation of the 4-hydroxyacetophenone-anil such as 4-HAP-anil. Generally, three acetophenone molecules, in the presence of sufficient quantities of aniline and anilinium hydrochloride, and optionally in the presence of a solvent, for example, a non-polar solvent such as toluene, are condensed to provide the corresponding 1,3,5-trisaryl benzene. Reaction conditions can be varied but generally are ambient pressure and temperatures and times which do not significantly decompose the reactants and/or product, and, which provide a satisfactory yield of desired product. Typical reaction times are about 0.5 to 8 hours, and typical reaction temperatures range from about 150° to about 220° C.
Alternatively, the substituted 4-HAP can be contacted with an aniline to yield the anil; the contacting is preferably in the presence of a solvent. Anilinium hydrochloride is thereafter added in a sufficient quantity and the solvent removed by distillation. These reaction mixtures are each heated at a temperature and for a time, again, so as to not result in significant decomposition of reactants and/or product, and, so as to obtain a satisfactory yield of desired product. For contacting the substituted 4-HAP with an aniline derivative to yield the anil, the reaction conditions are typically times of 2 to 24 hours and temperatures of 80° to 160° C.; and, for contacting the anil with the acidic anilinium salt (e.g., anilinium hydrochloride), the reaction conditions are typically times of 0.25 to 4 hours and temperatures of 180° to 220° C.
The 1,3,5-trisaryl benzene, for instance, THPB, is recovered from the reaction mixture by, for instance, cooling the reaction mixture and precipitating the product; addition of a suitable solvent, for example, a non-polar solvent such as toluene, in a suitable amount, to separate out oil, decanting the supernatant liquid to leave an oily residue, and adding a suitable solvent, for example, a non-polar solvent such as hexane, to the oily residue to cause the THPB to precipitate is also possible. The 1,3,5-trisaryl benzene such as THPB is preferably recrystallized to increase its purity. Whether the 1,3,5-trisarylbenzene is prepared from corresponding acetophenone or acetophenone-anil as illustrated above, the starting material is to be used in at least 3 molar ratios with respect to the quantity of the end product.
It is within the ambit of the skilled artisan to select appropriate quantities of the reactants, aniline, anilinium salts and solvent and to select appropriate reaction times and temperatures. The selection of appropriate reaction times and temperatures depends upon various factors, such as the quantity of reactants. Furthermore, in this Description, wherever aniline is described as a reactant, it is to be presumed that aniline derivative, as explained above, may be substituted as a reactant.
When the aniline and anilinium salt are aniline and anilinium hydrochloride respectively, it is preferred that the number of moles of aniline present during the reaction be at least equal to or more than the number of moles of the substituted 4-hydroxyacetophenone present. The ratio of the number of moles of aniline to the number of moles of the substituted 4-hydroxyacetophenone (e.g., aniline: 4-hydroxyacetophenone) is about 1.0:1.0 to about 10:1. The aniline: substituted 4-hydroxyacetophenone mole ratio is most preferably about 2:1.
Anilinium hydrochloride is present in sufficient quantities to catalyze the cyclotrimerization and the regeneration of aniline. In the reaction mixture, the ratio of the number of moles of anilinium hydrochloride to the number of moles of the 4-hydroxyacetophenone such as 4-HAP is preferably about 0.01:1 to about 0.25:1 (or about 1:4 to about 1:100).
When the aniline: 4-hydroxyacetophenone mole ratio is about 2:1, the ratio of the number of moles of anilinium hydrochloride to the number of moles of 4-hydroxyacetophenone is about 0.02:1 to about 0.1:1, preferably about 0.04:1.0 (or, about 1.0:10 to about 1.0:50, preferably about 1.0:25). Likewise, a preferred ratio of the number of moles of aniline initially added to the number of moles of anilinium hydrochloride is about 1:0.02, when the aniline: 4-hydroxyacetophenone mole ratio is about 2:1.
As to the solvents used in the reaction, the substituted 4-hydroxyacetophenone and aniline are preferably contacted in the presence of a solvent such as toluene. A preferred solvent to add to the cooled reaction mixture is also toluene, and, it is preferably added in about the same amount used during the initial contacting. To precipitate the 1,3,5-tris(4'-hydroxyaryl)benzene from the oily residue, hexane is a preferred non-polar solvent, and, it is preferably present in excess.
Other suitable solvents used during the reaction of the 4-hydroxyacetophenone in the presence of the aniline include xylene; during the oil separation include pentane; and, during the precipitation of the 1,3,5-tris(4-hydroxyaryl)benzene may be pentane, cyclohexane, and the like.
The aniline and aniline derivatives utilized to promote the formation of the 4-hydroxyacetophenone-anil are aniline, p-methyl aniline, nitro aniline, chloro aniline, and the like. Acids such as HCl, HBr, H 2 SO 4 and the like may be used to catalyze the condensation to the is 1,3,5-tris(4'-hydroxyaryl)benzene; however, acids derived from aniline, especially from the aniline used to form the anil, are preferred. Suitable acidic anilinium salts include aniline.HCl, aniline.HBr, aniline.sulfate, aniline.tosylate, or the like.
In another embodiment, the 4-hydroxyacetophenone-anil is prepared, isolated and then utilized to form the corresponding 1,3,5-trisaryl benzene. According to this process, in an initial reaction, a suitable quantity of the 4-hydroxyacetophenone such as 4-HAP is contacted with aniline, optionally in the presence of a solvent, e.g., a non-polar solvent such as toluene, under reaction conditions, to form the corresponding anil compound. The reaction conditions are temperature, time and pressure conditions which do not cause significant decomposition of reactants and/or product, and, which obtain a satisfactory yield of desired product. Typical reaction conditions include temperatures of about 150° C. to about 180° C. times of about 2 to about 24 hours and pressures of about 50 mm to about 760 mm Hg. For example, the reaction may be carried out under reflux for up to 17 hours at a pressure achieved using a condenser and Dean Stark trap. Conditions may vary depending upon the scale of the reaction (quantities of reactants) and other factors usually considered by the skilled artisan.
The number of moles of aniline present is an amount at least equal to or preferably exceeding the number of moles of the 4-hydroxyacetophenone present. The mole ratio of aniline: 4-hydroxyacetophenone ranges from about 1:1 to about 10:1, most preferably about 3.0:1.0. A preferred solvent for this reaction is toluene. This invention is not limited to the use of toluene as a solvent as other suitable solvents may also be employed, including xylene, cyclohexane and the like.
As the 4-hydroxyacetophenone and aniline are reacted, water from the reaction is collected by, for example, a trap via a condenser, and, after a sufficient time, the 4-hydroxyacetophenone-anil is recovered from the reaction mixture. For instance, when the reaction is complete, the reaction mixture is cooled after a period of time, for example, up to 17 hours and, then combined with a solvent, for example, a non-polar solvent such as hexane, to form an oily product, e.g. a yellowish-brown oily product in the case of 4-hydroxyacetophenone-anil, which separates out of the reaction mixture. The quantity of hexane used is preferably about 2.5 to about 500 moles per mole of the 4-hydroxyacetophenone initially added. Most preferably, the ratio is about 8.0:1.0. The oily product is recrystallized with a solvent, for example, a non-polar solvent such as hexane, to afford a solid. The recrystallization solvent is preferably used in an amount of the order mentioned above for the solvent utilized to separate the oily product from the cooled reaction mixture (e.g., on a small scale 3×200 ml). The solid is preferably recrystallized to afford a solid, e.g., 4-HAP-anil. Any suitable solvent or solvent combination, e.g., non-polar solvents or combinations of relatively non-polar solvents may be employed for the recrystallization. Ether/hexane is one suggested solvent combination for the recrystallization. However, the invention is not limited to these recovery steps for obtaining the anil compound from the reaction mixture as other effective procedures or solvents may be used, such other solvents including pentane, cyclohexane and the like.
4-Hydroxyacetophenone-anil compounds such as 4-HAP-anil may be reactive with water and should be kept dry prior to their further use.
In a second step the 4-HAP-anil isolated from the first step is contacted with an acid catalyst, preferably an anilinium salt such as anilinium hydrochloride under suitable reaction conditions to produce the desired 1,3,5-trisaryl benzene product. The mole ratio of anilinium hydrochloride to substituted 4-hydroxyacetophenone-anil is preferably about 0.01:1 to about 0.25:1, more preferably about 0.065:1.0 (or, preferably about 1.0:4.0 to about 1.0:100, more preferably about 1:15). The mole ratios for the two-step process may also be in the ranges described above in connection with the "one step" embodiment of the present invention, for instance ranges of about 1.0:4.0 to 1.0:100, and about 1:10 to about 1:50 such as about 1:12.5 to about 1:25 for the anilinium hydrochloride to 4-hydroxyacetophenone-anil mole ratio.
The reaction conditions of this second step are suitable time and temperature which will not cause significant decomposition of reactants and/or product, and, will obtain a satisfactory yield of the desired product. Reaction times of about 0.25 to about 4 hours and temperatures of about 180° to about 220° C. are preferred, e.g., reflux (about 190° C.) for about 2 hours.
The reaction mixture is cooled and extracted into an aqueous solution, e.g., a basic aqueous solution such as an aqueous alkali hydroxide solution, such as NaOH. When a NaOH solution is used, it may be used in a 1 molar solution (e.g., in small scale 2 g NaOH in 50 ml H 2 O). Extracting the reaction mixture into an aqueous solution results in a second aqueous solution which is washed with an organic solvent, such as, a relatively non-polar solvent like chloroform (e.g., two times, or in small scale 2×25 ml) and acidified at a pH of, for example, about 6.5 to 3.5, preferably about 5.5 to 4.0, whereby the 1,3,5-tris(4'-hydroxyaryl)benzene precipitates. The solid may be dried, e.g., in a vacuum oven for about 2 to 24 hours at a temperature of about 80° to 120° C. These recovery procedures are not limiting as variations are within the ambit of the skilled artisan. For instance, other aqueous solutions including KOH, Na 2 CO 3 and the like, and, other organic solvents such as methylene chloride and the like can be used.
Examples of 1,3,5-tris (4'-hydroxyaryl)benzenes which can be prepared in accordance with the invention are:
1,3,5-tris(4'-hydroxyphenyl) benzene;
1,3,5-tris (3'-alkyl-4'-hydroxyphenyl) benzene;
1,3,5-tris (3'-halophenyl-4'-hydroxyphenyl)benzene;
1,3,5-tris (3'-nitro-4'-hydroxyphenyl)benzene;
1,3,5-tris (2'-alkyl-4'-hydroxyphenyl) benzene;
1,3,5-tris(2'-alkyl-3'-alkyl 4'-hydroxyphenyl)benzene;
1,3,5-tris(2'-nitro-3'nitro 4'hydroxyphenyl)benzene; and
1,3,5-tris(2'-halophenyl-3'-halophenyl 4'-hydroxyphenyl)benzene and combinations thereof, e.g. 1,3,5-tris(2'-alkyl-6'-halo-4'-hydroxyphenyl)benzene.
Examples of 4-hydroxyacetophenones used in the reaction are:
4-hydroxyacetophenone;
3-alkyl-4-hydroxyacetophenone;
3-halo-4-hydroxyacetophenone;
3-nitro-4-hydroxyacetophenone;
2-alkyl-4-hydroxyacetophenone;
3-alkyl-4-haloacetophenone; and
2-alkyl-6-halo-4-hydroxyacetophenone.
From the above examples of 1,3,5-tris(4'-hydroxyaryl)benzenes which can be prepared in accordance with the invention, and, the above examples of 4-hydroxyacetophenones used in the reaction, it is to be understood that in the foregoing description terms such as "4-hydroxyacetophenone" and "substituted 4-hydroxyacetophenone" and abbreviations thereof can include both 4-hydroxyacetophenone, i.e., when R 1 is hydrogen and x is 1, and substituted 4-hydroxyacetophenones, e.g., when R 1 can be other than hydrogen and x is 1 to 4, or when x is greater than 1 and the R 1 substituents are the same or different and include at least one substituent other than hydrogen. Likewise, in the foregoing description, the terms "1,3,5-tris(4'-hydroxyphenyl)benzene" and "substituted 1,3,5-tris (4'-hydroxyphenyl)benzene" include 1,3,5-tris (4'-hydroxyphenyl)benzene, i.e., when R 1 is hydrogen and x is 1 as well as substituted 1,3,5-tris(4'-hydroxyphenyl)benzene, e.g., when R 1 is other than hydrogen and x is 1 to 4, or when x is greater than 1 and the R 1 substituents are the same or different and include at least one substituent other than hydrogen. And, in this description the terms "1,3,5-trisaryl benzene" and " 1,3,5-tris (4'-hydroxyaryl)benzene" are meant to include both 1,3,5-tris (4'-hydroxyphenyl)benzene and substituted 5-tris(4'-hydroxyphenyl)benzene.
The inventive method may be further illustrated by the following examples, many apparent variations of which are possible without departing from the spirit and scope thereof.
EXAMPLE 1
One Step Conversion of 4-hydroxyacetophenone to THPB:
4-Hydroxyacetophenone (13.6 g, 0.1 mol) was contacted with aniline (18.6 g, 0.2 mol) in the presence of toluene (100 ml; as solvent) and heated to reflux in a round bottom flask equipped with a condenser and a Dean and Stark trap. After most of the 4-HAP was converted to 4-HAP-anil (conversion followed by gas chromatography), anilinium hydrochloride (0.5 g, 0.0038 mol) was added and the toluene was removed via distillation. The reaction mixture was heated at 190°-200° C. for 3 hours, cooled to 120° C. and THPB was recovered as follows. Toluene (100 ml) was added to the cooled reaction mixture and an oil was separated. The supernatant liquid was decanted leaving an oily residue to which was added hexanes (100 ml) to precipitate THPB as a yellow solid (5.3 g). THPB was 88% pure by HPLC analysis.
EXAMPLE 2
Synthesis of THPB via intermediate formation of 4-hydroxyacetophenone (4-HAP) anil
Step One: Preparation of 4-MAP-anil
4-Hydroxyacetophenone (27.2 g, 0.2 mol), was contacted with aniline (50 g, 0.54 mol) in the presence of toluene (50 ml) of and heated to reflux in a round bottom flask equipped with a condenser and a Dean and Stark trap. The water from this reaction was collected in the trap. After 17 hours, this reaction mixture was cooled and the 4-HAP-anil was recovered by pouring the cooled reaction mixture into 200 ml of hexanes. A yellowish-brown oily product separated out of the reaction mixture. The oily product was triturated with hexanes (3×200 ml) to afford 45.0 g of a brown solid. Recrystallization of a small sample (5.0 g) with ether/hexane afforded 1.2 g of a yellowish-white solid which by melting point (139°-141° C.) and 1 H and 13 C NMR spectra was determined to be 4-hydroxyacetophenone-anil (4-HAP-anil).
Step Two: THPB from 4-HAP-anil
To a round bottom flask equipped with a magnetic stirrer and a condenser, 4-hydroxyacetophenone-anil (2.5 g, 0.0118 mol) and anilinium hydrochloride (0.1 g, 0.00077 mol) was added. The reaction mixture was heated at reflux (bath temperature 190° C.) for 2 hours, and cooled. THPB was recovered by extracting the reaction mixture into an aqueous 1 molar NaOH solution (2 g NaOH in 50 ml water). The resulting aqueous solution containing extracted reaction mixture was washed with chloroform (2×25 ml) and the chloroform wash was discarded. The aqueous layer was acidified to a pH of 4.0, and the product precipitated as a yellow solid. The solid was dried in a vacuum oven to provide 1.4 g of 84% pure THPB (by HPLC analysis).
EXAMPLE 3
4-HAP to THPB: One Step
4-hydroxyacetophenone (13.6 g) was contacted with (18.6 g) aniline and aniline-HCl (0.5 g) and heated to 185°-190° C. for two hours. A sample was removed from the reaction mixture and by LC analysis determined to be 31% 4-HAP and 67.5% THPB. Heating at 185°-190° C. continued for another two hours and thereafter a sample was removed from the reaction mixture. By LC analysis, the reaction mixture after four hours was 23% 4-HAP and 75% THPB. 10 ml of toluene was then added to the reaction mixture and heating at 190°-200° C. was continued for about another 2 hours. A sample was then analyzed by LC analysis and determined to be 6% 4-HAP and 93% THPB.
Heating was continued until most of the aniline was distilled out. The THPB was recovered by pouring the reaction mixture after the aniline distillate was distilled out into dilute H 2 SO 4 and extracting with ethyl acetate. The ethyl acetate was washed with water and product was crystallized to yield (by LC analysis) 95% 4-HAP-trimer (THPB).
This Example demonstrates that the use of toluene solvent is optional, but preferred.
EXAMPLE 4
4-HAP to THPB: One Step
A reaction mixture of 4-hydroxyacetophenone (13.6 g), aniline (28.0 g) and aniline HCl (1.0 g) was heated to 220° C. in a reaction flask fitted with a Dean and Stark trap filled with 90% aniline and stirred for 4 hours at that temperature. The reaction mixture was cooled to room temperature and the THPB was recovered by pouring the cooled reaction mixture into a dilute sodium hydroxide solution (12.0 g NaOH in 200 ml H 2 O), separating out the aniline and washing the aqueous solution with chloroform. The aqueous layer was acidified, with drops of dilute HCl, to a DH of about 5.5, and a solid was precipitated. The precipitated solid was collected via filtration and dried in a vacuum oven to yield 10.8 g. Using 1 H and 13 CNMR and LC analyses, the product was 48% pure. Recrystallization would produce a more purified product.
EXAMPLE 5
4-HAP to 4-HAP-anil
A reaction mixture of 4-hydroxyacetophenone (27.2 g) and aniline (50.0 g) in toluene (100 ml.) as solvent was mixed in a two-necked 500 ml flask equipped with a Dean and Stark trap and a condenser and heated to reflux using an oil bath at about 180° C. for 16 hours. Samples were withdrawn at 4, 12, and 16 hours and analyzed by Gas Chromatography. After 4 hours there was 50% conversion to 4-HAP-anil; after 12 hours there was 80% conversion to 4-HAP-anil; and, after 16 hours there was 88% conversion to 4-HAP-anil. After 16 hours, the reaction mixture was cooled, petroleum ether was added and an oily layer separated in the bottom. The oily layer was triturated with petroleum ether to give a thick pasty oil which was dissolved in chloroform. The addition of petroleum ether resulted in a reddish brown solid. Gas Chromatography on a sample of this solid showed it to be 80% imine (4 -HAP-anil), 6% 4-HAP, and 4.5% aniline. 5.0 grams of the solid was recrystallized with chloroform/hexane to give a yellow solid which was 96% pure 4-HAP-anil by Gas Chromatographic analysis. It was also observed that the 4-HAP-anil was reactive with water. A sample of 4-HAP-anil left in an open flask overnight hydrolyzed to 4-HAP and aniline as determined by Gas Chromatography. Thus, the imine was kept dry prior to its use in making THPB.
EXAMPLE 6
THPB from 4-HAP-anil
In a flask, 4-hydroxyacetophenone-aniline imine (4-HAP-anil) (2.11 g; 0.01 mol) was heated at about 190° C. for 0.5 hours in the presence of about 0.1 g anilinium hydrochloride. The flask was cooled and the product was dissolved in dilute aqueous sodium hydroxide, and the aqueous solution was washed with chloroform. The aqueous layer was separated and acidified slowly by the addition of dilute HCl until obtaining a pH of about 4.0. A yellow solid precipitated which was collected via filtration, air dried and then dried in an oven at about 70° C. and a pressure of about 50 man Hg. The resultant solid weighed 1.18 g and, by analysis, was 71.4% THPB and 0.6% 4-HAP.
EXAMPLE 7
THPB from 4-HAP-anil
Step two of Example 2 was repeated, except that the reaction mixture was refluxed for 4 hours. THPB was recovered as set out in step two of Example 2 to provide 1.4 g of 75% pure THPB (by 13 C and 1 H NMR and HPLC analyses).
Having described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the claims is not to be limited by particular details set forth in the description as many apparent variations are possible without departing from the spirit of the present invention.
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Novel 4-substituted acetophenone anils and methods for preparing 1,3,5-tris(4'-hydroxyphenyl)benzenes from 4-substituted acetophenones such as 4-hydroxyacetophenones or, from substituted 4-hydroxyacetophenone-anils such as 4-hydroxyacetophenone-anil by reacting the 4-substituted acetophenone or corresponding anil with an aniline derivative.
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BACKGROUND OF THE INVENTION
This invention relates generally to processing of pulp for papermaking and more particularly to washing of the pulp on a drum filter.
Processing of papermaking pulp requires washing to remove the digesting liquor. This has been performed in a series of pulp washers or in a single multiphase washer. After each washing cycle, i.e., after removal from each washer, the pulp mat is commonly diluted, formed into a new pulp mat, and washed again until the desired degree of washing is accomplished. If washing is prolonged, channels form in the mat and the wash liquor flows through those channels instead of displacing the pulping liquor. For effective washing, the pulp mat must be as uniform as possible, and washing must only continue so long as the degree of channeling is not excessive. This allows maximum displacement of pulping liquor by a minimal amount of wash liquor.
In multiphase washing, the mat is washed several times without reforming. After the first wash phase, washing becomes less effective due to channeling. Thus, the number of wash phases which can be effective in a single pulp mat washing cycle is limited.
Various types of multiphase pulp washers are used. One of these is a belt washer wherein the pulp is washed by a series of showers as it travels horizontally on a flexible belt over a number of vacuum boxes. The wash liquor flow is countercurrent, meaning that the wash liquor for the first shower is fed from the effluent of the second shower. The last shower is fed by the cleanest water.
Operation of belt washers is costly due to belt wear caused by dragging the belt across the vacuum boxes, the belt tension needed to drag it across those boxes, the operating temperature, and the corrosive action of the pulp liquor. In addition, distribution of the shower liquor is not uniform, and tends to disrupt the mat aggravating the channeling condition.
One known drum type washer features two phase washing with countercurrent flow. The wash liquor is applied under pressure so that it flows through the pulp mat to the inside of the filter drum.
In this design, the wash zones are quite short which limits the drum speed and, hence, the capacity. Since there is one pump for the wash liquor, seals are required between the zones, to prevent crossflow between the zones. Seal contact against the pulp mat can cause disruption of the mat, pulp pile-up at the seals, and clogging of the machine.
Another problem associated with this design is excessive bearing wear and cylinder ring deflection, due to unbalanced radial side loads caused by the unbalanced pressure. Exposure of the inside of the cylinder and its reinforcing rings to the corrosive liquor also contributes to deterioration of the cylinder structure.
In vacuum washers, the wash liquor is collected in the deck channels and piped to a valve at one or both ends of the cylinder. Thus, the interior drum structure is protected from the corrosive effects of the wash liquor.
To obtain effective displacement washing, the pulp mat must be well formed and free of channels and lumps. Avoiding formation of flocs and a non-uniform pulp mat on a vacuum filter, requires that the pulp be fed at a consistency below about 11/2%. It is, therefore, necessary to heavily dilute the feed pulp. This requires a large quantity of forming liquor and, consequently, large deck drainage channels which permit excessive intermixing between filtrates collected at the forming zone and the washing zone. This makes multiphase washing on vacuum filters impractical.
The foregoing illustrates limitations known to exist in present devices and methods. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the invention, this is accomplished by providing a multiphase pulp washer comprising a generally drum shaped rotatable filter having segregated low-volume interior filtrate drainage channels. The filter is rotated about its axis while pulp, at 4% to 6% consistency is fed to form a pulp mat on a surface of the filter. After forming, the pulp mat is pressed on the filter surface to increase its consistency by more than 150% and to thereby decrease the required volume of wash liquor and passes through at least two wash phases in each of which it is washed with wash liquor fed by a separate pump for that wash phase. This makes it possible to maintain uniform constant fluid pressure about the entire circumference of said drum shaped filter.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross sectional transverse view of a multiphase washing filter;
FIG. 1A is an enlarged view of the circled portion labeled "A" in FIG. 1.
FIG. 2 is a flow chart showing the countercurrent paths of the pulp mat and wash liquor;
FIG. 3 is a fragmentary schematic sectional transverse view of one port of the filter drum deck; and
FIG. 4 is a longitudinal schematic cross section of the filter drum showing one possible drainage scheme.
DETAILED DESCRIPTION
Referring to FIG. 1, the feed pulp 1 is fed to the filter surface 2 through pulp feed nozzle 9. Near the discharge end of pulp feed nozzle 9 is a pulp distributor and deflocculator 5 which prevents pulp floc formation to avoid a lumpy mat. The pulp mat 3 is formed in forming zone 10 by the filtering action of the filter surface 2 upon the feed pulp 1.
To optimize the washing process, a deflocculator and pulp distributor 5 is provided in the pulp feeder 9. The pulp distributor provides uniform spreading of the pulp along the full length of the filter. The deflocculator 5 prevents formation of flocs or lumps. Without the deflocculator, the consistency of feed pulp 1 would have to be maintained at less than approximately 11/2%. Provision of the deflocculator 5 permits feeding of the pulp at a consistency of approximately 4 to 6%. This means that the liquor volume in the forming zone 10 is approximately one-fourth what it would be, were it not for the deflocculator. Thus, smaller flow channels may be used within the deck and filtrate mixing is reduced accordingly.
After the pulp mat 3 is formed, it travels through the compaction zone 20 on the filter surface 2 where it is pressed by a first compaction baffle 6 having very gradual convergence to increase the consistency and the uniformity of the pulp mat 3. In first wash zone 30, it is washed by the first wash liquor 70 which is fed to the pulp mat 3 through first wash liquor nozzle 71. This wash liquor 70 fills the space outside the first compaction baffle 6 and the excluder baffle 8. It passes through the slot between the compaction baffle 6 and the excluder baffle 8 to wash the pulp mat 3 on the deck 2 in the first wash zone.
Following the first wash zone 30 is the second wash zone 40. In this zone, the second wash liquor 60 is fed through the second wash liquor nozzle 61 from which it flows beneath the excluder baffle 8 and second compaction baffle 7. In the circled region labeled A, an interface 75, as shown enlarged in FIG. 1A, exists between the two wash liquors at the boundary of the wash zones 30 and 40. This is merely a liquid interface and does not include any mechanical separation features. This interface is possible because both the first wash liquor 70 and the second wash liquor 60 are fed by separate pumps which maintain a pressure equality between the two wash zones. There is, therefore, no tendency for either wash liquor to flow into the neighboring wash zone.
Provision of a separate wash liquor supply pump for each wash zone permits operation of the multiphase washer without seals between the wash zones. Because both zones are maintained at equal pressure, there is no driving force for inter-zone flow. The only mechanical separation required is provided by an excluder baffle which does not touch the pulp mat and which separates the wash liquors of the two wash zones prior to their contact with the pulp mat.
During travel of the pulp mat 3 beneath the second compaction baffle 7 it is further dewatered to a consistency of about 15-24% in the second compaction and dewatering zone 45 before it reaches the take-off zone 50 where it is diluted to approximately 12% and removed from the deck by take-off roll 55 or other take-off means. It then passes from the discharge box 51 through the pulp outlet 100.
FIG. 2 presents a schematic flow chart which illustrates the countercurrent paths of the pulp mat and the wash liquor. In this figure, the pulp travels in a rightward direction, the wash liquor travels in a generally leftward direction.
It should be noted that the feed pulp is supplied at a consistency of approximately 12% and is diluted to 4 to 6% before passing through pulp feed nozzle 9. From there, after passing through the deflocculator and distributor 5, the pulp enters forming zone 10 where the pulp mat 3 is formed by extraction of a portion of the pulp liquor. Immediately after forming, the mat passes through the first compaction zone 20 in which its consistency is raised to approximately 15 to 24%.
Achievement of this relatively high consistency prior to washing makes it possible to reduce the amount of wash liquor necessary to achieve thorough displacement of the pulp liquor in the mat. Because of the low degree of dilution; the pulp liquor effluent requires a significantly lessor amount of evaporation and concentration for regeneration. Once it is compacted, the pulp mat 3 passes through the first wash zone 30 where the first displacement washing is performed.
The second wash zone 40 immediately follows first wash zone 30. After the second wash, the pulp mat enters the second compaction zone 45 where it is again compacted to approximately 15-24%. At this higher consistency, the pulp is more readily removed from the filter drum as it enters the discharge box 51. From there it is discharged at the higher consistency or at a desired diluted consistency through the pulp outlet 100.
The flow of wash liquor through the system is countercurrent to that of the pulp. Starting with a fresh water supply 60, pump 59 forces the water through the pulp mat in second wash zone 40. In second wash zone 40, the wash water displaces the wash liquor of first wash zone 30. During this displacement the consistency of the pulp mat is maintained at approximately 12%--the same consistency at which it left first wash zone 30. During its travel through the second compaction and dewatering zone 45, the consistency of the mat is increased to approximately 15-24% prior to entering the discharge box 51. Filtrate from the second compaction and dewatering zone 45, and filtrate from the second wash zone 40, is collected in a reservoir for first wash liquor 70. From there, first wash liquor pump 69 forces the first wash liquor 70 through the pulp mat in first wash zone 30. The filtrate from first wash zone 30, together with the filtrate from first compaction zone 20 and forming zone 10, are collected and part of this liquor is used to dilute the feed consistency to 4-6%. The balance is returned to the liquor treatment operation for evaporation, concentration, and regeneration. Thus, the first displacement wash is performed with the filtrate from the second wash. After first wash zone 30, and aggregation with the filtrate from the first compaction zone 20 and the forming zone 10, the liquor is slightly more concentrated than it was after the first wash only. A degree of dilution is unavoidable in the washing process; however, this dilution is minimized in the present invention for the reasons already described.
FIG. 3 shows a schematic transverse cross section of one port of the drum deck. In this view, are shown filter surface 2, division grids 80, support grids 82, sealed channels 84, drain divider grid 85, deck drainage flow channel 86, and corrugated deck drain 88. It should be noted that support grids 82, unlike those of many standard filter drum decks are preferably solid and result in sealed channels 84 which do not communicate with deck drainage flow channel 86. All support grids 82 except the drain divider grid 85, separating deck drainage flow channel 86 from sealed channels 84, may be optionally perforated. Thus, the only drainage path from filter surface 2 is along the circumferential corrugations of the deck below filter surface 2, through corrugated deck drain 88, and then into deck drainage flow channel 86. This relatively small drainage channel volume limits the mixing of filtrates, because it provides for incremental separation. This is separation of the first filtrate in a wash zone, and the middle filtrate in that zone from each other and from the last filtrate as chronologically generated.
FIG. 4 shows a schematic longitudinal cross section of a filter drum and indicates one possible drum drainage scheme. Bearings 90 and 92 support the drum for rotation.
Next to bearing 92 is drain control valve 94 and drum drain 95. Drain control valve 94 is designed to incrementally segregate the filtrate from the first and second pulp wash zones 30 and 40, respectively. Drainage flow channel 86 is shown tapering toward the drum center from where it connects to the drain control valve 94 by means of drainage tube 93. Note that, because of the small drainage flow channels 86, it is preferred that they be as short as possible in order to drain completely in the minimum time. Thus, a filter drum of great length may require quarter point drainage in order to maintain the preferred short and fast draining deck drainage flow channels 86 and may even require valves and drains at both ends of the drum. In this way the incremental filtrate separation is made possible and filtrate can be segregated in each work zone according to when it was generated within that zone.
Under the conditions described, the flow volume within the deck drainage flow channels 86 will equal approximately one-third to one-fourth of the wash liquor flow per cylinder revolution per phase under commonly used supply conditions for the wash liquor.
The foregoing has described a multiphase washing system which employs two wash zones. The use of two washing zones is preferred, because it permits longer wash zones, higher rotation speed, and thus higher washing capacity. It would be possible, however, to design this system using three or more wash zones.
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Multiphase washing of pulp is accomplished on a fully pressurized drum filter by employing compaction baffles to increase the consistency of the pulp mat and by providing a separate pump for each wash zone so that there is no pressure difference between the wash zones and, thus, no need for any mat contacting mechanical seal. This avoids mat disruptions and machine clogging often caused by pulp pile-up at such seals. Feed pulp of relatively high consistency is made possible by incorporation of a deflocculator and distributor in the pulp feed nozzle.
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This application is a Continuation-in-part of U.S. Ser. No. 07/964,936, filed Oct. 22, 1992, now abandoned, which was a Continuation of U.S. Ser. No. 07/611,936 filed Nov. 9, 1990 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing a carbonaceous material. In particular, the present invention relates to a process for producing a carbonaceous material having an excellent oxidation resistance.
2. Prior Art
A carbon/carbon composite capable of maintaining its high strength and high modulus even at a temperature as high as 1,000° C. or above in an inert gas and having a low coefficient of thermal expansion is expected to be used as a material for the parts of aircrafts and space crafts, brakes and furnace materials. However, this material has such a poor oxidation resistance that oxidative consumption begins at around 500° C. in air. To overcome this defect, an attempt has been made to form a ceramic coating on the surface of the carbon/carbon composite in order to improve its oxidation resistance. However, the essential function of the coating cannot be fully obtained, since the coating is peeled off or cracked because of a difference in the coefficient of thermal expansion between the carbon/carbon composite used as the substrate and the ceramic.
SUMMARY OF THE INVENTION
After investigations made for the purpose of providing a process for producing a carbonaceous material having an excellent oxidation resistance and solving the above-described problems, the inventors have completed the present invention.
The present invention relates to a process for producing a carbonaceous material characterized by heating a carbon/carbon composite, bringing it into contact with an element or a compound of said element capable of forming a heat-resistant carbide on the surface thereof to convert the surface of the carbon/carbon composite into carbide ceramics or both of said surface and part of the interior thereof, and forming a coating film comprising a ceramic or both a ceramic and carbon on the convert surface by vapor phase decomposition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail.
The carbon/carbon composite used as the base in the present invention comprises carbon fibers and a carbonaceous matrix, etc. The volume fraction of the carbon fibers is usually 10 to 70%, preferably 20 to 60%.
The carbon fibers constituting the carbon/carbon composite include various ones such as pitch, polyacrylonitrile and rayon carbon fibers, among which the pitch based carbon fiber is preferred, because it can readily enhance the oxidation resistance.
The carbon fiber is used usually in the form of a bundle of 500 to 25,000 continuous fibers. Further carbon fibers in the form of a laminate of unidirection, two-dimensional textile or a laminate thereof, three-dimensional textile, or two-dimensional or three-dimensional moldings of carbon fibers in the form of mat or felt, among which the three-dimensional textile is particularly preferred.
The carbonaceous matrix includes those prepared by carbonizing a carbonaceous pitch, those prepared by carbonizing a carbonizable resin such as a phenolic resin or furan resin and those prepared by chemical vapor deposition (CVD), among which those prepared by carbonizing the carbonaceous pitch are particularly preferred.
The carbonaceous pitch ordinarily used includes coal and petroleum pitches each having a softening point of 100° to 400° C., preferably 150° to 350° C. The carbonaceous pitch may be an optically isotropic or anisotropic pitch or a mixture thereof, and particularly preferred is an optically anisotropic pitch having an optically anisotropic phase content of usually 60 to 100% by volume, most desirably 80 to 100% by volume.
The process for producing the carbon/carbon composites used as the base in the present invention is not particularly limited and any known process can be employed.
This material can be produced by, for example, impregnating a textile or a molding of the carbon fiber with the carbonaceous pitch, phenolic resin or furan resin and carbonizing it under atmospheric or elevated pressure or under a press. The impregnation is conducted by melting the carbonaceous pitch or the like through heating in vacuum.
The carbonization under atmospheric pressure can be conducted by heating to 400° to 3,000° C. in an atmosphere of an inert gas such as argon, nitrogen or helium. The carbonization under elevated pressure can be conducted by heating to 400° to 3,000° C. under an isostatic pressure of usually 50 to 10,000 kg/cm 2 , preferably 200 to 2,000 kg/cm 2 with an inert gas. The carbonization under a press can be conducted by heating to 400° to 3,000° C. under uniaxial pressure of 10 to 500 kg/cm 2 with a hot press or the like.
After the completion of the carbonization, the product can be preferably carbonized or graphitized under atmospheric pressure. The carbonization or graphitization can be conducted by heating to 400° to 3,000° C. in an inert atmosphere.
In the present invention, the surface of the heated carbon/carbon composite is brought into contact with an element or a compound of said element capable of forming a heat-resistant carbide thereon to convert the surface of the carbon/carbon composite into carbide ceramics or both said surface and the interior thereof by the chemical reaction of carbon of the carbon/carbon composite with said element or its compound.
The carbides include SiC, ZrC, TiC, HfC, B 4 C, NbC and WC, among which SiC, ZrC, TiC and HfC are particularly preferred. The elements capable of forming a heat-resistant carbide include Si, Zr, Ti, Hf, B, Nb and W, while the compounds of these elements include halides and hydrides thereof. For example, Si, SiCl 4 or SiH 4 is usable for forming SiC; Zr or ZrCl 4 is usable for forming ZrC; Ti or TiCl 4 is usable for forming TiC; and Hf or HfCl 4 is usable for forming HfC. The element or its compound capable of forming a heat-resistant carbide is used usually in gaseous form to be brought into contact with the carbon/carbon composite for reaction.
The carbide forming reaction is preferably conducted in the presence of hydrogen. The amount of hydrogen used may be determined without any limitation depending on the reaction temperature, amount of the feed gas, amount of the fiber, structure of the furnace, etc. For example, it is not larger than 5 parts by volume, preferably 0.01 to 5 parts by volume, per unit volume of the element or its compound capable of forming the carbide.
The carbide forming reaction is preferably conducted under atmospheric or reduced pressure. The pressure is usually 0.1 to 760 mmHg, preferably 10 to 760 mmHg and more preferably 50 to 760 mmHg.
The reaction atmosphere may be diluted with N 2 , Ar, He, Ne, Kr, Xe, Rn or other inert gases.
The temperature of heating the carbon/carbon composite is usually 800° to 1,700° C., preferably 1,000° to 1,500° C. When the temperature is lower than 800° C., no carbide coating having a sufficient thickness can be obtained and, on the contrary, when it exceeds 1,700° C., no homogeneous, dense carbide coating can be obtained.
The method of heating the carbon/carbon composite is not particularly limited. For example, a method wherein the carbon/carbon composite is heated with an induced current, a method wherein this material is externally heated or a method wherein an electric current is directly applied to the carbon/carbon composite to heat the latter can be employed.
The carbide forming reaction time can be determined without any limitation. It is usually about 1 min. to about 10 hrs.
The thickness of the carbide coating which is determined depending on the use without any limitation is usually 0.1 to 500 μm, preferably 0.5 to 200 μm. When the thickness of the coating film is less than 0.1 μm, the adhesion between the carbon/carbon composite and the coating film comprising a ceramic or both of a ceramic and carbon is insufficient to cause the peeling or cracking of the coating film.
The weight gain of the material after the carbide coating formation is usually not more than 15%, preferably not more than 10% and more preferably not more than 5%. When the thickness of the carbide coating exceeds 1 μm, the strength of the carbon/carbon composite might be reduced by the formation of the carbide coating. However, a sufficient strength of this material can be kept by using a carbon fiber having less reactivity, such as a high-modulus pitch carbon fiber, as the carbon fiber which is the main factor of controlling the strength and also by using less or no graphitizable matrix such as a thermosetting resin.
In the present invention, a coating film comprising a ceramic or both of a ceramic and carbon is formed on the surface of the carbide by vapor phase decomposition. This is usually called CVD and includes thermal CVD, plasma CVD and optical CVD.
The ceramics include carbides, nitrides, borides and oxides such as SiC, ZrC, TiC, HfC, B 4 C, NbC, WC, TiB 2 , BN and Si 3 N 4 , among which SiC, ZrC, TiC and HfC are particularly preferred. These ceramics can be deposited together with carbon.
The CVD gases to be used for obtaining the carbon include hydrocarbons, particularly those having 1 to 6 carbon atoms, such as methane, natural gases, propane and benzene.
The CVD gases to be used for obtaining the ceramics include halides, hydrides and organometallic compounds of elements such as Si, Zr, Ti, Hf, B, Nb and W and mixtures of them with the above-described hydrocarbon gas, hydrogen or inert gas. For example, SiCl 4 , CH 3 SiCl 3 , (CH 3 ) 2 SiCl 2 or SiH 4 is usable for forming SiC; ZrCl 4 is usable for forming ZrC; TiCl 4 is usable for forming TiC; and HfCl 4 is usable for forming HfC.
The thickness of the coating film is suitably determined depending on the use thereof. It is usually 1 to 2,000 μm, preferably 5 to 1,000 μm. When the thickness is less than 1 μm, the oxidation resistance is insufficient.
In the present invention, after the surface or both of the surface and part of the inner of the carbon/carbon composite are converted into carbide ceramics, it may be further heat-treated. Thus the carbide can be stabilized.
The heat treatment is conducted at a temperature of usually 1,000° to 3,000° C., preferably 1,200° to 3,000° C., in an inert gas or under reduced pressure. It is particularly desirable that the heat treatment be conducted at a temperature equal to or higher than the carbonization temperature. The heat treatment time ranges 1 min. to 10 hrs., while the heating method is not particularly limited.
The heat treatment is conducted in an inert gas or under reduced pressure. The inert gases usable herein include N 2 , Ar, He, Kr, Xe and Rn. The reduced pressure ranges from 10 -3 to less than 760 mmHg, preferably 0.1 to 500 mmHg.
The effect of the present invention resides in that a carbonaceous material free from the cracking or peeling of the coating film and having an excellent oxidation resistance can be produced.
PREFERRED EMBODIMENTS OF THE PRESENT INVENTION
The following Examples will further illustrate the present invention, which by no means limit the invention.
EXAMPLE 1
A carbon/carbon composite comprising an orthogonal three-dimensional textile prepared from 2,000 pitch carbon fibers having a diameter of 10 μm (in Z-axis direction) and 4,000 same fibers (in X-axis and Y-axis directions) as the reinforcing fibers and a petroleum pitch as the matrix material was heated to 1,400° C. in a reaction vessel and kept at this temperature for 60 min. under atmospheric pressure while introducing a gaseous mixture of SiCl 4 and H 2 (H 2 /SiCl 4 =0.25) thereinto. Then SiC was deposited on the surface thereof by using a gaseous mixture of CH 3 SiCl 3 and H 2 (H 2 /CH 3 SiCl 3 =10) as the starting gas by conducting thermal CVD at 1,350° C. under a pressure of 5 Torr for 5 hrs. to form a coating film.
The product was observed with a scanning electron microscope to find that neither cracks nor peeling was recognized on the surface of the carbon/carbon composite, at the interface between the carbon/carbon composite and the carbide, at the interface between the carbide and the ceramic coating or on the surface of the ceramic coating.
The oxidation resistance of the obtained carbonaceous material was examined by heating it at 600° C. in air for 2 hrs. and then determining the weight change thereof. The weight loss was 9.8%.
COMPARATIVE EXAMPLE 1
SiC was deposited on the surface of the same carbon/carbon composite as that of Example 1 by conducting thermal CVD by using a gaseous mixture of CH 3 SiCl 3 and H 2 (H 2 /CH 3 SiCl 3 =10) as the starting gas at 1,350° C. to form a coating film.
The product was observed with a scanning electron microscope to find that SiC was deposited on the surface of the carbon/carbon composite. However, cracks and peeling were recognized at the interface between the carbon/carbon composite and the carbide.
COMPARATIVE EXAMPLE 2
The same carbon/carbon composite as that of Example 1 was heated to 1,400° C. in a reaction vessel and kept at this temperature for 60 min. while introducing a gaseous mixture of SiCl 4 and H 2 (H 2 /SiCl 4 =0.25) thereinto under atmospheric pressure.
The oxidation resistance of the product was examined in the same manner as that of Example 1 to find that the weight loss was 21.4%.
EXAMPLE 2
The same carbon/carbon composite as that of Example 1 was heated to 1,300° C. in a reaction vessel and kept at this temperature for 2 hrs. while introducing a gaseous mixture of SiCl 4 and H 2 (H 2 /SiCl 4 =0.25) thereinto under atmospheric pressure. Then SiC was deposited on the surface thereof by conducting thermal CVD using a gaseous mixture of CH 3 SiCl 3 and H 2 (H 2 /CH 3 SiCl 3 =10) as the starting gas at 1,350° C. under a pressure of 50 Torr for 3 hrs.
The product was observed with a scanning electron microscope to find that neither cracks nor peeling was recognized on the surface of the carbon/carbon composite, at the interface between the carbon/carbon composite and the carbide, at the interface between the carbide and the ceramic coating or on the surface of the ceramic coating.
EXAMPLE 3
The same carbon/carbon composite as that of Example 1 was heated to 1,300° C. in a reaction vessel and kept at this temperature for 2 hrs. while introducing a gaseous mixture of SiCl 4 and H 2 (H 2 /SiCl 4 =0.25) thereinto under atmospheric pressure. After the heat treatment at 1,700° C. in argon gas for 30 min. SiC was deposited on the surface thereof by conducting thermal CVD using a gaseous mixture of CH 3 SiCl 3 and H 2 (H 2 /CH 3 SiCl 3 =10) as the starting gas at 1,350° C. under a pressure of 50 Torr for 3 hrs. to form another coating film.
The product was observed with a scanning electron microscope to find that neither cracks nor peeling was recognized on the surface of the carbon/carbon composite, at the interface between the carbon/carbon composite and the carbide, at the interface between the carbide and the ceramic coating or on the surface of the ceramic coating.
The oxidation resistance of the product was examined in the same manner as that of Example 1 to fined that the weight loss was 9.1%.
EXAMPLE 4
The same carbon/carbon composite as that of Example 1 was heated to 1,300° C. in a reaction vessel and kept at this temperature for 2 hrs. while introducing a gaseous mixture of SiCl 4 and H 2 (H 2 /SiCl 4 =0.25) thereinto under atmospheric pressure. Then it was subjected to thermal CVD by feeding 40 cm 3 /min. (under normal conditions) of C 3 H 8 as the starting gas onto its surface at 1,150° C. under a pressure of 50 Torr. Then the pressure was altered to 100 Torr and the starting gas was replaced with a gaseous mixture of C 3 H 8 (40 cm 3 /min.), SiCl 4 (170 cm 3 /min.) and H 2 (700 cm 3 /min.) (under normal conditions) to deposit SiC and carbon on the surface thereof, thereby forming a coating film.
The product was observed with a scanning electron microscope to find that neither cracks nor peeling was observed on the surface of the carbon/carbon composite or at the interface between the carbon/carbon composite and the coating film.
COMPARATIVE EXAMPLE 3
In order to compare the performances of material obtained by the process of the present invention with that obtained by the closest prior art, the following comparative tests were conducted.
PREPARATION OF TEST SAMPLE
A two-dimensional prepreg using phenolic resin and 2,000 pitch-based carbon filaments each 10 μm in diameter was cured, carbonized and then densified with an optically anisotropic pitch having a softening point of 280° C. The thus densified composite was graphitized at 2000° C. to obtain a carbon/carbon composite.
The carbon/carbon composite, which was found to comprise 60 vol. % of carbon filaments, was placed with metallic silicon in a furnace and subjected to conversion process at 1,800° C. to convert a part of the composite into SiC. Then, the surface was coated with SiC deposition by thermal CVD at 1,350° C. The pressure was 100 Torr and the feed gases were a mixture of SiCl 4 (170 cm 3 /min)+C 3 H 8 (40 cm 3 /min)+H 2 (700 cm 3 /min).
The thus converted and coated composite was observed using a scanning electron microscope (SEM) to find that a couple of layers of the carbon/carbon composite were converted into SiC and that the surface was coated with SiC by CVD.
TESTS AND EVALUATION
SiC-coated carbon/carbon composites were tested in oxidation tests. These tests were performed by heating the sample in the air to the desired temperature. Table 1 shows that the carbon/carbon composites with coating of the present invention has very high strength. SiC-coated carbon/carbon composites with a SiC/C-graded interface showed good results in comparison with the conventional SiC-coated carbon/carbon composites.
Test results thus obtained are shown in Table 1.
TABLE 1______________________________________The results of oxidation tests Comparative PresentSample Example 3 invention______________________________________Temperature (°C.) 1600 1600Time (min) 30 30 × 3Tensile Strength 230 550(MPa)______________________________________
As will be understood from the above test results, the material obtained by the process of the present invention showed high tensile strength as compared with that of the Comparative Example 3.
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A process for producing a carbon/carbon composite having a ceramic and carbon coating on its surface consists essentially of the steps of heating a carbon/carbon composite at a temperature of from 800° to 1,700° C., contacting the thus heated composite in the presence of hydrogen with at least one compound selected from the group consisting of halides and hydrides of Si, Zr, Ti, Hf, B, Nb and W in gaseous form to convert the surface of the carbon/carbon composite, in the absence of a carbon releasing gas, into a carbide ceramic layer and then forming a coating film consisting of both carbon and ceramic by vapor phase decomposition at a pressure of 5-100 Torr on said carbide ceramic.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional of U. S. Ser. No. 10/905,229 filed Dec. 22, 2004, which is a divisional of U.S. Ser. No. 10/079,670, filed Feb. 20, 2002, which is a continuation-in-part of U.S. Ser. No. 09/779,861, filed Feb. 8, 2001 as well as U.S. Ser. No. 10/021,724 filed Dec. 12, 2001 (which claims priority to provisional patent applications 60/261,752 filed Jan. 16, 2001, 60/286,155 filed Apr. 24, 2001 and 60/296,042 filed Jun. 5, 2001). The following is also based upon and claims priority to U.S. provisional application Ser. No. 60/354,552, filed Feb. 6, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a well screen for use in a wellbore aspects relates to a well screen. More specifically, the present invention relates to a partial filter media used to advantage with side conduits (i.e., alternate flowpaths), control lines, and the like.
BACKGROUND OF THE INVENTION
[0003] It is common to place a sand screen in a well to filter solids from the production fluid (e.g., hydrocarbons, water). It is often desirable to route cables or side conduits adjacent the screens. For example, a side conduit, or shunt tube, may be used to improve a gravel pack in a well. As another example, a control line may be routed to bypass at least a portion of the sand screen. Likewise, it may be desirable to route other types of conduits, like chemical injection lines, to bypass at least a portion of the screen. It may also be desirable to mount other equipment (e.g., sensors) adjacent the screens. Many other such examples exist.
[0004] Typically, however, mounting a device (e.g., control line, side conduit, other equipment) adjacent the screen or inside the screen reduces the inside diameter of the screen. Mounting equipment inside the screen's base pipe may create other issues as well.
[0005] Accordingly, there exists a continuing need for a screen and related devices that maximizes the inner diameter of the screen while still allowing devices such as control lines, tubes, side conduits, and equipment to bypass the screen or mount adjacent the screen.
SUMMARY
[0006] In general, according to one embodiment, the present invention provides a partial filter media used to advantage with side conduits (i.e., alternate flowpaths), control lines, and the like. Other features and embodiments will become apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a illustrates a well having a screen with a partial screen wrapping and screen-adjacent devices placed therein.
[0008] FIGS. 2 through 5 illustrate various embodiments of the screen of the present invention.
[0009] FIGS. 6 through 17 are cross-sectional views of various embodiments of the screen of the present invention.
[0010] FIGS. 18 through 24 are cross-sectional views of various embodiments of the expandable screen of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] In the following description of the present invention, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0012] In this description, the terms “up” and “down”; “upward” and “downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
[0013] FIG. 1 illustrates a typical gravel pack completion in which a wellbore 10 penetrates a subterranean zone 12 that includes a productive formation. The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 which allow fluid communication between the wellbore 10 and the productive formation 14 . A well tool 20 is positioned within the casing 16 in a position adjacent productive formation 14 , which is to be gravel packed.
[0014] The well tool 20 comprises a tubular member 22 attached to a production packer 24 , a cross-over 26 , one or more screens 28 and optionally a lower packer 30 . Blank sections 32 of pipe may be used to properly space the relative positions of each of the components. An annulus area 34 is created between each of the components and the wellbore casing 16 .
[0015] In a typical gravel pack operation the packer elements 24 , 30 are set to ensure a seal between the tubular member 22 and the casing 16 . Gravel laden slurry is pumped down the tubular member 22 , exits the tubular member through ports in the cross-over 26 and enters the annulus area 34 . Slurry dehydration occurs when the carrier fluid leaves the slurry. One way the carrier fluid can leave the slurry is by way of the perforations 18 and entering into the formation 14 . The carrier fluid can also leave the slurry by way of the screen 28 and entering the tubular member 22 . The carrier fluid entering through the screen 28 flows up through the tubular member 22 until the cross-over 26 places it into the annulus area 36 above the production packer 24 , where it can be circulated to the surface. With proper slurry dehydration the gravel grains should be deposited within the annulus area 34 and pack tightly together. Note that there are many processes used to provide a gravel pack in a well and the above description is but one example.
[0016] As used herein, the term “screen” refers to wire wrapped screens, mechanical type screens and other filtering mechanisms typically employed with sand screens. Screens generally have a perforated base pipe with a filter media (e.g., wire wrapping, mesh material, pre-packs, multiple layers, woven mesh, sintered mesh, foil material, wrap-around slotted sheet, wrap-around perforated sheet, or a combination of any of these media to create a composite filter media and the like) disposed thereon to provide the necessary filtering. The filter media may be made in any known manner (e.g., laser cutting, water jet cutting and many other methods). Sand screens need to have openings small enough to restrict gravel flow, often having gaps in the 60-120 mesh range, but other sizes may be used. The screen element 28 can be referred to as a screen, sand screen, or a gravel pack screen. Many of the common screen types include a spacer that offsets the screen from a perforated base tubular that the screen surrounds. The spacer provides a fluid flow annulus between the screen and the base tubular. Screens of various types commonly known to those skilled in the art. Note that other types of screens will be discussed in the following description. Also, it is understood that the use of other types of base pipes, e.g. slotted pipe, remains within the scope of the present invention.
[0017] However, as shown in FIG. 1 , the sand screens of the present invention have a first portion 46 that has a filter media 42 thereon and a second portion 48 that does not have a filter media thereon. Thus, the filter media 42 is provided around a portion of the circumference of the base pipe 40 only as shown in the figures. Thus, in the embodiment of the present invention shown, the base tubular, or base pipe, 40 comprises apertures 44 located within a certain radial arc. A screen element, or filter media, 42 is attached to the exterior of the base tubular 40 and covers the apertures 44 ( FIG. 2 ). The portion of the base tubular containing apertures is referred to as the first portion, or radial aperture zone, 46 . The portion of the base tubular 40 not containing apertures is referred to as the second portion, or radial blank zone, 48 .
[0018] As shown in FIG. 1 , one or more adjacent-screen devices 50 are placed radially adjacent to the second portion of the screen 28 . Placing the adjacent-screen devices 50 radially adjacent to the second portion of the screen 28 increases the inner diameter of the screen 28 by reducing the overall outer profile of the screen 28 . Note that the outer diameter of the screen 28 is limited by the inner diameter of the casing 16 and other considerations.
[0019] As used herein, the general term adjacent-screen device 50 shall be used to refer generally to equipment placed in the well that is radially adjacent to a screen. For example, adjacent screen devices may comprise control lines and cables, side conduits (e.g., shunt tubes, chemical injection lines, fluid conduits, hydraulic control lines), intelligent completion devices, (e.g., sensors) and other equipment. Examples of control lines 52 are electrical, hydraulic, fiber optic lines and combinations of thereof. Note that the communication provided by the control lines 52 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices.
[0020] Examples of intelligent completions devices 54 are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, perforating devices, shape charges, locators, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement, pressure measurement, sand detection, phase measurement, oil-water content measurement, seismic measurement, and the like. In one example, the fiber optic line provides a distributed temperature functionality (or distributed temperature sensor) so that the temperature along the length of the fiber optic line may be determined.
[0021] FIG. 2 illustrates one embodiment of the present invention in which the filter media 42 comprises multiple layers. The figure shows a control line 52 extending through the second portion 48 of the screen 28 . In one embodiment, the screen 28 is made by cutting along the longitudinal wire to which the wrapped wire (for example) of the filter media 42 is welded. This cut is made on such that the longitudinal wire remains with the screen section to be used in the screen 28 . Two boss rings are then cut to provide the same gap as in the cut screen. The boss rings are then welded to each end of the screen with the cutaway section of ring oriented with that of the screen. A base pipe 40 is selectively perforated such that the portion of the base pipe 40 corresponding to the second portion 48 remains unperforated and the screen section is positioned on the base pipe 40 so that the cutaway section is aligned with the unperforated portion of the base pipe. The screen section and boss members are then welded to the base pipe 40 so that the unperforated section and the cutaway sections define the second portion 48 of the screen 28 .
[0022] FIG. 3 illustrates another embodiment in which the filter media 42 comprises an inner mesh layer and an outer wire wrap layer. The figure also shows a control line 52 extending through the second portion 48 of the screen 28 as well as an intelligent completions device (e.g., a sensor) 54 placed in the second portion 48 . The intelligent completions device 54 has a control line 52 extending therefrom that is also positioned in the second portion 48 . In one embodiment, the screen 28 is made in a manner similar to that of the screen of FIG. 2 . Note that the mesh material may be provided in a predetermined width so that the material does not require cutting to define a cut-away portion for the second portion 48 .
[0023] FIG. 4 illustrates another embodiment in which the filter media 42 is a mesh material. The second portion 48 extends along a helical path and has a control line 52 positioned therein. Accordingly, FIG. 4 illustrates that the second portion 48 may follow a path other than a linear path along the screen 28 . Thus, the path of the second portion 48 along the screen 28 may be arcuate. In one embodiment, the screen is manufactured by cutting the filter media 42 to define the helical (or arcuate) path and attaching the filter media to the base pipe 40 with the arcuate path aligned with an unperforated section of the base pipe 40 to define the second portion 48 .
[0024] In FIG. 5 , the second portion 48 does not extend the length of the screen 28 . Instead, the second portion 48 is in the form of a cut-out. An intelligent completions device 54 is placed in the cut-out second portion 48 . In the illustration, a control line 52 extends from the intelligent completions device 54 outside of the second portion 48 (adjacent the first portion 46 ).
[0025] Referring to FIG. 6 , an embodiment of the screen 28 is illustrated in cross-section. As in the previously described embodiments, the filter media 42 is provided around a portion of the circumference of the base pipe 40 . The screen material 42 extends about a portion of the circumference of the base pipe 40 to define the first portion 46 of the circumference that is covered by the screen material 42 and the second portion 48 of the circumference that is not covered by the screen material 42 . As shown in the figures there may be one or any number of second, unwrapped portions 48 (as well as first portions 46 ).
[0026] One or more side conduits, or shunt tubes, 56 (two shown) are affixed directly onto or adjacent the base pipe 40 in the second portion 48 and extend longitudinally along the length of the base pipe 40 (or at least a portion of the length thereof). The side conduits 56 are shown as having an elliptical cross-section, but other cross-sections (e.g. rectangular) may be used with the present invention.
[0027] An example of an embodiment of the screen 28 used with a control line 52 is shown in FIG. 7 . In the illustrated embodiment, both a side conduit 56 and two control lines 52 are affixed, or adjacent, to the base pipe 40 . In this embodiment, the control line 52 comprises an intelligent completions device 50 .
[0028] FIG. 8 shows another embodiment of the invention in which the screen 28 has a side conduit 56 mounted in the second portion 48 thereof. A shroud 70 surrounds the screen 28 providing protection for the screen 28 and side conduit 56 . In the embodiment shown, the shroud 70 is eccentrically mounted with respect to the screen 28 .
[0029] FIG. 9 shows another exemplary embodiment in which the one wall of the side conduits 56 is formed by the base pipe itself by welding a u-shaped member to the base pipe. In the embodiment of this figure, the screen material is then connected to the side conduit 56 (at its outer diameter as measured from the center of the base pipe). FIG. 9 illustrates two such side conduits 56 . FIG. 10 is similar to FIG. 9 , but shows four such side conduits. In one embodiment, the screen 28 is manufactured by selectively perforating a base pipe 40 and connecting the side conduits 56 to the unperforated portion thereof to form a first assembly. A filter media 42 is laser cut or water jet cut to the desired filtering specification and size and is connected to the first assembly.
[0030] FIG. 11 illustrates an alternative embodiment in which an outer member 60 is mounted to the base pipe 40 (as by attaching the outer member 60 to the side conduits 56 ). The outer member 60 and the base pipe 40 define a side passageway 62 therebetween which may be used to transport fluids, solids (e.g., sand), slurries and other materials. Note that the outer member 60 surrounds an unperforated portion of the base pipe 40 (a second portion 48 ).
[0031] FIG. 12 illustrates yet another embodiment similar to FIG. 9 . In this embodiment, the filter media 42 is connected to the side conduit 56 on one end and spacing members 64 on the other end. The spacing members 64 may also provide protection for the control line 40 and may have the associated and required strength to provide such protection. Note that the base pipe 40 in FIG. 12 is unperforated about its full circumference in the cross section shown. Thus, in this embodiment, the flow may be directed to another perforated area of the screen, to a valve, to pressure equalizing equipment (e.g., a tortuous path), or to other equipment through the annulus between the filter media 42 and the base pipe 40 as desired.
[0032] FIG. 13 discloses another embodiment similar to that shown in FIG. 12 , but further including a protective shroud 70 . In the embodiment shown, the shroud 70 has an optional side opening 72 that facilitates placement of the control line in the second portion 24 .
[0033] In FIG. 14 , the base pipe 40 includes a side pocket 82 and comprises a side pocket mandrel 80 . The side pocket mandrel 80 has a conventional design in that it has a main bore 84 and a side pocket 82 and is capable of receiving a device, such as an adjacent-screen device 50 in the side pocket 82 . A filter media 42 extends about a portion of the side pocket mandrel 80 . For example, the filter media 42 may extend about the portion of the side pocket mandrel 80 defining the main bore 84 and attach to the portion of the side pocket mandrel 80 surrounding the side bore 82 (as shown in the figure). The portion covered by the filter media 42 is perforated and represents the first portion 46 of the screen 28 .
[0034] FIGS. 15 shows another embodiments of the screen 28 having a protective shroud 70 . The figure illustrates a sand screen 28 in which the second portion 48 of the screen 28 covers a greater portion of the circumference (arc) than the first portion 46 . The figure shows a number of adjacent-screen devices 50 in the second portion 48 . The large arc of the second portion 48 facilitates the placement of numerous adjacent-screen devices 50 as well as alignment of control lines 52 and side conduits 56 with other equipment. The figure shows a number of control lines 52 , a side conduit 56 , and an intelligent completions device 54 in the second portion.
[0035] FIG. 16 shows a screen 28 having three first and second portions 46 , 48 with adjacent-screen devices 50 mounted in the second portions.
[0036] FIG. 17 illustrates an alternative embodiment of the present invention in which the adjacent-screen device 50 mounted in the second portion 48 is a shape charge 90 . A clip 92 holds the shape charge 90 to the base pipe 40 . Note that with a helical or other pattern of the second portion 48 along the length of the screen 28 a plurality of shaped charges can provide a spiral or other shot pattern. In this manner the shape charges are provided on the screen 28 and the well may be perforated and then gravel packed without moving the completion in a single trip into the well. Methods and devices for detonating the shape charges 90 are well known.
[0037] In another embodiment of the present invention, the screen 28 is of the expandable type. Expandable screens generally have an expandable base pipe 100 , an expandable shroud, or protective tube, 102 , and a filter media 104 of one or more layers interposed therebetween that can expand without losing its expanding characteristics. It should be noted that many types of expandable tubes are available. As examples, the expandable tubing may be a solid expandable tubing, a slotted expandable tubing (or other types wherein the structure is weakened by perforating the base pipe, as with holes), or any other type of expandable conduit. Examples of expandable tubing are the expandable slotted liner type disclosed in U.S. Pat. No. 5,366,012, issued Nov. 22, 1994 to Lohbeck, the folded tubing types of U.S. Pat. No. 3,489,220, issued Jan. 13, 1970 to Kinley, U.S. Pat. No. 5,337,823, issued Aug. 16, 1994 to Nobileau, U.S. Pat. No. 3,203,451, issued Aug. 31, 1965 to Vincent, the expandable sand screens disclosed in U.S. Pat. No. 5,901,789, issued May 11, 1999 to Donnelly et al., U.S. Pat. No. 6,263,966, issued Jul. 24, 2001 to Haut et al., PCT Application No. WO 01/20125 A1, published Mar. 22, 2001, U.S. Pat. No. 6,263,972, issued Jul. 24, 2001 to Richard et al., as well as the bi-stable cell type expandable tubing disclosed in U.S. patent application Ser. No. 09/973,442, filed Oct. 9, 2001. Each length of expandable tubing may be a single joint or multiple joints.
[0038] FIG. 18 discloses one embodiment of the present invention comprising an expandable base pipe 100 , an expandable shroud 102 and a filter media 104 . In the embodiment shown, the filter media 104 is a series of scaled filter sheets. The screen 28 has a first portion 46 that has a filter media 104 thereon and a second portion 48 that does not have a filter media thereon. A protective member 106 is provided on the second portion 48 and an adjacent screen device 50 (e.g., a control line 52 ) is placed therein. The protective member 106 may take the form, as an example, of a channel that extends the length of the screen 28 . In another embodiment, the protective member 106 extends only a portion of the full length of the screen 28 or comprises multiple devices spaced along the length of the screen 28 . The protective member may be attached to the expandable base pipe 100 , the expandable shroud 102 , or formed as an integral part of one or more of these elements.
[0039] In FIG. 19 , the protective member 106 is formed as part of the expandable shroud 102 . In the embodiment shown, the shroud 102 forms two protective members 106 . A first protective member 108 is in the form of a channel. Although not shown, the filter media 104 could pass beneath the shroud channel. A second protective member 110 forms an internal cavity 112 through which a control line 52 may pass or an intelligent completions device 54 may reside. In an alternative embodiment, the internal cavity 112 may itself comprise a side conduit 56 .
[0040] FIG. 20 shows another embodiment of the present invention illustrating two additional alternative protective members 106 . The first protective member 114 shown comprises a pair of parallel bars 116 mounted to the expandable base pipe 100 and the expandable shroud 102 on either side of the second portion 48 . The bars 116 extend longitudinally along the screen 28 . A clip 118 is then locked to the two bars 116 to secure the control line 52 in place.
[0041] The second protective member 120 shown in FIG. 20 is a channel. The channel 120 has a dovetail groove forming a mouth with a smaller width than the inner portion of the channel 120 . In this embodiment, the control line 52 is noncircular and capable of fitting through the mouth in one orientation after which it is reoriented so that it cannot pass through the mouth. Thereby the control line 52 is held in the channel 120 .
[0042] FIG. 21 illustrates one possible technique for manufacturing a screen 28 of the present invention. One or more protective members 106 are mounted to the base pipe 100 . In the illustration, one of the protective members 106 is a channel attached to the base pipe 100 . A control line 52 is placed in the channel. A clip (not shown) may be used to maintain the control line 52 in the channel. The other illustrated protective members 106 comprises a side conduit 56 mounted to the expandable base pipe 100 and a protruding member 122 spaced therefrom and also mounted to the base pipe 100 . A control line 52 may be placed in the space between the side conduit 56 and the protruding member 122 . The filter media 104 are attached to shroud sections 102 (although they may also be connected to the base pipe 100 ). The filter media 104 is provided in sheets that are arranged in an overlapping fashion so that the sheets slide over one another during expansion.
[0043] The side conduit 56 of the expanding embodiment of the screen 28 may be used, for example, to deliver chemicals to the well (chemical injection line), to deliver fluids to below the screen 28 , to gravel pack areas around the screen 28 that are not fully expanded or where there is an annulus, to deliver fracturing fluids, or for other purposes. Thus, the method would be to place the expandable screen 28 having a side conduit 56 attached thereto into the well, expand the expandable screen, and deliver a fluid through the side conduit 56 to complete the desired operation.
[0044] FIG. 22 illustrates another embodiment of the present invention expanded in a wellbore 10 . The screen 28 has an expandable base pipe 100 , an expandable shroud 102 , and a series of scaled filter sheets therebetween providing the filter media 104 . Some of the filter sheets are connected to the protective member 106 . The figure shows, for illustration purposes, a control line 52 , an intelligent completions device 54 , and a side conduit 56 positioned within the second portion 48 of the screen 28 .
[0045] FIG. 23 illustrates another embodiment of the present invention in which the expandable base pipe 100 has a relatively wider unexpanding portion (e.g., a relatively wider thick strut in a bistable cell) that defines the second portion 48 . The screen 28 does not have a shroud, although one may be included as previously discussed. One or more grooves 124 extend the length of the screen 28 . An adjacent-screen device 50 may be placed in the groove 124 or other area of the second portion 48 . Additionally, the base pipe 100 may form a longitudinal passageway 126 therethrough that may comprise or in which an adjacent-screen device 50 may be placed. FIG. 24 shows a groove 124 in the expandable base pipe 100 that has a dovetail design as previously described. Note that, although the grooves and passageways are described as formed in the expandable base pipe 100 , they may also be formed in a shroud 102 of the screen 28 .
[0046] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
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The present invention provides a screen for a well that utilizes a partial screen wrapping used to advantage with side conduits (e.g., alternate flowpaths), control lines, intelligent completions devices, and the like. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
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FIELD OF INVENTION
[0001] This invention is related to a Biocatalyst and its use in the process concerning production, transportation and accumulation of sucrose in the sugar cane crop.
BASICS OF THE INVENTION
[0002] The sugar cane crop was set up in Brazil since the colonial period and it became one of the main crops in the Brazilian economy.
[0003] As the largest sugar cane producer in the world, Brazil is also the first one in ethanol and sugar production. This allows Brazil to capture even more the international market due to the biofuel employed as an alternative energy.
[0004] The agricultural production and the amount of sugars (TRS—total recoverable sugar) are responsible for the economic viability of a sugar cane crop (ton of sugar cane/ha) that is presented by certain variety in its harvest.
[0005] Nowadays, varieties with low fiber content and high sucrose content are known and they can provide excellent agricultural and industrial productivity. However, sometimes it is not possible to cultivate ideal varieties in different production environment. It is necessary to reconcile the beginning of the harvest (precocity and maturation) with the time of harvest and industrialization in order to meet the demand of Pol (% of sucrose) required for an economically ideal production.
[0006] Since the first months of growth and development of sugar cane, the storage of sugar occurs gradually in fully developed nodes of aculm base. The maximum accumulation of sucrose only occurs when the plant faces restrictive conditions regarding its growth, and the total sugar accumulation process is commonly described as ripening.
[0007] Maturation of the sugar cane is a physiological process that basically involves three processes: (i) synthesis of sugars in leaves (photosynthesis), (ii) translocation or transport of the photo-assimilated products and (iii) storage of sucrose in the culms.
[0008] Maturation, as a biological process, is complex and highly dynamic and it is subject to changes due to weather conditions. Interruption in rainfall and fall in average temperature are crucial conditions to begin it.
[0009] For example, in the Southeastern region in Brazil, the maturation begins in mid-April when the average temperature goes down, thus hindering the vegetative development without, however, affecting the photosynthesis process occurring in the active leaves. Thus, with near-zero growth rates, plant starts to storage sugars produced and its maximum maturity is reached in September/October (see FIG. 1 ).
[0010] According to FIG. 1 , we observe that the average results of pol % sugar cane, under experimental conditions in improvement programs, prove that only from May the varieties available in the market start to reach the maturity point for cutting and industrialization. By observing the lower limit established by the average value of pol % sugar cane less the standard deviation (bottom curve), we can evidence that there are varieties only reaching the maturity point from June, that is, after 30 days from the harvest.
[0011] The use of vegetal regulators in areas and varieties harvested in this period is a technique that admittedly hastens the maturity of the sugar cane and increases the productivity.
[0012] Today, it is common to cultivate sugar cane throughout the year, in case of high average temperature and humidity in the soil, it is possible to find, even in the harvest, varieties presenting low industrial efficiency if cultivated in the last winter prior to its harvest, because they have no adequate time for maturity. In this scenario, it would be interesting and advantageous to hasten the maturity.
[0013] After few months, the sugar cane can have high sugar content due to lack of water, nutrients and other factors relevant to its development. This fact does not mean that it will be physiologically mature, that is, for the harvest stage. Following this reasoning, it is possible to conclude that adulthood itself does not mean full maturity.
[0014] Currently, sugar cane plants use chemicals such as ripeners to increase the sucrose content at the beginning of the harvest. Such chemicals are herbicide compounds, such as glyphosate or growth inhibitors, such asphytohormones. These products, however, are limited, such as the drift in crops near the canebrakes because an airplane sprays the herbicide.
[0015] Due to the action, it can kill or cause injury in neighboring crops, which is very common in São Paulo, the largest sugar cane producer (including orange, soybean, peanut, and vegetable and fruits in general), or even poisoning people living near canebrakes.
[0016] Another limitation is the period required for the next sugar cane harvest, because they are “chemical products”, according to the product we have to wait 20-40 days for the harvest. This period is important to prevent the sugar cane from contamination.
[0017] This period, therefore, can be critical, if the sugar cane is fully developed and/or it must be harvested before this time.
[0018] The prior art searching detected some priorities related to herbicides, control, sucrose and sugar cane crops, which were not considered impeditive for the present invention. Among them, the following can be mentioned:
PI0100470-0, filing date Feb. 8, 2011, title “Regulação e manipulação do teor de sacarose em cana-de-açúcar”. This request is related to the regulation and manipulation of sucrose content in a plant that stores sugar, such as sugar cane, by regulating the PFP enzyme activity in the plant. We observed that the sub-regulation of PFP enzyme by reducing the concentration of one of the subunits, that is, subunit SS of the enzyme increases the sucrose content in the plant. In a preferred modality of invention, the PFP enzyme activity is sub-regulated by adding a non translated element or an anti-sensoria element of an isolated nucleotide sequence for the invention. PI 9702457-0, filing date Jun. 6, 1997, title “Método para melhorar e/ou aumentar o tear de açúcar e/ou prevenir a redução do teor de açúcar de plantas, método para controle de pestes, método para controle de teredem gorgulho de cava-de-açúcar e use de um composto”. This invention is related to a method for improving and/or increasing the sugar content and/or preventing the reduction of sugar content in plants, especially sugar cane, which includes the treatment of plants with an effective amount of a compound 1-aripirazole. PI 1106811-6, filing date Oct. 27, 2011, title “Composição herbicida sinérgica contendo penoxsulame e orizalin”. This invention is related to herbicidal synergistic composition containing (a) penoxsulam and (b) oryzalin that provide improved post-emergence herbicidal weed control in tree and vine crops, turf, sugar cane, range and pasture, parks and alleyways, and industrial vegetation management. PI 9400602-4, filing date Feb. 17, 1994, title “Processo para controle de crescimento indesejado de plantas, Composição herbicida e Processo para com bate de ervas daninhas em cana-de-açúcar”. The invention describes that the co-application of dimethenamid with other herbicides provides improved herbicide activity.
[0023] As we can observe, the prior art did not describe a Biocatalyst to be used in sugar cane crops yet.
[0024] This invention, in order to remedy some of the prior art limitations, developed a Biocatalyst to be used in the process concerning production, transportation and accumulation of sucrose in the sugar cane crop. The Biocatalyst mentioned do not causes harm or risk to any neighboring cultivation, as well the period of 20-40 days for the harvest can be avoided.
DESCRIPTION OF FIGURES
[0025] FIG. 1-0 Graph 1 , according to the figure mentioned, shows the average maturity curve (Poi % Sugar cane) for 48 clones and varieties of sugar cane available in the market (Source: UfsCar—Federal University of São Carlos and CTC—Technology Center).
SUMMARY OF THE INVENTION
[0026] After an extensive investigation, inventors developed a Biocatalyst to be used in sugar cane crops. The Biocatalyst mentioned do not causes harm or risk to any neighboring cultivation, as well the period of 20-40 days for the harvest can be avoided.
[0027] Thus, factor of this invention is to provide the Use of Biocatalyst in the process concerning production, transportation and accumulation of sucrose in the sugar cane. The Biocatalyst can be used throughout the year and includes the following stages:
[0028] identification of the ideal moment for adding nutrients to the system;
[0029] adding nutrients to the system; and
[0030] nutrients acting inside the plant.
DETAILED DESCRIPTION OF THE INVENTION
[0031] In order to overcome problems found in the prior art, this invention aims at describing a Biocatalyst for sugar cane and its use in the process concerning production, transportation and accumulation of sucrose throughout the year.
[0032] The Biocatalyst mentioned do not causes harm or risk to any neighboring cultivation, as well the period of 20-40 days for the harvest can be avoided.
[0033] The Biocatalyst mentioned is based on the balance of nutrients (which ones and which amounts) required to change the ratio of enzymes responsible for accumulating sugar in the plant.
[0034] In the past, two nutrients (nitrogen and potassium) were used in an attempt to promote the accumulation of sugar at the end of the sugar cane crop. However, this operation was unsuccessful because the sugar cane grew without accumulating sugar.
[0035] Under the economic point of view, sugar cane is considered ready for industrialization when it shows 13% of sucrose in relation to the weight of culm and 85% of purity (Brieger, 1968; In: Felipe, D.C., 2008) and a mature sugar cane can reach indices greater than 90% of purity (see Table 1 below).
[0000]
TABLE 1
Components of the sugar cane juice
Sugar cane -
immature
Sugar cane -
stage
mature stage
Components
Water
88%
79%
Soluble solids (Brix)
12%
21%
Soluble solids
Sucrose (Pol)
8%
19%
Glucose
1.9%
0.4%
Fructose
1.0%
0.3%
Non Sugars*
1.1%
1.3%
Apparent Purity (Pol/Brix * 100)
66.7%
90.5%
*Fats, waxes, dyes, starch, macro and micronutrients, etc.
[0036] Results from technological analyses in sugar cane samples made at the beginning of the harvest, in Jaboticabal, São Paulo (see Table 2), show that, from end of April, sugar canes ageing about 14 months already initiated their natural maturity process (Purity=80.1%) and thirty days later they were found mature, that is, suitable for the harvest.
[0000]
TABLE 2
Results from technological analyses in sugar cane
samples made at the beginning of the harvest, in
Jaboticabal, SP, (12 clones/varieties on average).
Results
March 14
April 4
April 27
May 18
June 6
Brix % Juice
14.9
16.5
17.6
18.8
19.2
Pol % Juice
10.9
12.7
14.1
15.5
16.6
Purity
73.2
77.0
80.1
82.4
86.5
[0037] Once sugar canes whose Purity is 85% are considered mature, the application of vegetal regulators must be made before this stage, so that the induced maturation can takes place.
[0038] Vegetal regulators are substances that change plant physiology by interfering with the amino acids and enzymes synthesis or by stimulating hormone production, thus limiting the cell division or growth in the meristematic growth.
[0039] However, there are evidences regarding the use of macro and micronutrients because they directly act in the maturation process stages that can hasten the sugar cane maturity. Furthermore, it is advantageous to use nutrients because they do not pose a risk to crops in areas close to canebrakes.
[0040] From the evidences resulted the development of the Biocatalyst mentioned, to be used in the process concerning production, transportation and accumulation of sucrose in the sugar cane crop throughout the year. The Biocatalyst is employed in the three stages described below:
[0041] Stage 1—Identification of the Ideal Moment for Adding Nutrients to the System
[0042] The proper way to define the ideal moment for adding nutrients to the system in order to increase the sugar at the end of the cycle is to analyze the Purity of the sugar cane. This information is an indicative of canebrakes where this technique can provide better gains.
[0043] In percentage, Purity is the amount of sucrose in the sugar cane juice (Pol % Juice or Sucrose from Juice Extraction—SCE) contained in soluble solids of the juice (Juice Brix). It is calculated by the equation:
[0000] Purity= Pol/BrIx× 100
[0044] The ideal levels of Purity for better gains of sugar are between 75% and 85%. At this moment, nutrients must be added in the system.
[0045] Stage 2—Adding Nutrients to the System
[0046] The specific function of each nutrient for this stage of the sugar cane crop was studied, as well as the necessary amount for each one so that the desired reaction can specifically occur. Thus, each nutrient is relevant, in accordance with the characteristics described below:
nitrogen (N) found in chlorophyll; pigment in chloroplasts of the plants, essential for capturing the solar energy that is transformed into chemical energy, its synthesis is compromised in conditions of nitrogen (N) deficiency, symptoms known as chlorosis occur. Its excess, however, stimulates the growth, undesirable factor at this stage; potassium (K) is responsible for activating enzymes and maintaining the cell turgescence and dispersion of protoplasm. It regulates the opening of stomata and, therefore, the entry of C02, the carbon source for the sugar synthesis. It acts in the metabolism of hexoses and affects directly the transport of sucrose from leaves to calm; phosphor (P) acts directly in transforming fructose into sucrose. Moreover, it is responsible for transforming luminous energy into chemical energy (ATP) in the photosynthesis; boron (B) is responsible for developing roots and acts directly in the transport of sugars. It is directly related to the metabolism of calcium, that is, this nutrient is required for the adequate formation of the cell wall. The boron's physiological function differs from the other micronutrients'; because this anion was not identified in any specific compound or enzyme. The metabolism of carbohydrates and transport of sugars through the membranes are among the main functions related to this micronutrient; nucleic acid (DNA and RNA) and phytohormones synthesis; formation of cell walls and cell division (Dechen et al, 1991); copper (Cu) takes part in iron-porphyrin biosynthesis, forerunner of chlorophyll; therefore, its absence impairs the photosynthetic process; manganese (Mn) is the electron donor in the Photosystem II, in the chlorophy synthesis and in the formation and functioning of the chloroplasts. It acts in the photosynthesis, being involved in the structure, functioning and multiplication of chloroplasts, also carrying out the electronic transport. It is required for the activity of some dehydrogenases, decarboxylases, kinases, oxidases and peroxidases. It is involved with other enzymes activated by cations and with the photosynthetic evolution of oxygen (Taiz & Zeiger, 2004). Large amount of manganese in the growth zones of the plant, mainly in the heart of palm, is observed. It is found mainly on the meristematic tissues; molybdenum (Mo) acts in the nitrogen fixation systems and its deficiency results in lower levels of sugars and ascorbic acid. It is essential for the metabolism of nitrogen in plants that use, as source of this nutrient, the nitrate from the soil and/or atmospheric nitrogen from the biological fixation process by diazotrophic bacteria associated to the plant. Sugar cane can receive N from these two sources, and, therefore, it is formulated the hypothesis that the Mo is a production factor for this crop, for its adequate supply is required to meet the great demand of N by the plants, mainly for the improvement of the contribution of the biological nitrogen fixation (FBN) in the nitrogen-based nutrition. In the biological systems, molybdenum consists of at least five catalytic reaction enzymes. Three out of these enzymes (nitrate reductase, nitrogenase and sulfite oxidase) are found in plants (Gupta & Lipsett, 1981 apud Dechen et al, 1991); zinc interferes with the level of tryptophan, forerunner of auxin amino acid (AIA), hormone essential for the elongation and increase in cell volume; therefore, elongation of the internodes (space for storage); sulfur (S) plays important role in the metabolism and, therefore, the vital cycle of the plants. Molecules containing S take part in the essential amino acid structure, chlorophyll, enzymes and coenzymes, as well as taking part in diverse metabolic processes as enzymatic activation; magnesium (Mg) plays several key roles in the sugar cane. The metabolic processes and the reactions particularly affected by the Mg are: photophosphorylation (such as the formation of ATP in the chloroplasts), photosynthetic carbon dioxide fixation, protein synthesis, formation of chlorophyll, phloem loading, separation and use of assimilated photo, generation of reactive oxygen species. Therefore, many physiological and biochemical processes are affected by magnesium.
[0057] Due to the aforementioned, a balance of nutrients was developed for 1 hectare of sugar cane. Please see Table 3 below:
[0000]
TABLE 3
Balance of nutrients
Nutrient
Amount
Nitrogen (N)
90 g
Potassium (K 2 O)
400 g
Magnesium (MgO)
40 g
Sulfur (S)
150 g
Boron (B)
12 g
Copper (Cu)
4 g
Manganese (Mn)
12 g
Molybdenum (Mo)
0.3 g
Zinc (Zn)
24 g
[0058] Stage 3: Nutrients Acting Inside the plant
[0059] The availability of these nutrients in the plant acts directly in (i) photosynthesis, (ii) transport and (iii) storage of sugars, thus enhancing and catalyzing each phase and increasing the efficiency of the process. In accordance with the stage 2, each nutrient acts as follows:
[0060] (i) Photosynthesis:
[0061] Due to large amount of glucose being produced in the photosynthesis, this is transformed into sucrose in the cytosol of the mesophyll cells from where it is carried to the vacuoles of the cells in the culm.
[0062] (ii) Transport:
[0063] Should the transport of sucrose be also potentiated by the presence of the nutrients involved, no concentration of sucrose in the apoplast will occur (external compartments in relation to the plasmatic membrane). This occurs because there are evidences that the deficiency in nitrogen, phosphor, potassium and boron reduces considerably the speed for transporting sucrose.
[0064] (iii) Accumulation of Sucrose:
[0065] As an advantage in this invention, the largest accumulation of sucrose in apoplast inhibits the action of the acid invertase (SAD ; which is responsible for transforming sucrose into hexoses (glucose and fructose) that makes available carbon and energy for the metabolic activities of the plant as part of the breathing process and differentiated compound synthesis used in the growth. Therefore, there is stimulation in the neutral invertase synthesis (NI), which is the enzyme responsible for transporting sucrose for storage, thus resulting in larger accumulation of sugar and hastening the maturity.
[0066] For instance, the enzymatic balance in this present invention, which can be changed by the concentration of sucrose (hexoses) in the cells of culm, is represented as follows:
[0000] ↑ SAI (high)→↓NI(low)=Vigorous Growth (Little Hexose)
[0000] ↓SAI(low)→⇑NI(high)=Accumulation of Sugar (Much Hexose)
[0067] Another advantage to be mentioned in this invention is that the artificial maturity by employing chemicals makes possible the handling of varieties by increasing in sugar contents, middle and apical internodes, thus promoting the industrial quality of the raw and contributing for better economic outcomes.
[0068] The artificial maturity is an important tool for planning the harvest. In practice, it favors the hastening of cutting in a canebrake with vertical increase in production, that is, a bigger productivity in the same unit of area.
[0069] Cutting, loading, transport and industrialization are also benefited, due to more sugar and ethanol per ton of sugar cane.
[0070] Specialists in the technique will understand that small variations in this invention are within the scope of the invention.
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The present invention relates to a plant activator for sugar cane crops and the use thereof. The activator is based on a balanced combination of nutrients, required to alter the proportion of enzymes responsible for the accumulation of sugars in the plant, the activator comprising the following nutrients: nitrogen, potassium, magnesium, sulfur, boron, copper, manganese, molybdenum and zinc. The use of the activator comprises three distinct steps: identifying the ideal moment for introducing the nutrients into the system, introducing the nutrients into the system and action of the nutrients in the plant.
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FIELD OF THE INVENTION
[0001] This invention involves vacuum folding apparatus to make single or double transverse folds in articles like napkins from one, two, or more, different colored webs and delivering them as color or material mixed stacks.
[0002] Other embodiments include means for making multiple sizes for single or double vacuum cross folds in single or two color stacks.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] Co-invented U.S. Pat. No. 6,375,605 B 1 describes apparatus for combining spaced segments from each of two or more tandem mounted cutoff units to form a continuous intermixed stream of differently colored segments that are subsequently folded by air blast, etc.
[0004] By using slow speed metering rolls in U.S. Pat. No. 6,375,605 B 1, each incoming web is slidably advanced to alternate repeat surfaces of an anvil roll before cutting. One cutoff unit feeds spaced segments to even repeats, a second cutoff unit feeds spaced segments to odd repeats. The two streams of spaced segments are transferred to, and combined on a carrier for subsequent air folding as a continuos series of intermixed colors or materials for subsequent packout and delivery into stacks.
[0005] In the instant invention, segments are vacuum held against the anvil roll and advanced until vacuum is applied to carrier ports along a pre-selected fold line.
[0006] This extended timing of anvil roll vcuum results in the fold being made by interaction between the anvil and carrier roll vacuum before and as it is transferred to the carrier surface.
[0007] Apparatus for vacuum folding is described in prior art teachings U.S. Pat. No. 3 , 689 , 061 of Nyatrand, U.S. Pat. No. 3,870,292 of Bradley, and U.S. Pat. No. 4,329,185 of Small, all of which produce single color stacks of one size.
[0008] The instant invention utilizes the same slow speed infeed and cutoff and further describes details for vacuum ports arrangements and timing needed to produce color mixed stacks, but also the use of slow speed feed rolls in combination with multiple ports on multiple fold lines to produce products of various sizes for single or multiple color stacks.
[0009] It is an object of this invention to describe means to complete an overfold using vacuum in anvil and carrier roll ports rather than air blast and a stationary plate.
[0010] Another object is to define folding apparatus using various combinations of vacuum port placement and timing to describe apparatus for multiple sizes, including independent drives for selected components and changes in phase relationships between anvil and carrier rolls as a function of product size.
[0011] These and other advantages and objects of the invention may be seen in the ensuing specifications:
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a side elevation schematic illustrating a prior art single napkin folder for packout of napkins from a series of napkins to produce a one color stack.
[0013] [0013]FIG. 2 is a side elevation schematic illustrating a prior art doublefold napkin folder for packout of napkins from a series of napkins to produce a one color stack.
[0014] [0014]FIG. 3 is a side elevation schematic of the inventive folder illustrating placement and timing of two cutoff units to produce a stream of single folded napkins with alternating colors or materials for packout into stacks.
[0015] [0015]FIG. 4 is an enlarged side elevation of the anvil/knife roll pair illustrating typical components to control and cut segments from a web.
[0016] [0016]FIG. 5 is an enlarged side elevation of the two cutoff units in FIG. 3 illustratnig phase relationships and folding cooperation between the anvil and carrier rolls.
[0017] FIGS. 6 A through FIG. 6H are side elevation schematics illustrating advancement of segments at anvil surface speed and slipping advancement of the incoming web to create an open repeat surface on the anvil roll in order to receive alternate segments from the second cutoff unit.
[0018] [0018]FIG. 7A and FIG. 7B are plan view schematic diagram illustrating vacuum timing, force, and duration to achieve advancement and slipping advancement of segments (shown unfolded) along a path from each of two cutoff units.
[0019] [0019]FIG. 7C is a plan view schematic illustrating placement of the combined folded segments on the carrier surface to produce a stream of alternately colored napkins.
[0020] [0020]FIG. 8 is a side elevation schematic illustrating placement of three cutoff units mounted in tandem along a common carrier roll path.
[0021] [0021]FIG. 9 is a side elevation schematic illustrating location of two cutoff units along a common carrier roll path, each including a first anvil/folding roll and second folding roll coacting with a carrier to produce a two color stack of doublefolded products.
[0022] [0022]FIG. 10 is a plan view schematic of one repeat surface of the carrier roll arranged with air apertures to complete a second cross fold on a consecutive series of single folded segments.
[0023] [0023]FIG. 11 is a front elevation view schematic of longitudinal folding plates viewed along line 11 - 11 of FIG. 3 illustrating the arrangement of folding plates, draw rolls, and turning bars for a plurality of product webs from a multi-width web.
[0024] [0024]FIG. 12 is a top view schematic viewed from line 12 - 12 of FIG. 11 illustrating one of two full width webs being slit into a plurality of product width webs and advanced over V-fold plates into the nip of pull rolls before advancement over turning bars and subsequent slow speed draw rolls.
[0025] [0025]FIG. 13 is a plan view schematic viewed from line 13 - 13 of FIG. 11 illustrating superposed product webs being separated and turned 90 degrees for advancement to the slow speed and cutoff section.
[0026] [0026]FIG. 14 is a a simplified side elevation schematic of FIG. 8 illustrating the three color being advanced for packout.
[0027] [0027]FIG. 15 is a simplified side elevation schematic illustrating two folders of FIG. 8 arranged face-to-face and the resultant color sequence produced for packout.
[0028] [0028]FIG. 16 is a side elevation schematic view of an anvil roll illustrating means for selecting a vacuum conduit for a selected product length.
[0029] [0029]FIG. 17A is a plan view schematic of anvil repeat surfaces illustrating vacuum port arrangment for a segment length equal to a repeat surface.
[0030] [0030]FIG. 17B is a plan view schematic of anvil repeat surfaces on a second unit illustrating vacuum port arrangement for a segment length equal to about ⅔ of a repeat surface.
[0031] [0031]FIG. 17C is a plan view schematic of anvil roll repeat surfaces illustrating vacuum port arrangement for a segment length equal to about ½ of a repeat surface.
[0032] FIGS. 18 A- 18 C are simplified side elevation schematics of the FIG. 3 apparatus illustrating changes in phase relationships between anvil and carrier for three different segment sizes.
[0033] [0033]FIG. 18A is a side elevation schematic illustrating roll phase relationships for a product length that equals length of a repeat surface.
[0034] [0034]FIG. 18B is a side elevation schematic illustrating phase relationships for a product length equal to about ⅔ of a repeat surface.
[0035] [0035]FIG. 18C is a side elevation schematic illustrating phase relationships for a product length equal to about ½ of a repeat surface.
[0036] [0036]FIG. 19 is a simplified side elevation schematic illustrating apparatus with only one cutoff unit and separate stepping motor drives for phase change between anvil—carrier, selected slow speed for metering roll and synchronous roll rotation.
[0037] [0037]FIG. 20A is a plan view schematic illustrating vacuum ports along the leading margin for three different segment lengths on an anvil surface.
[0038] [0038]FIG. 20B is a plan view schematic illustrating vacuum ports arranged along fold lines for three different segment lengths on a carrier surface.
[0039] [0039]FIG. 20C is a side elevation schematic illustrating two longest segments L 1 folded, placed. and advancing on 2 consecutive carrier repeats.
[0040] [0040]FIG. 20D is a side elevation schematic illustrating two folded segments L 2 folded, placed and advancing on 2 consecutive carrier repeats.
[0041] [0041]FIG. 20E is a side elevation schematic illustrating two folded segments L 3 folded, placed and advancing on 2 consecutive carrier repeats.
DETAILED DESCRIPTION OF THE INVENTION
[0042] In prior art folders of FIGS. 1 - 2 , rolls having the same function have the same reference numbers.
[0043] In FIG. 1, vacuum folding apparatus 1 produces a singlefolded product and is comprised of draw rolls 2 , knife roll 3 , anvil roll 4 , and carrier 5 .
[0044] In FIG. 1, longitudinally folded web 6 (folding plates not shown) is advanced by draw rolls 2 and held on the surface of anvil roll 4 by vacuum ports that communicate with conduits drilled into the solid roll blank parallel to the axis of rotation.
[0045] After a segment is cut by knife roll 3 , anvil roll 4 grips the leading edge of the front half panel until it reaches release position 7 . Similar vacuum ports in carrier 5 located midway between segment ends 8 advance the trailing portion until the lead panel portion is released from anvil roll 4 to complete the fold.
[0046] In folding apparatus 9 of FIG. 2, a first transverse fold is completed by folding co-action between anvil roll 4 and a subdequent vacuumized roll 5 ′.
[0047] In FIG. 2, roll 5 ′ includes a transverse line of vacuum ports along a second fold line FD-FD′ (see FIG. 10) between first fold line FS-FS′ and the cut end 8 ′ of a segment S to create a double cross folded product like a dinner napkin by second folding co-action between rolls 5 ′ and roll 5 .
[0048] In FIG. 3, cutoff units 16 and 21 are spaced one repeat R apart along the periphery of the carrier 22 . Cutoff units can be spaced differently and the anvil/carrier roll phasing of each advanced or retarded as required.
[0049] In FIG. 3, lower cutoff unit 16 and related components are described below. Upper cutoff unit 21 operates the same and similar elements have the same reference numbers with a prime mark (′).
[0050] In FIG. 3, cutoff unit 16 creates a series of spaced apart segments S 1 , S 3 , S 5 , etc. (see FIG. 7A), for cooperative folding with anvil vacuum V 1 (see FIGS. 5,7) and carrier vacuum V 4 for transfer to spaced carrier roll repeats R 1 , R 3 , R 5 , etc., and for subsequent combining with folded segments from a second unit 21 .
[0051] Surface speed of anvil rolls 19 and carrier 22 are the same carrier.
[0052] In FIG. 3, cutoff unit 21 simultaneously processes web W 2 into a series if spaced segments S 2 , S 4 , S 6 , etc. (see FIG. 7B) held on alternate repeats of the anvil for cooperative folding with anvil vacuum V 1 ′ and carrier V 5 , and transfer to spaced unoccupied repeat surfaces R 2 , R 4 , R 6 , etc. on the carrier to create a series of segments S 1 , S 2 , S 3 , S 4 , etc on consecutive repeats of the carrier (see FIG. 7C) and advancment to removal position 23 and packout by reciprocating fingers 24 .
[0053] Prior to the above functions in FIG. 3, web W 1 advances through constant tension device 10 , and slitters 11 to slit a full width web into two or more product webs (slitting not required for 1-wide parent rolls), over longitudinal folding plate 12 , through pull rolls 13 , over turning bar 14 , through draw roll 5 15 , S-wrap roll 17 , and over variable speed metering roll 18 at a pre-selected speed less than anvil roll surface speed.
[0054] Details for each cutoff unit 16 , 21 are similar and FIGS. 5, 6, 7 below describe slow speed web feed by metering rolls 18 , 18 ′ relative to slippage and advancement to create the above-mentioned space between consecutive segments on each anvil roll.
[0055] One embodiment for a second fold involves air blast through apertures 53 in the carrier surface (see FIG. 10) to lift the front portion of the already folded product, and stationary plate 25 creates the second cross foldover (see also FIG. 9 for another doublefold embodiment).
[0056] In FIG. 4, machined slot 26 contains anvil holder 27 fastented by bolt 28 to roll 19 . Vacuum passages 29 communicates with vacuum conduits drilled parallel with the axis of rotation. Vacuum is applied from circular grooves in a stationary valve communicating with a vacuum source (both known means not shown).
[0057] In FIG. 4, co-acting knife roll 20 includes an adjustable knife holder 30 containing knife 31 . Ports 32 adjacent anvil 33 normally hold the web taut during cutoff.
[0058] In well known practice, vacuum to grip the leading edge of a segment is applied before the cut. The gripping vacuum applies tension to the web from the cut edge to the incoming web portion approaching the cutting position. Other means to hold the web at cutoff can include instantaneous vacuum on the web when cut (on-off of ports 32 ), or smaller and fewer ports adjacent the anvil since the web must slip immediately after the cut.
[0059] In FIG. 5, a lower 2-time anvil roll 19 having one anvil 33 contacts the surface of carrier 22 at radial line RL 2 and is arranged one repeat distance R 1 apart from second anvil roll 19 ′.
[0060] Both cutoff systems 16 , 21 are the same. For brevity, function of only the first unit is described noting that folded segments FS 1 from cutoff unit 16 and FS 2 from unit 21 (both shown dashed) are placed on consecutive repeats R 1 , R 2 ′ of the carrier surface as described above.
[0061] In FIG. 5, anvil 33 underlies a cut common to the trailing edge 38 of a cut segment and the leading edge 37 ″ of the incoming slow speed web.
[0062] In FIG. 5, the leading edge of segment S 3 is cut on the same line as the trailing edge 38 of segment S 1 . In FIGS. 6A to 6 H, segment S 3 is progressively slipped over one repeat surface of the anvil roll to create a blank space between S 1 , S 3 . etc.
[0063] In FIGS. 5 , 6 A- 6 J, the anvil roll is marked in 22 ½ degree segments as a common reference for anvil roll rotation versus the lead edge of the next to be cut segment, noting that the knife/anvil rolls make one cut each revolution of 24″ versus 12″ web feed during the same time.
[0064] In a typical example, the surface speed of the anvil roll is 450 fpm for transferring folded 12″ segments to the carrier (also at 450 fpm), while the webs from each cutoff unit are advancing at 225 fpm and combined to deliver 450 products/min to the carrier roll.
[0065] For larger repeat lengths and larger roll diameters requiring more space than 1 repeat between two successive cutoff units, phasing of anvils relative to carrier roll fold lines change along with timing of carrier folding vacuum.
[0066] In FIG. 5, the leading edge 37 of segment S 1 is gripped by vacuum V 1 in ports 32 at position 39 and advanced to position 40 where the lead panel is overfolded, vacuum V 1 stops, and the folded segment FS 1 is transferred to the carrier 22 by vacuum in ports 36 .
[0067] In FIG. 6A (like FIG. 5), anvil 33 and knife 31 cut web W land at the same time as vacuum V 1 is applied at position 39 to advance the leading edge of the first cut degment S 1 to position 40 .
[0068] Carrier 22 (not shown) coacts with roll 19 to complete he fold by applying vacuum V 4 to ports 36 (dashed) at the mid-point fold line FS-FS′ of segment S 1 (see FIG. 10).
[0069] In FIG. 6B, cut segment S 1 advances two 22 ½ degree arcuate portions whille web W 1 advances one portion at half speed. Vacuum V 1 in path 42 grips and advances the segment.
[0070] In FIG. 6C, similar S 1 and W 1 advances occur. Reduced vacuum path 43 terminates at 40 when the leading edge of S 1 is ready to be overfolded as shown dashed in FIG. 6D.
[0071] Upon further anvil rotation in FIGS. 6E through 6H, the slow speed web is slideably advanced until reaching the position shown as S 3 .
[0072] In FIG. 6J, the absence of a segment on 180 degrees of anvil surface 44 results in a blank space on alternate repeats of the carrier roll 22 . FIGS. 6J, 8A, and FIG. 5 are similar and comparable.
[0073] In FIG. 5, similar means and operation place folded segments S 2 , S 4 , etc. from cutoff unit 21 on the alternate blank repeats of the carrier.
[0074] In FIG. 7A, segment S 1 on lower roll 19 (See FIGS. 3, 5) is severed from web W 1 at cut line 19 C
[0075] In FIG. 7A (left side), vacuum ports 32 under leading edge 37 of segment S 1 grip and advance it to position 40 of the anvil roll without slippage (see FIGS. 5, 6C)
[0076] In FIG. 7A, ports 47 ′ under web W 1 apply restricted vacuum to allow slipping advancement. In one anvil roll revolution, the web slips 180 degrees to be deposited as S 3 when the next cut occurs.
[0077] In FIG. 7A, the same slipping advancement occurs to cut another segment shown as S 5 . Vector 45 represents full speed advancement of S 1 . Vector 46 represents resultant half speed of the sliding web.
[0078] In FIGS. 7A and 7B, vacuum V 1 is applied to ports 32 ′ on the lead edge 37 , 37 ′ of segment S 1 , S 2 respectively. V 2 restricted vacuum is applied to ports 47 (circles) which grip a cut segment S and V 3 (solid) to allow slippage of the uncut slow speed web as described.
[0079] In FIG. 7B, space D is segment displacement due to a repeat space between the carrier contact point with two spaced cutoff units 16 , 21 .
[0080] In FIG. 7B, segments S 2 , S 4 , S 6 , etc are cut, slipped, and advanced by the upper cutoff unit 21 .
[0081] In FIG. 7C, both streams of spaced folded segments are combined to form a consecutive series of products advancing on the carrier at speed vector 45 .
[0082] In FIG. 7C, full vacuum V 4 (shown in FIG. 3) is applied to carrier ports for segments S 1 , S 3 , S 5 , etc and full vacuum V 5 (see FIG. 3) is applied to carrier ports for S 2 , S 4 , etc.
[0083] In each instance, vacuum starts just before the carrier reaches the midpoint segment fold line FS-FS′. (see FIG. 10).
[0084] In FIG. 8, three cutoff units 16 , 21 , and 48 are arranged one repeat R apart on the periphery of carrier 22 to advance, cut, fold and transfer segments S A, S B, S C etc, to consecutive repeat surfaces of the carrier for packout in the same sequence at position 23 .
[0085] The apparatus of FIG. 8 produces a 3-color (or 3 different materials) sequence from 3 webs each advancing at ⅓ the surface speed of the anvil 19 and carrier 22 rolls, etc.
[0086] In FIG. 8, each of three webs run at a speed equal to one-third of the carrier surface, and with one web stopped, each web in a two color sequence runs at ½ carrier surface speed.
[0087] In FIG. 9 double folding apparatus, each cutoff unit 49 , 50 , includes a second folding roll 51 to make the second fold.
[0088] In FIG. 9, roll 51 grips the leading folded edge, and in cooperation with carrier ports 52 , completes a second cross fold on line FD-FD′ for advancement on spaced repeat surfaces of the carrier.
[0089] In FIG. 9, roll 51 ′ of upper cutoff unit 50 coacts with ports 52 ′ on carrier 22 to fold and deposit doublefolded segments on alternate blank repeat surfaces left blank by first unit 49 .
[0090] In FIG. 10 when making a single fold product (as in FIGS. 3, 5, 6 , 7 ), ports 32 on leading edge 8 of segment S advance with anvil roll 19 until ports 36 in carrier roll grip the segment along FS-FS′ to complete the first fold.
[0091] In FIG. 10 when making a doublefold, ports 36 B (same location as 36 , but on second roll 51 ) complete the first fold and ports 52 on the carrier roll 22 complete the second fold along line FD-FD′.
[0092] Referring back to FIGS. 3 , another embodiment for double folding involves two cutoff units (each with one anvil/folding roll) that complete the first fold with vacuumized anvil ports 32 and carrier ports 36 for the first fold along FS-FS′ (see FIG. 10), and air blast A through carrier apertures 53 (see FIG. 10) to uplift the leading portion and complete the second fold along line FD-FD′ with a stationary plate (see 52 , 53 , and 25 on left side of FIG. 3).
[0093] In FIG. 11, incoming web W 1 is supported by slitter bedroll 54 as it is slit into a plurality of product width webs P. For single width parent rolls slitters 11 are not required.
[0094] With one or more producrt width webs P, each web is drawn over folding plates 12 by draw rolls 13 , threaded around turning bars 14 and pulled toward web metering rolls 18 by pull rolls 15 . (see right side of FIG. 3). In lieu of turning bars, parent rolls can be fed from the side.
[0095] In FIG. 12, after individual webbs P are longitudinally folded by plates 12 , they are superposed for a short distance (as at 55 ) before each web is turned 90 degrees as at 57 for entry into the metering and cutoff units 16 , 21 , etc.
[0096] .FIG. 13 turning bars 14 , superposed webs 55 and individual webs 57 are shown in plan view for clarity.
[0097] [0097]FIG. 14 (like FIG. 8 above) is a complete (single) folding apparatus that includes three cutoff units referenced a for W 1 , b for W 2 and c for W 3 to produce a color sequence. If three webs are used, unit a will deposit the first folded segment a (see Sa in FIG. 8) and in turn, b, then c, to define a series of sequences A-B-C . . . A-B-C . . . etc.
[0098] In FIG. 15, two duplicate folding apparatus are arranged face-to-face to deliver superposed folded segments 60 between delivery belt pair 59 for packout by reciprocating packers 24 to define a series of sequences CF-BE-AD . . . CF-BF-AD . . . etc.
[0099] Generally, the arrangement of FIG. 14 ( 1 - 4 wide webs) is used to produce coin edge embossed napkins from 2 or 3 ply stock, while the arrangement of FIG. 15 would use multiple width parent rolls of 1-ply stock for commercial or consumer napkin products.
[0100] In FIG. 16 cross section adjacent an end of roll 19 , bored holes (not referenced for clarity) each contain rotatable inserts 61 , 61 ′, 61 ″ with passage holes 62 , 62 ′, 62 ″.
[0101] Hole 62 is shown open for vacuum V 1 to communicate with a matching conduit drilled transversely in the roll body. Drilled holes (shown dashed) connect vacuum in the conduits to ports 32 . 32 ′, 32 ″ on the surface of roll 19 .
[0102] Insert 61 is shown activated for product L 1 while inserts 61 ′, 61 ″ are turned 90 degrees and are inactive.
[0103] One selected insert is rotated to activate a selected conduit and line of vacuum ports while others are turned off. Electronic valve means can be used for programmable activation or shutoff.
[0104] In FIG. 16, roll 19 has one anvil 33 . The incoming web W 1 advances at a selected speed to make the anvil/knife cut at position 33 ′ (shown phantom) when the proper length L 1 , L 2 etc. is fed beyond cutting position at 33 ′.
[0105] In FIG. 16, vacuum V 1 on leading edge 37 of segment L 1 (see left side of anvil roll) ends when fold line FS-FS′ reaches line 63 (zero reference line) when product length equals repeat length.
[0106] For shorter lengths L 2 , L 3 , folded length and fold lines change, and retarding carrier 22 compensates to keep the segment trailing edge at the nip between anvil and carrier rolls
[0107] Means and steps to change sizes are detailed below.
[0108] In FIGS. 16,17, segment lengths L 1 , L 2 , L 3 , are generated on the surface of anvil roll 19 and in this instance product lengths of 12″, 8″, and 6″ are described as a typical example.
[0109] In FIG. 17A, slippage of 12″ (S 12 ) is required to keep every other repeat open for segments L 1 ′ from another unit—as in FIG. 5.
[0110] In FIG. 17A, leading edge 37 of W 1 advances at slow speed toward position 33 during one anvil roll revolution of 2 repeat surfaces. Slippage S 12 represents retarding the lead edge (of web L 1 ) 12″ until it reaches the position of anvil 33 (shown solid) and thereafter is cut and folded by coaction of anvil and ports 36 on the carrier roll.
[0111] In FIG. 17B for shorter product L 2 (8″), the amount of web slip S 16 on the anvil roll is one repeat plus 4″ with the phase angle correction made by retarding the carrier to fold line position 64 .
[0112] In FIG. 17C, for product L 3 (6″ length), the amount of web slip (S 18 ) is one repeat plus 6″, with phase correction made by retarding the carrier to fold line position 66 .
[0113] In FIG. 18A, carrier ports 36 on fold line 63 (base reference) is in phase for L 1 .
[0114] In FIG. 18B, due to shorter folded length 2, the fold line is retarded by rotating carrier 22 to position 64 by retarding the carrier an amount shown as 65 .
[0115] In FIG. 18C, shorter product L 3 and shorter folded length FL 3 require rotation of carrier 22 to fold line 66 by retarding it an amount shown as 67 .
[0116] In FIGS. 18 A- 18 C, separate, digitally controlled variable speed programmable stepping motors M rotate metering roll 18 for a pre-determined web speed and drive the anvil/knife roll pair in synchronous surface speed with the carrier, after the steps of; selection of the active anvil roll vacuum conduit 61 , 61 ′ etc., phasing of carrier fold line to the anvil roll, adjust for proper web speed required by L 1 . L 2 , etc and energizing drives to maintain the set relationships in synchronism.
[0117] In the apparatus of FIGS. 3 to 15 with one or two curoff units, web feed speeds of ½ or ⅓ of the anvil surface speed are required to slip the incoming web to create blank repeat space (s) for full length segments from other units.
[0118] Apparatus described in FIGS. 16 - 18 are also capable of making a range of product sizes in a color mixed sequence and require ½ web speed times the ratio of segment sengths. For example, ½×8″/12″ or 0.333 of anvil surface speed.
[0119] [0119]FIGS. 19 and 20 describe the use of only one of the described cutoff units for a range of sizes in only one color.
[0120] In the embodiment of FIG. 19, similar elements including drives, cutoff and carrier components etc., are located and operated in similar manner using a 2-time anvil roll and 2-time knife roll to cut and advance a segment on each consecutive repeat surface for folding transfer to the carrier.
[0121] In FIG. 19, segments FL 1 , FL 1 ′ advance on consecutive repeat surfaces R 1 , R 2 respectively and web speed is increased equal to anvil and carrier roll surface speed times the ratio of product size.
[0122] Apparatus in the embodiment of FIG. 19 produces multiple sizes without intermediate blank repeat spaces at pre-selected uniform web speed for slippage of shorter products. For example, for the 3 sizes compared above, zero slip for 12″, 4″ slippage for L 2 , and 6″ slippage for L 3 using the approporate web speeds.
[0123] In FIG. 20A, anvil roll ports 32 , 32 ′, 32 ″ are positioned for the leading edge of three product lengths for two consecutive repeat surfaces R 1 , R 2 . etc.
[0124] In FIG. 20B, carrier fold line ports 36 . 36 ′ etc. are positioned along fold lines 63 , 64 , 66 for products L 1 , L 2 , L 3 respectively.
[0125] In FIG. 20C, folded segments SF 1 , FS 1 ′ are deposted on repeats R 1 , R 2 , respectively to result in folded lengths FL 1 , Fl 2 , FL 3 .
[0126] In FIGS. 20 C- 20 E, folded lenght is ½ of segment length, but can be changed to other ratios.
[0127] It is furthermore to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes, and it is therefore desired that the present embodiments be considered in all respects as illustrative, and therefore not restrictive, reference being made to the claims rather than the foregoing description to indicate the scope of the invention.
[0128] Having thus described the invention, what is desired to protect by Letters Patent are the following claims:
Reference Numbers
[0129] FIG Ref No Description
[0130] [0130] 1 singlefold apparatus
[0131] [0131] 2 draw rolls
[0132] [0132] 3 knife roll
[0133] [0133] 4 anvil roll
[0134] [0134] 5 carrier roll
[0135] [0135] 6 longitudinally folded web
[0136] [0136] 7 release position of leading edge from anvil roll
[0137] [0137] 8 vacuum ports at miidway folding position
[0138] [0138] 9 doublefold apparatus
[0139] [0139] 5 ′ doublefold vacuum folding roll
[0140] W 1 bottom first web
[0141] W 2 top second web
[0142] [0142] 10 3 -roll constant tnesion system
[0143] [0143] 11 product width web slitter
[0144] [0144] 12 plates for longitudinal fold
[0145] [0145] 13 pull rolls
[0146] [0146] 14 turning bars
[0147] [0147] 15 pull rolls
[0148] [0148] 16 first web cutoff unit
[0149] [0149] 17 s-wrap roll pair
[0150] [0150] 18 variable speed metering roll
[0151] [0151] 19 anvil roll
[0152] [0152] 20 knife roil
[0153] [0153] 21 second web cutoff unit
[0154] [0154] 22 carrier roll (or cyllinder)
[0155] [0155] 23 product removal position
[0156] [0156] 24 reciprocating packer fingers
[0157] [0157] 25 stationary plate to complete a doublefold (air blast apertures not shown in carrier)
[0158] R 1 first repeat surface on carrier
[0159] R 2 . . . subsequent repeat surfaces on carrier
[0160] S 1 . . . folded segments S 1 , S 3 , S 5 from cutoff 16
[0161] V 4 vacuum for fold line ports on segments from 16 (unit 19 )
[0162] S 2 ′ . . . folded segment S 2 , S 4 , S 6 , from cutoff 21
[0163] V 5 vacuum for fold line ports on segments from cutoff 21
[0164] [0164] 26 machined slot for anvil holder
[0165] [0165] 27 anvil holder in roll 19
[0166] [0166] 28 bolt for holder
[0167] [0167] 29 vacuum passage in anvil
[0168] [0168] 30 knife holder in roll 20
[0169] [0169] 31 knife blade
[0170] FS 1 first segment from cutoff unit 16
[0171] FS 2 first segment from c.o. unit 21
[0172] S 3 slow speed web for next spaced segment
[0173] [0173] 33 anvil in roll 19
[0174] [0174] 34 vacuum conduit in carrier 22
[0175] [0175] 35 vacuum channel to carrier ports 36
[0176] [0176] 36 carrier vacuum ports
[0177] [0177] 37 leading edge of first segment
[0178] [0178] 37 ′ leading cut edge of incoming web
[0179] [0179] 38 trailing edge of segment
[0180] [0180] 39 leading margin when anvil vacuum V I starts
[0181] [0181] 40 leading margin when anvil vacuum V 1 stops
[0182] V 1 anvil roll vacuum applied to lead edge 37
[0183] V 2 anvil roll restricted vacuum (circle) (no slip)
[0184] V 3 anvil roll restricted vacuum (solid)-web slippage
[0185] RL 2 carrier radial line of contact w/anvil roll
[0186] V 5 anvil roll vacuum applied to lead edge 37 ″
[0187] [0187] 41 22 ½ degree arcuate portion of rotation
[0188] [0188] 42 vacuum path in FIG. 6 b
[0189] [0189] 43 vacuum path in FIG. 6 c
[0190] [0190] 44 blank repeat (no segment)
[0191] [0191] 45 full speed forward vector
[0192] [0192] 46 resultant half speed forward vector
[0193] [0193] 47 restricted vacuum carrier ports for gripping
[0194] [0194] 47 ′ restricted vac. carrier ports for slip(ping advancement
[0195] D spacing on carrier between cutoff units
[0196] [0196] 19 C cut line, lower cutoff unit
[0197] [0197] 19 ′C cut line, upper c.o. unit
[0198] [0198] 48 third cutoff unit
[0199] S A segment from # 1 cutoff
[0200] S B segment from # 2 cutoff
[0201] S C segment from # 3 cutoff
[0202] [0202] 49 lower double fold cutoff unit
[0203] [0203] 50 upper double fold cutoff unit
[0204] [0204] 51 second fold roll-lower unit
[0205] [0205] 51 ′ second fold roll-upper unit
[0206] [0206] 52 vacuum ports for doublefold line FD-FD′
[0207] [0207] 53 air blast apertures
[0208] FS-FS′ fold line for first fold
[0209] FD-FD′ fold line for second (double) fold
[0210] [0210] 54 slitter bedroll
[0211] [0211] 55 superposed webs
[0212] [0212] 56 intermediate frame
[0213] P product width web
[0214] [0214] 57 longitudinally folded product web
[0215] [0215] 58 singlefold apparatus for 3-color mix
[0216] [0216] 22 ′ duplicate folder-face-to-face
[0217] CDE cutoff units on dual folder
[0218] [0218] 59 delivery belt pair
[0219] [0219] 60 pair of superposed napkins
[0220] L 1 length of product =repeat surface length
[0221] [0221] 32 leading edge ports on anvil roll for L 1
[0222] L 2 length of segment L 2
[0223] [0223] 32 ′ leading edge ports on anvil roll for L 2
[0224] L 3 length of segment L 3
[0225] [0225] 32 ″ leading edge ports on anvil roll for L 3
[0226] [0226] 61 rotatable insert
[0227] [0227] 62 hole in insert for path to roll conduit
[0228] S 1 slippage to alternate space—L 1
[0229] S 2 slippage to alternate space—L 2
[0230] S 3 slippage to alternate space—L 3
[0231] V 3 restricted vacuum for slipping
[0232] L 1 segment length (example 12″)
[0233] [0233] 63 reference line for phasing carrier to anvil
[0234] S 12 slippage of L 1 web ( 12 ′)
[0235] L 2 segment length (example 8″)
[0236] [0236] 64 fold line for phasing to 12
[0237] S 16 slippage for L 2 web ( 8 ″)
[0238] [0238] 65 phase angle for L 2 fold line
[0239] L 3 segment length (example 6″)
[0240] [0240] 66 fold line for phasing to L 3
[0241] S 18 slippage for L 3 web ( 6 ″)
[0242] [0242] 67 phase angle for L 3 fold line
[0243] FL 1 folded segment on R 1 repeat
[0244] FL 1 ′ folded segment on R 2 repeat
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Apparatus for producing selected color or material sequences within a stack of transversely single or doublefolded products. Product width webs are longitudinaly folded and slideably advanced at slow speed metering rolls to create alternate void spaces before a segment is cut so that unocuppied alternate repeats on each anvil roll of the plurality can accept folded segments from other units in the plurality. With programmable changes to the same plurality of cutoff units including changes in the amount of web slippage before cutoff, several smaller product segments are cut, cooperatively folded and advanced by anvil and carrier rolls to produce different sizes within the color sequence defined by machine configuration. In another embodiment, programmable commands for selection of vacuum path, phase change of fold line, speed change to web metering roll and synchronized speed control during production vary the amount of web slippage, the resultant segment size, and folded product size within a single color stack.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional application of U.S. patent application Ser. No. 11/766,380 filed Jun. 21, 2007, the entire disclosure of which is incorporated herein by reference.
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation in part application of U.S. Ser. No. 11/230,890, filed Sep. 20, 2005, the contents of which are incorporated by reference herein in their entirety.
BACKGROUND
Fastener setting tools have become common tools in the construction industry. Their ability to drive a fastener fully with just the pull of a trigger is significantly more efficient than methods of hammering or screwing fasteners in. Traditionally, setting tools required their fasteners be loaded one at a time into the proper position in the setting tool before they could be driven into the work piece. More recently, setting tools have included a magazine that spring loads several fasteners, for auto loading, which significantly increases the speed at which large numbers of fasteners can be driven. Such magazines are augmented with respect to function by the advent of fastener holders in the form of carrier strips.
A wide variety of fasteners are now available for use with setting tools. This variety is required to meet the particular demands of the work pieces being joined together. One common variation in fasteners is their diameter. Different diameter fasteners are employed in distinct magazines or distinct setting tools. Distinct magazines at best are required in order to ensure proper feed of the fasteners. Such arrangements require a user employing fasteners of different diameters to have multiple magazines or multiple setting tools, and further may require additional time when magazines are replaced to accommodate different diameter fasteners. This leads to inefficiency and is therefore undesirable.
SUMMARY
A carrier strip system includes a plurality of discrete carrier strips respectively receptive of fasteners of substantially different dimensions the strips having internal features configured to engage the fasteners, the strips further having substantially identical external dimensions said external dimensions being substantially symmetrical with respect to a virtual surface defined by inclusion of axes of the plurality of discrete fasteners, and the external dimensions being engagable with a single setting tool magazine such that fasteners with different dimensions have consistent alignment within a single setting tool magazine.
A method of presenting substantially differently dimensioned fasteners to a single setting tool through a single setting tool magazine includes sizing internal dimensions of a plurality of discrete carrier strips to engage substantially different dimensions of discrete fasteners; loading the discrete fasteners into the plurality of discrete carrier strips; and maintaining external dimensions of the plurality of discrete carrier strips such that the plurality of discrete carrier strips are engagable in a single setting tool magazine by at least the external dimensions to consistently align the discrete fasteners relative to a single setting tool magazine.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a front elevation view of a large diameter carrier strip assembly of an embodiment of the invention;
FIG. 2 is a side elevation view of the carrier strip assembly of FIG. 1 ;
FIG. 3 is a front elevation view of a small diameter carrier strip assembly of an embodiment of the invention;
FIG. 4 is a side elevation view of the carrier strip assembly of FIG. 3 ;
FIG. 5 is a front elevation view of a varied diameter carrier strip assembly of an embodiment of the invention;
FIG. 6 is a side cross sectional view of the carrier strip assembly of FIG. 5 taken at arrows 6 - 6 ; and
FIG. 7 is a side cross sectional view of an alternate carrier strip with short fasteners.
DETAILED DESCRIPTION
In connection with the above-identified drawbacks of the prior art, the presently disclosed concept allows for fasteners of different diameters to be run in the same magazine of a setting tool. In order for such an application to be possible, an outside diameter of a fastener carrier strip must remain the same for different fastener diameters and yet securely hold the fastener in place. Moreover, since setting tool magazines employ a diametric surface of the fastener as an additional guiding surface, where narrower diameter fasteners are to be utilized in the same setting tool magazine accommodation must be made for the guiding function of the outside diameter of the larger diameter fasteners when using the smaller diameter fasteners.
Referring to FIG. 1 , a large diameter carrier strip assembly 1 is illustrated comprising: large diameter fastener(s) 2 , a large diameter head-end break-free strip 4 made of several head-end segments 5 , and a large diameter point-end break-free strip 6 made of several point-end segments 7 . The carrier strip assembly 1 is illustrated in a condition in which it may be loaded into a fastener setting tool such as a combustion driven fastening system.
Referring to FIG. 2 , each head-end segment 5 has a hole 12 therethrough and each point-end segment 7 has a hole 14 therethrough. The segment 5 to segment 5 spacing in the head-end break-free strip 4 is equal to the segment 7 to segment 7 spacing of the point-end break-free strip 6 , causing the hole 12 to hole 12 spacing to be the same as the hole 14 to hole 14 spacing. Holes 12 and 14 are sized to create an interference fit with the outside diameter 3 of the large diameter fastener 2 . The interference fit maintains the relative position of the large diameter head-end break-free strip 4 , the large diameter point-end break-free strip 6 and the large diameter fastener(s) 2 to each other.
As alluded to above there are several registers for the strip in a magazine (not shown), these are both diametrical and axial. These registers contact surfaces on the components that make up the large diameter carrier strip assembly 1 to assure the large diameter carrier strip assembly 1 will be properly guided and indexed within the magazine and setting tool (not shown). Diameters 8 and 9 are registered in the magazine to assure proper alignment of the fastener 2 prior to discharge from the fastener setting tool. Diameter 8 is immediately beyond radial surface 16 of head-end segment 5 in the direction of the point-end of the fastener 2 , and diameter 9 , is immediately beyond radial surface 20 of point-end segment 7 in the direction of the point-end of the fastener 2 . Radial surfaces 18 and 20 are also registered in the magazine to properly locate the fastener 2 in an axial direction prior to its discharge from the fastener setting tool. Radial surface 18 is formed on the head-end of segment 7 and radial surface 20 is formed on the point-end of segment 7 . Since surface 18 and surface 20 are formed on the same component, segment 7 , the distance between them can be accurately controlled.
As is easily observable in FIG. 2 the segments 5 and 7 are symmetrical about a virtual surface defined by inclusion of axes of the fasteners 2 and the segments 5 and 7 that make up the strip 1 . Such symmetry allows the fastener setting tool to contact the segments 5 , 7 from either or both sides of the virtual surface and thereby accurately align the fasteners 2 relative to the fastener setting tool. The symmetry of the strip 1 also allows the strip 1 to be installed into the magazine of the fastener setting tool in one of two orientations, resulting in easier and faster loading of strips 1 into the magazine since orienting the strip 1 into one of two orientations relative to the magazine is not necessary.
Referring to FIG. 3 , a small diameter carrier strip assembly 10 is illustrated comprising: small diameter fastener(s) 22 , a small diameter head-end break-free strip 24 made of several head-end segments 25 , and a small diameter point-end break-free strip 26 made of several point-end segments 27 . The carrier strip assembly 10 is illustrated in a condition in which it may be loaded into a fastener setting tool such as a combustion driven fastening setting tool, for example.
Referring to FIG. 4 , each head-end segment 25 has a hole 42 therethrough and each point-end segment 27 has a hole 44 therethrough. The segment 25 to segment 25 spacing in the head-end break-free strip 24 is equal to the segment 27 to segment 27 spacing of the point-end break-free strip 26 , causing the hole 42 to hole 42 spacing to be the same as the hole 44 to hole 44 spacing which also matches the hole 12 to hole 12 spacing of the large diameter head-end break-free strip 4 . Holes 42 and 44 are sized to create an interference fit with the outside diameter 23 of the small diameter fastener 22 . The interference fit maintains the relative position of the small diameter head-end break-free strip 24 , the small diameter point-end break-free strip 26 and the small diameter fastener(s) 22 to each other.
As described earlier, there are several registers for guiding the large diameter carrier strip assembly 1 within the magazine of the fastener setting tool. The surfaces on the components of the small diameter carrier strip assembly 10 that interface with the registers in the magazine must therefore match those from the large diameter carrier strip assembly 1 in order for the small diameter carrier strip assembly 10 to feed properly into the magazine of the fastener setting tool.
Segments 27 , therefore, which make up the small diameter point-end carrier strip 26 , have surfaces to match those of the segments 7 of the large diameter point-end carrier strip 6 . Specifically, the radial surfaces 48 and the radial surfaces 50 will register within the magazine just as the radial surfaces 18 and radial surfaces 20 did for the large diameter head-end segments 5 . Further, the axial distance separating radial surfaces 48 from radial surfaces 50 of segments 27 match the axial distance separating radial surfaces 18 from radial surfaces 20 of segments 7 . Thereby, allowing either the large diameter fastener carrier strip 1 or the small diameter fastener carrier strip 10 to axially register within a single magazine.
Similarly, the diametrically registering surfaces match as well. Specifically, diameters 28 of segments 25 positioned immediately beyond radial surfaces 46 match the diameters 8 of the large diameter fasteners shank. The fact that diameters 28 are formed as part of the segments 25 whereas diameters 8 are formed as part of the fasteners 2 do not effect the registration within the magazine as long as the diameters are substantially equal.
The other diametrically registering surfaces from the large diameter carrier strip 1 are diameters 9 of the large diameter fasteners shank. Therefore, diameters 29 of segments 27 match that of diameters 9 of large diameter fasteners 2 .
Referring to FIG. 5 , a varied diameter carrier strip assembly 100 is illustrated. The strip assembly 100 includes, a plurality of varied diameter fasteners 110 , a varied diameter head-end break-free strip 114 made of several head-end segments 118 , and a varied diameter point-end break-free strip 122 made of several point-end segments 126 . The carrier strip assembly 100 is illustrated in a condition in which it may be loaded into a fastener setting tool such as a combustion driven fastening setting tool, for example.
Referring to FIG. 6 , a cross sectional view of the varied diameter carrier strip assembly 100 is illustrated. One of the one of the varied diameter fasteners 110 is shown as having a first diameter portion 130 and a second diameter portion 134 with the first diameter portion 130 being a larger diameter than the second diameter portion 134 . A first varied diameter portion 138 transitions the first diameter portion 130 to the second diameter portion 134 . The first varied diameter portion 138 of this embodiment has a frustoconical shape, however, other transitional shapes could be employed between the first diameter portion 130 and the second diameter portion 134 . Similarly, a second varied diameter portion 142 transitions the second diameter portion 134 to a point 146 of the fastener 110 with a frustoconical shape. The point 146 of this embodiment has a flat surface truncating the second varied diameter portion 142 , however, other embodiments could have other point geometries such as a small spherical radius at the apex, for example.
Each head-end segment 118 has a hole 150 therethrough and each point-end segment 126 has a hole 154 therethrough. The segment 118 to segment 118 spacing in the head-end break-free strip 114 is equal to the segment 126 to segment 126 spacing of the point-end break-free strip 122 , causing the hole 150 to hole 150 spacing to be the same as the hole 154 to hole 154 spacing which also matches the hole 12 to hole 12 spacing of the large diameter head-end break-free strip 4 . Holes 150 and 154 are sized to create an interference fit with the first diameter portion 130 and the second diameter portion 134 respectively. Friction generated by the interference fit maintains the relative position of the varied diameter head-end break-free strip 114 , the varied diameter point-end break-free strip 122 and the varied diameter fastener(s) 110 to each other. The fact that a portion 158 of the first varied diameter portion 138 is positioned axially within the hole 150 is acceptable since a portion 162 of the first diameter portion 130 is also positioned axially within the hole 150 . As such, the interference fit of the portion 162 of the first diameter portion 130 with the hole 150 provides the friction required to maintain the relative position of the varied diameter head-end break-free strip 114 to the fasteners 110 . Similarly, the fact that a portion 162 of the second varied diameter portion 142 is positioned axially within the hole 154 is acceptable since a portion 166 of the of the second diameter portion 134 is also positioned axially within the hole 154 . As such, the interference fit of the portion 170 of the second diameter portion 134 with the hole 154 provides the friction required to maintain the relative position of the varied diameter point-end break-free strip 122 to the fasteners 110 .
The varied diameter carrier strip assembly 100 has several registers for guiding the strip assembly 100 within the magazine of the fastener setting tool. These registers of the strip assembly 100 interface with the registers in the magazine and also match registers from the large diameter carrier strip assembly 1 in order for the strip assembly 100 to feed properly into the magazine of the fastener setting tool. Specifically, segments 126 have surfaces that match those of the segments 7 of the large diameter point-end carrier strip 6 . For example, radial surfaces 174 and 178 register within the magazine just as the radial surfaces 18 and 20 for the large diameter head-end segments 5 do. Further, the axial distance separating the radial surfaces 174 from radial surfaces 178 of segments 126 match the axial distance separating radial surfaces 18 from radial surfaces 20 of segments 7 , thereby allowing either the large diameter fastener carrier strip 1 or the varied diameter fastener carrier strip 100 to axially register within a single magazine.
Similarly, the diametrically registering surfaces match as well. Specifically, diameters 134 immediately below (in the Figures) radial surfaces 186 of the segments 118 match the diameters 8 additionally diameters 182 immediately below the radial surfaces 178 match the diameters 9 . In this embodiment the diameters 134 are a portion of the fastener 110 , while in alternate embodiments the diameter 134 could be on a portion of the segments 118 , for example. By having registering diameters, for example, such as the diameters 134 immediately below the radial surface 186 and diameters 182 immediately below radial surface 178 that are consistent between various embodiments of the strip assemblies 1 , 10 and 100 the fit to the same fastener setting tool magazine and subsequently to the fastener setting tool will be assured.
Referring to FIG. 7 , a cross sectional view of a varied diameter carrier strip assembly 200 is illustrated. The strip assembly 200 is similar to the strip assembly 100 in that the head-end segments 118 and the point-end segments 126 that are uses in strip assembly 100 are also used in strip assembly 200 . By using the same segments 118 , 126 the strip assembly 200 is sure to fit and function within the same setting tools and magazines that the strip assembly 100 does. The difference between the strip assembly 200 and the strip assembly 100 is that the strip assembly 200 uses varied diameter fasteners 210 that are shorter than the varied diameter fasteners 110 that are used in the strip assembly 100 . In fact, the fasteners 210 are so short, they do not extend beyond a radial surface 214 that is the furthest portion of the strip assembly 200 in a direction of a point 218 of the fastener 210 . The only limitation on the length of the fastener 210 is that the second diameter portion 134 has a portion 222 that extends within the diameter 154 long enough to provide a frictional engagement between the fastener 210 and the point-end strip 126 to positionally locate them relative to one another. Thus, one embodiment of the present invention, disclosed in FIG. 7 , permits usage of fasteners in a magazine and a setting tool receptive of the magazine that are dimensionally smaller (in at least one direction) than the guide strips 118 , 126 through which they are mounted and fixtured.
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A carrier strip system includes a plurality of discrete carrier strips respectively receptive of fasteners of substantially different dimensions the strips having internal features configured to engage the fasteners, the strips further having substantially identical external dimensions said external dimensions being substantially symmetrical with respect to a virtual surface defined by inclusion of axes of the plurality of discrete fasteners, and the external dimensions being engagable with a single setting tool magazine such that fasteners with different dimensions have consistent alignment within a single setting tool magazine and method.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a rotation detecting sensor comprising a detecting element for detecting rotation of a rotary body as a change in magnetic flux and outputting an output signal corresponding thereto, initializing means for effecting an initialization including at least a gain adjustment for obtaining a desired gain as an initial value based on variation in the output signal upon lapse of a predetermined number of rotations of the rotary body, means for amplifying said output signal together with said gain to provide an amplified signal, and pulse generating means for generating a pulse corresponding to the rotation of said rotary body based variation in said amplified signal amplified based on said gain.
[0003] 2. Related Art
[0004] A rotation detecting sensor of the above-noted type is designed for detecting change in a magnetic flux which occurs in association with rotation of a rotary body. More particularly, as shown in FIG. 4 , such rotary body 7 includes a number of teeth 8 along its outer periphery and detecting elements 1 constructed as Hall elements, magnetoresistive elements or the like are disposed at operatively appropriate positions relative to the rotary body. Then, output signals from the detecting elements are used for determining e.g. a rotational speed, a rotational direction of the rotary body.
[0005] More particularly, this rotation detecting sensor utilizes change in the magnetic flux on detecting surfaces of the detecting elements which change occurs in association with rotation of the rotary body. The detecting elements detect this magnetic flux change and convert it into an amplitude-variable electric signal corresponding thereto. Then, this output signal is inputted to a logical determining section 4 in which the output signal is e.g. binarized through an arithmetic logical operation, thus converted into a pulse corresponding to e.g. the detected rotational speed of the rotary body.
[0006] The rotation detecting sensor normally comprises the magnetism detecting elements 1 and a single integrated circuit for effecting amplification, offset adjustment and pulse generation.
[0007] According to a recent version of the above type of rotation detecting sensor now commercially available, in order to extend its detection distance (i.e. to obtain greater freedom in the choice of the separating distance between the teeth 8 of the rotary body and the magnetism detecting elements 1 ), within a period delimited by power-ON (energization) of the sensor and occurrence of a predetermined number of amplitude variations subsequent thereto (specifically at a predetermined rotational speed of the rotary body when it is being rotated), the sensor automatically effects a gain adjustment and/or an offset adjustment on the signal to be inputted to the logical determining section so that an appropriate threshold value may become available for use in a logical threshold processing operation in the logical determining section.
[0008] The gain adjustment is effected for automatically obtaining such an appropriate gain as will result in a signal having an appropriate intensity confined within a predetermined range. Whereas, the offset adjustment is effected for automatically obtaining such an appropriate offset value as will result in a signal having an appropriate median amplitude value within a predetermined range.
[0009] In effecting “initialization” exemplified by the gain adjustment and the offset adjustment described above, determination of the timing for effecting this process relies upon the counted number of cycles of the signal.
[0010] Incidentally, one possible application of such rotation detecting sensor is its use in a vibrating machine body such as an automobile body. In such case, the vibration of the machine body per se such as the automobile body can cause a periodic change in the separating distance between the rotary body and the detecting element even when the rotary body is not rotating. Or, a small periodic rotational vibration can occur in the rotary body due to the vibration of the machine body These cause a change in the magnetic flux, so that the sensor may generate an inadvertent output signal based on such vibration, not on rotation of the rotary body.
[0011] Then, if the initialization is effected under such condition in the presence of inadvertent vibration-associated variation (i.e. vibration noise) in the output signal from the detecting element, the gain adjustment will result in an excessively large gain, since the vibration noise is a very small change in the magnetic flux.
[0012] Thereafter, when the rotary body is actually rotated, the sensor picks this up as a sufficiently large magnetic flux. Hence, when this output signal is amplified together with the excessively large gain previously obtained, the resultant amplified signal will have a value exceeding a maximum signal processing range of the integrated circuit. Then, if the pulse generation is effected under this condition, there will occur such inconvenience as disturbance in the pulse generation timing.
[0013] As a solution to such problem, it is conceivable to reduce the sensitivity of the sensor or increase the separating distance between the rotary body and the detecting element. Obviously, such solutions are undesirable because of disadvantageous reduction in the sensor sensitivity.
[0014] Another solution has been proposed which detects or monitors stop condition of the rotary body (which occurs e.g. when the automobile body is stopped) continued for a predetermined period and then effects an initialization again thereafter. With this solution, however, the initialization is effected when it is not actually needed. Hence, there is the possibility of disturbance in the output pulse while the initialization is being effected.
[0015] Still another solution has been proposed (see patent reference 1: Japanese Patent Application “Kokai” No. 2000-205259, its claim and FIG. 1 ) which provides e.g. a “displacement sensor” separately for detecting the physical vibration (i.e. another sensor dedicated for detection of vibration, not rotation), so that the output of the rotation detecting sensor may be appropriately compensated for based on the vibration detection by this displacement sensor. This solution is also disadvantageous or not practical because of significant cost increase expected from the provision of the additional sensor.
[0016] Next, what happens if such erroneous initialization is effected in the presence of vibration noise will be described in greater details with reference to FIGS. 4 , 5 , 6 and 7 .
[0017] FIG. 4 is a functional block diagram of a conventional rotation detecting sensor. FIG. 5 is a flowchart illustrating initialization and detection operation effected by the rotation detecting sensor shown in FIG. 4 . FIG. 6 is a diagram showing amplified signal and its associated output pulse waveform (output pulses) when the initialization is effected based on an amplified signal from the detecting element resulting from vibration.
[0018] Referring first to FIG. 4 , the conventional rotation detecting sensor includes a pair of detecting elements 1 , a pre-amplifier 2 for amplifying signals from these detecting elements 1 , an offset adjustor 21 for effecting an offset adjustment on the pre-amplified signals, a main amplifier 20 for amplifying the signals after the offset adjustment, a logical determining section 4 for effecting a logical operation on the resultant signals to convert them into e.g. pulses and an output section 5 for outputting the pulses.
[0019] In the above, the logical determining section 4 is responsible for generating at least a number of pulses corresponding to rotation of the rotary body 7 and optionally shaping the pulses in accordance with e.g. a rotational direction of the rotary body, so that such shaped pulses may be outputted.
[0020] As shown in FIG. 4 , when an initialization determining section 3 has determined that a certain condition such as power-ON is satisfied, an offset value to be used by the offset adjuster 21 and a gain value to be used by the main amplifier 20 are obtained in advance by effecting an offset adjustment by the offset adjuster 21 and a gain adjustment by the main amplifier 20 .
[0021] Conventionally, the gain adjustment is effected only once at the time of power-ON which satisfies the initialization determining condition and the gain value thus obtained is retained as it is to be used subsequently for e.g. amplification of the output signal.
[0022] Next, this type of initialization and signal processing subsequent thereto will be described in details with reference to the flowchart of FIG. 5 .
[0000] (Initialization)
[0023] As shown at the upper part of in this flowchart, in response to power-ON, while serially inputting the output signals from the detecting element 1 , the process effects an offset adjustment and a gain adjustment (# 51 - 1 and # 52 ) with using the cycle of the signal as a unit therefor. Then, the process effects a logical determination for pulse generation (# 53 - 1 ) and output of generated pulse (# 54 - 1 ). This process is continued or repeated until it is judged (# 55 ) the number of outputted pulses exceeds a predetermined number of times (e.g. 6-times). With this initialization, an appropriate gain is obtained.
[0024] Therefore, after this initialization, the resultant gain has a value which is appropriate for that particular instance in the process.
[0000] (Signal Processing After Initialization)
[0025] Upon completion of the initialization, the process goes on to a closed loop shown at the lower part of the chart. In this loop, while inputting new signals, the process obtains amplified signals with using the gain previously obtained through the initialization described above and effects a logical determination and generates and outputs including pulses (# 53 - 2 and # 54 - 2 ).
[0026] As shown, the offset adjustment is effected in each cycle of inputting new signals (# 51 - 2 ).
[0027] The forms of signals processed by the above are illustrated in the diagram of FIG. 6 which shows time along the horizontal axis and shows amplified signals (upper row), undesired output pulse waveform (middle row) and optimal pulse waveform (lower row) all along the vertical direction.
[0028] Referring first to the horizontal axis representing time, an area (Area A) shown on the left end and including relatively small (amplified) signals is an area when element output signals due to vibration are being inputted. From the center to the right side of the diagram, there is shown another area (Area B) which is an area when output signals due to rotation of the rotary body are being inputted. The figure includes still another area (Area C) which is included in the Area A at the beginning thereof. This Area C is an initialization area for effecting the initialization.
[0029] Referring next to the vertical direction of the diagram, the lowermost row represents the optimal pulse waveform to be obtained from the element outputs. The middle row represents the undesired pulse waveform obtained from amplified signals which were erroneously amplified with using the gain set based on vibration-associated output variation. The upper row represents amplified signals which result in or correspond to the undesired pulse waveform.
[0030] Further, within the upper row, a pair of opposed two dot chain lines denote or delimit together a maximum signal processing range of this sensor. Further, one dot chain lines denote threshold values for pulse generation. In this diagram both the “appropriate or optimal threshold value” and the “inappropriate threshold value” are denoted with the one-dot chain lines. The “appropriate threshold value” is a threshold value which should be employed in threshold value processing for proper pulse generation even in the presence of a signal which exceeds the maximum signal processing range. Whereas, the “inappropriate threshold value” is an undesirable threshold value which is set relying solely on the maximum signal processing range.
[0031] As described above, the pulse waveform shown in the middle row is a pulse waveform obtained by a threshold value processing based on the inappropriate threshold value. Whereas, the pulse waveform shown in the lower row is a pulse waveform obtained by a threshold value processing based on the appropriate threshold value.
[0032] Hence, in this prior art, as shown, there exists disagreement between the pulse waveform shown in the lower row and the pulse waveform shown in the middle row.
[0033] According to the sensor of the type to which the present invention pertains, the sensor is constructed such that a pulse generation threshold value for delimiting pulse generation timing may be automatically set. More particularly, as illustrated in the pulse generation process in the Area B (rotation) shown in FIG. 6 , this pulse generation timing is set as a timing when an amplified signal intersects this pulse generation threshold value (one dot chain line).
[0034] Referring now to FIG. 7 , in the process of processing amplified signals having predetermined unit cycle, the above-described pulse generation threshold values are set based on a width or difference Vpp between a maximum value Vmax and a minimal value Vmin of the single unit cycle of amplified signal. More particularly, an upper threshold value VthH and a lower threshold value VthL are set one after another as values which respectively satisfy: e.g. VthH=Vmax−r*Vpp, VthL=Vmin+r*Vpp, where r=0.15.
[0035] Namely, these pulse generation threshold values are automatically set based on range (magnitude) of amplitude variation occurring in a unit cycle of the amplified signal.
[0036] Referring back to FIG. 6 , when the initialization is effected in the presence of vibration-associated signals detected. The amplified signals resulting therefrom have a small signal intensity as shown in the left end of the upper row. Under this condition, if output signals are inputted one after another and the gain adjustment as an example of initialization is effected for obtaining an appropriate gain (i.e. appropriate for such outputs), because of the weak signal intensity, the resultant gain will approximate a maximum gain permissible with this sensor,.
[0037] If the vibration continues under the above condition, as shown, upon lapse of a predetermined number of amplitude variations thereof, the process automatically effects pulse generation in accordance with the standard sequence. In this condition, however, the hysteresis widths of the pulse generation threshold values are extremely small.
[0038] Thereafter, when the rotary body actually begins to rotate, because of the excessively large gain obtained previously, the resultant amplified signals should exceed the maximum signal processing range of the circuit. Consequently, because the pulse generation threshold values employed at this stage are inappropriate, inappropriate pulses will be generated as exemplified by the relationship between the undesirable pulse waveform shown in the middle row and the appropriate pulse waveform shown in the lower row of the FIG. 6 .
[0039] In the construction of the present invention, as will be described later herein, the pulse generation threshold values are continuously updated and optimized according to the range of the periodic variation in the amplified detection signals, thereby to provide an appropriate pulse waveform. In contrast, with the conventional construction, as shown on the right side in FIG. 6 , the generated pulses have a relatively large pulse width as determined by the maximum signal processing range.
[0040] As a result, if the sensor detects the rotational speed of the rotary member and effects the predetermined control scheme in the manners described above, proper performance cannot be obtained with this sensor.
[0041] In view of the above-described state of the art, a primary object of the present invention is to provide an improved rotation detecting sensor capable of obtaining an appropriate gain through initialization even when this initialization is effected based on a change in output signals from a detecting element due to a factor other than rotation, thereby to generate appropriate signals such as pulses associated with rotation of a rotary member, so that the sensor can provide highly reliable rotation information.
SUMMARY OF THE INVENTION
[0042] According to the present invention, there is provided a rotation detecting sensor comprising: a detecting element for detecting rotation of a rotary body as a change in magnetic flux and outputting an output signal corresponding thereto, initializing means for effecting an initialization including at least a gain adjustment for obtaining a desired gain as an initial value based on variation in the output signal upon lapse of a predetermined number of rotations of said rotary body, means for amplifying said output signal together with said gain to provide an amplified signal, and pulse generating means for generating a pulse corresponding to the rotation of said rotary body based variation in said amplified signal amplified based on said gain; and initial value evaluating means for evaluating whether said initial value obtained by said initialization is appropriate or not and subsequently causing said initializing means to effect a re-initialization to obtain a new initial value when said initial value is evaluated inappropriate, so that said sensor obtains a new amplified signal based on said new initial value.
[0043] According to the rotation detecting sensor having the above described construction, the initial value evaluating means evaluates whether an initial value obtained by the initialization is appropriate or not. And, if this value is evaluated as inappropriate, an initialization is effected again. As a result, the sensor obtains at least a gain which accurately reflects the rotation of the rotary body and subsequently generates pulses with less disturbance in the pulse generation timing by applying the gain.
[0044] Therefore, even if this sensor is employed as a rotation detecting sensor in a vibrating machine, it is possible to avoid generation of inappropriate pulses under the influence of initial vibration of the machine.
[0045] Preferably, said sensor has a threshold value for delimiting a pulse generating timing in response to said amplified signal, and said threshold value is set by said pulse generating means based on a range of variation occurred in the amplified signal prior to the pulse generation.
[0046] With this construction, for generating a predetermined pulse waveform associated with rotary body rotation, the sensor can effect the threshold processing therefor in such a manner as suitable for the detection condition of the rotation detecting element.
[0047] Preferably, said sensor has a preferred range for said amplified signal, and said initial value evaluating means evaluates said initial value as inappropriate and causes said initializing means to effect said re-initialization when said amplified signal exceeds said preferred range.
[0048] With the conventional rotation detecting sensor of this type in general, as described hereinbefore, the sensor includes, on the side of the output of the magnetism detecting element, a circuit for effecting a predetermined logical determination on the output from the detecting element to generate a pulse corresponding thereto or for obtaining optionally a shaped pulse corresponding thereto. Such circuit has a fixed maximum signal processing range.
[0049] Therefore, if a predetermined preferred range is set for such maximum signal processing range and the re-initialization is effected when the amplified signal exceeds this preferred range, the resultant amplified signal from which the pulse is to be generated can always be confined within the preferred range suitable for the subsequent signal processing.
[0050] Preferably, if the amplified signal has exceeded the preferred range for a predetermined number of times in a row, the signal is determined as being associated with vibration, then, the re-initialization is effected.
[0051] Still preferably, a target amplitude is set for said amplified signal, so that said amplified signal is confined within said target amplitude as a result of said re-initialization.
[0052] Further, as described hereinbefore, when the sensor picks up small vibration of a vibrating machine body as a noise and then sets a gain appropriate therefor, thus set gain will be excessively large. Therefore, the gain may be updated to the decreasing side in the re-initialization.
[0053] This quickens the process to obtain a really appropriate gain during the re-initialization when this is needed.
[0054] Further, the re-initialization can be effected at the timing of start of rotation of the rotary body. Hence, optimum initialization can be effected with a minimum number of rotation of the rotary body.
[0055] Still preferably, said threshold value for delimiting a pulse generating timing includes upper and lower threshold values which are alternately generated one after another based on the range of variation occurred in the amplified signal prior to the pulse generation.
[0056] With this, the pulse-timing delimiting threshold values can be reliably obtained in the alternate and serial manner based on a certain present condition of the amplified signal.
[0057] Preferably, said threshold value is set based on a maximum value Vmax, a minimum value Vmin a difference Vpp therebetween of said amplified signal prior to the pulse generation.
[0058] With this, the pulse generation can be readily carried out by utilizing the readily obtainable values characterizing the amplified signal (i.e. the maximum value Vmax, the minimum value Vmin and a difference Vpp therebetween).
[0059] Advantageously, said initializing means, said amplifying means, said pulse generating means and said initial value evaluating means are constructed and incorporated together as a single integrated circuit.
[0060] The rotation detecting sensor of the invention can be used in great number and in numerous applications. Hence, the construction of the various means in the form of a single integrated circuit is advantageous for mass production, stability of performance as well as readiness of replacement of the sensor when needed.
[0061] As described above, according to the rotation detecting sensor of this invention having the constructions described, when this sensor is employed in a vibrating machine body such as an automobile body as a rotation detecting sensor for automatic transmission or ABS (anti-lock braking system) thereof, the sensor is still capable of effecting an optimal pulse waveform generating/shaping operation through the re-initialization regardless whether the change in magnetic flux is due to vibration of the rotary body or to its rotation.
[0062] Further and other features and aspects of the present invention will become apparent upon reading the following description of preferred embodiments thereof with reference to the accompanying drawings; in which,
[0063] FIG. 1 is a functional block diagram of a rotation detecting sensor according to the present invention, the sensor being designed for effecting a re-initialization,
[0064] FIG. 2 is a flowchart illustrating operating of the invention's sensor which effects a re-initialization,
[0065] FIG. 3 is a diagram showing sensor operation when a re-initialization is effected,
[0066] FIG. 4 is a functional block diagram of a conventional rotation detecting sensor,
[0067] FIG. 5 is a flowchart illustrating operation of the conventional sensor which effects an automatic initialization function,
[0068] FIG. 6 is a diagram illustrating showing the operation of the conventional sensor, illustrating its problem in particular, and
[0069] FIG. 7 is a diagram illustrating setting of threshold values for delimiting a pulse generating timing.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0070] Next, preferred embodiments of the invention will be described with reference to FIGS. 1, 2 and 3 in correspondence with FIGS. 4, 5 and 6 for comparison, respectively.
[0071] FIG. 1 is a functional block diagram of a rotation detecting sensor relating to the present invention. This sensor is designed for effecting a re-initialization when needed. FIG. 2 is a flowchart illustrating initialization, re-initialization and detection operations effected by the rotation detecting sensor shown in FIG. 1 .
[0072] FIG. 3 is a view corresponding to FIG. 6 described hereinbefore and showing amplified signals, output pulse waveform obtained by the rotation detecting sensor of the invention capable of re-initialization and appropriate pulse waveform.
[0073] Describing with reference to FIG. 4 for comparison, like the conventional rotation detecting sensor, the rotation detecting sensor according to the present invention includes a pair of detecting elements 1 . Outputs (element outputs) from these elements 1 are subjected to an offset adjustment by an offset adjustor 21 and the resultant signals are then amplified by a main amplifier 20 and sent to a logical determining section 4 to be subjected to a predetermined logical determination therein to be converted into pulse signals, which are then transmitted an output section 5 downstream. These final signals include at least pulses.
[0074] At the logical determining section 4 , as described hereinbefore in connection with the prior art, a threshold setting operation is automatically effected for pulse generation and at least pulses are generated in correspondence with rotation of a rotary body 7 . Further, at this section, a pulse shaping operation can optionally be effected in accordance with e.g. the rotational direction of the rotary body 7 . So that, this section can output such shaped pulses also.
[0075] In the case of the conventional construction described hereinbefore, the construction includes only the initialization determining section 3 for effecting initialization only once. In the case of the construction of the present invention, there is further provided a re-initialization determining section 30 for effecting a re-initialization if necessary. More particularly, in this re-initialization too, a gain adjustment is effected so as to obtain a new gain value accurately reflecting the actual condition of the rotary body. In this re-initialization, the gain is updated to the decreasing side.
[0076] FIG. 2 is a flowchart corresponding to the flowchart shown in FIG. 5 . The flowchart of FIG. 2 includes steps # 21 - 25 as well as additional steps # 30 , 31 which latter steps are provided in connection with the essential feature of the present invention.
[0000] [Initialization]
[0077] In this flow, upon power-ON, while inputting output signals one after another, the process effects an offset adjustment (# 21 - 1 ) and a gain adjustment (# 22 - 1 ), both using amplitude variation in the output signals as a unit therefor. Then, at the logical determining section 4 , the process effects a logical determination (# 23 - 1 ) for pulse generation and outputs the generated pulses (# 24 - 1 ). This initialization process is continued until it is judged (# 25 ) that the number of pulses exceeds a predetermined number of times (e.g. 6 times). This initialization process is substantially identical to that conventionally effected.
[0000] [Signal Processing After Initialization]
[0078] Upon completion of this initialization (or re-initialization described later), the process goes to a flow shown at the lower-right part in FIG. 2 .
[0079] In this, while serially inputting new output signals, the process an offset operation (# 21 - 2 ) again. At this stage, however, the process processes signals which were amplified by using the gain previously obtained as it is. Thereafter, the process effects an initialization determination at a re-initialization determining section 30 (initial value evaluating means) (# 30 , # 31 ), at which if it is determined that an initialization is needed, the process goes back to the above-described initialization process to effect an initialization again. If, on the other hand, it is determined that no initialization is needed, the process just moves to the logical determination step to generate pulses and output the generated pulses (# 23 - 2 , and # 24 - 2 ). This process is repeated by a predetermined timing.
[0080] The process for effecting the above described steps is illustrated in the diagram of FIG. 3 which corresponds to FIG. 6 .
[0081] FIG. 3 employs similar principle of diagrammatical illustration to that employed in FIG. 6 . In addition, however, this FIG. 3 shows re-initialization determining threshold values (actually consisting of an upper threshold value H and a lower threshold value L for the determination of re-initialization) denoted with narrow solid lines, which threshold values are used by the re-initialization determining section 30 . FIG. 3 further shows a gain-setting target amplitude and a re-initialization area (Area D) where the re-initialization is effected as needed.
[0082] In this diagrammatical representation, any disagreement or displacement between the pulse waveform shown in the middle row relative to the pulse waveform shown in the lower row would be a problem. In this respect, in FIG. 3 , it is observed that there is no such displacement at all after the start of rotation of the rotary body.
[0083] The pulse generating scheme effected at the logical determining section 4 is identical per se to that described hereinbefore for the prior art with reference to FIGS. 6 and 7 . Namely, the pulse generating threshold values are continuously, updated and set, so that the pulse generating timing is set by the timing when the amplified signal passes either pulse generating threshold value.
[0000] [Operation Under Vibration]
[0084] In comparison with the construction shown in FIG. 6 , when the rotary body is not rotated and the signals from the detecting elements due to certain vibration alone, the construction of the present invention functions similarly to the prior art. Hence, an excessive gain (substantially the maximum gain) will be set before rotation of the rotary body.
[0085] [Operation Under Rotation]
[0086] Therefore, when the rotary body actually begins to rotate, the resultant amplified signals will be excessively large exceeding the maximum signal processing range. However, this excess condition is detected as intercepts of the upper and lower re-initialization determining threshold values (H, L) by the amplified signals (shown at “intercept counts 1 , 2 3 ” denoted with white circles). Then, when the number of these intercepts (intercept counts) exceeds a predetermined number (3 (three) in the case of the illustrated example), the re-initialization determining section 30 determines that the previously effected initialization was inappropriate, hence, that a re-initialization is needed. This determination is the determination effected by the re-initialization determining section 30 referred to herein as “initial value evaluating means”.
[0087] In the illustrated case, in the same manner as the first initialization, the re-initialization is effected for three cycles shown as Area D. In this re-initialization stage, the gain is automatically and continuously adjusted to the decreasing side toward the gain setting target amplitude, so that the amplified signal too is progressively decreased in its signal intensity and the threshold value width (the width between the upper and lower thresholds) for the pulse generation too is progressively converged toward the median value.
[0088] Therefore, as shown on the right end in the figure, there is achieved good agreement between the actual pulse waveform and an ideal or optimum pulse waveform for pulse signal shown in the lower row.
Other Embodiment
[0089] In the foregoing embodiment, in the determination of the necessity of the re-initialization, a re-initialization is effected if the re-initialization determining threshold value (e.g. vibration noise determining threshold value) has been exceeded by a predetermined number of times (specifically, three times in the illustrated example). For this determination, it is also possible to set upper and lower limits for this type of determining threshold value and if the signal exceeds either one of them by a predetermined number of times in a row or has exceeded it by the predetermined number of times in total or exceeds the upper limit and the lower limit alternately in a row by a predetermined number of times, a re-initialization can be effected as determined needed.
[0090] The rotation detecting sensor of the invention can be used advantageously as a rotation detecting sensor to be installed in a vibration abundant place, e.g. as a rotation detecting sensor for an automatic transmission or ABS in an automobile body.
[0091] The present invention may be embodied in another manner than those described above. Hence, the disclosed embodiments are not intended to be limiting the scope of the invention, but various modifications thereof will be apparent for those skilled in the art without departing from the essential elements thereof set forth in the appended claims and such modifications too are to be understood as included within the scope of the invention.
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Disclosed is a rotation detecting sensor suitable for use under a vibration-abundant condition as e.g. a sensor disposed in an automobile body for detecting rotation of an engine or ABS. The sensor includes a detecting element for detecting rotation of a rotary body as a change in a magnetic flux and outputting a signal and an integrated circuit for processing the amplified signal into a pulse corresponding to the detected rotation of the rotary body. The signal processing includes an initialization such as a gain adjustment for obtaining an appropriate gain for use in the subsequent process of conversion of the amplified signal to the pulse. According to this invention, a re-initialization is effected to obtain a new initial value such as a new gain if the previously effected initialization is determined inappropriate.
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BAGKGROUND
(1) Field of the Invention
The invention relates to catheters. More specifically, the invention relates to a sleeve that positively engages an introducer to reduce the risk of unintentional needle sticks.
(2) Background
Catheters and sleeves therefor have been ubiquitous in the medical supplies market for some time. A typical catheter assembly arrives in sterile packaging and comprises a catheter, the introducer, and a sleeve. The purpose of the sleeve is to protect the needle tip during shipping and to prevent unintentional needle sticks as the catheter and introducer are removed from the sterile packaging. To that end, the sleeve needs to have sufficient retention force that it does not unintentionally become disengaged from the introducer as the sterile packaging is removed. However, if the retention force is too great, the incidence of needle pricks in the course of removing the sleeve actually increases. By way of example, a user typically grabs the sleeve in one hand and the introducer in the other, then pulling the sleeve in one direction and the introducer in the opposite direction, when the introducer snaps free, the arms of the user recoil, causing the user to inadvertently stick themself. This has been an area of substantial concern.
One common way of retaining the sleeve on the introducer is to mold three detents into the sleeve to engage an annular flange on the introducer. This works adequately for certain types of catheters. However, catheters have been developed that have wings that permit the catheter to be more easily secured to a patient after introduction. These wings necessitate grooves in the sleeve to accommodate the wings while the catheter is sleeved. With the introduction of the grooves, the structural integrity of the sleeve is such that disengagement from the detents is highly likely, as only a very loose hold is possible. Attempts to accommodate this problem by increasing the size of the detent between the grooves has resulted in cases of both an unreliable hold and too strong a hold, both resulting in increased risk for unintentional needle sticks.
BRIEF SUMMARY OF THE INVENTION
A positive engagement/disengagement catheter sleeve to reduce risks of needle sticks is disclosed. The sleeve has a base and a body which define a pair of grooves. The grooves define a deformable region of the sleeve therebetween. At least one detent is provided inside the base within the deformable region. A mechanism is provided to cause the detent to disengage when the mechanism is actuated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a catheter with introducer and sleeve of one embodiment of the invention.
FIG. 2 is a perspective view of the sleeve of the embodiment of FIG. 1 .
FIG. 3 is a partial cross-section view of the catheter assembly and sleeve of the embodiment of FIG. 1 .
FIG. 4 is a partial sectional view of a sleeve and catheter assembly of FIG. 3 with the arm depressed, thus releasing the detent
FIG. 5 is a perspective view of an alternative embodiment of the invention.
FIG. 6 is a partial cross-sectional view of the sleeve of FIG. 5 with a catheter assembly inserted therein.
FIG. 7 is a partial sectional view of a third alternative embodiment of the sleeve installed on a catheter assembly.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of a catheter with introducer and sleeve of one embodiment of the invention. The catheter 22 is coupled to a catheter hub 26 . Hub 26 has wings 24 formed as part thereof. Introducer 30 has an annular flange 28 as part thereof to engage sleeve 10 . Sleeve 10 has a pair of grooves 12 disposed to receive the wings 24 of catheter hub 26 . Sleeve 10 has a base 11 at an insertion end and a body 13 terminating in a distal end. The grooves define a deformable region 14 therebetween. Attached to the deformable region 14 is an arm 16 . Arm 16 has a first end where it attaches to the deformable region 16 and a free end down the sleeve from the base. Pressure on the arm 16 at its distal end causes the deformable region at the base to move away from an axis of the sleeve.
FIG. 2 is a perspective view of the sleeve of the embodiment of FIG. 1. A plurality of detents 18 , 20 are disposed within base 11 . While only two of the detents are shown in the figure, a third detent is typically positioned symmetrically on the base 11 across from the detent 20 . Detent 18 is disposed on deformable region 14 between grooves 12 on the base 11 . The detents 18 , 20 engage the annular flange ( 28 of FIG. 1) when the introducer 30 is seated in the sleeve 10 . Because the grooves 12 reduce the structural integrity, in some embodiments, it may be necessary to make detent 18 larger than detents 20 to ensure engagement even if the flexibility caused by the grooves 12 results in deformable region 14 holding less tightly against the annular flange 28 . Notably, even with grooves 12 , sleeve 10 would be suitable for a wingless catheter provided that the detents 18 , 20 provide sufficient holds so that the sleeve 10 does not easily become unintentionally disengaged.
FIG. 3 is a partial cross-section view of the catheter assembly and sleeve of the embodiment of FIG. 1 . As shown in FIG. 1, detent 18 engages annular flange 28 , and the wings 24 are seated in the slot 12 such that pressure on the distal end of arm 16 results in maximum translation away from the axis of the sleeve 10 . Arm 16 has a thickness 40 , which is greater than the distance 42 between the arm 16 and the body 13 of sleeve 10 . In one embodiment, the arm 16 is approximately aligned with detent 18 . By keeping the distance between the arm 16 and the body 13 of the sleeve, less than the thickness of the arm, inadvertent nesting, or interlocking of sleeves during manufacture is prevented.
FIG. 4 is a partial sectional view of a sleeve and catheter assembly of FIG. 3 with the arm depressed, thus releasing the detent. In this view, pressure is shown as being applied to the distal end of arm 16 , thereby releasing the engagement of detent 18 from annular flange 28 . Once detent 18 releases annular flange 28 , the remaining detents 20 provide little or no holding force and the catheter assembly may be easily withdrawn from the sleeve without the recoil risk present in the prior art.
FIG. 5 is a perspective view of an alternative embodiment of the invention. Sleeve 60 has a base 61 coupled to a shaft 63 , and a pair of grooves 62 define a deformable region 64 therebetween. A thin or flexible region 66 is provided partway down the deformable region 64 . Flexible region 66 is flexible relative to the remainder of deformable region 64 . This may be accomplished by making flexible region 66 of the same material as the rest of the deformable region 64 , only thinner. Alternatively, different material having different rigidities may be used. The detents (not shown) within the base 61 are as previously described.
FIG. 6 shows a partial cross-sectional view of the sleeve of FIG. 5 with a catheter assembly inserted therein. Pressure on the deformable region 64 distal to the thin region 66 causes detent 68 on the base within the deformable region to translate away from the axis of the sleeve and disengage from annular flange 28 of the introducer 30 .
FIG. 7 is a partial sectional view of a third alternative embodiment of the sleeve installed on a catheter assembly. This embodiment is similar to the embodiment of FIGS. 5 and 6, except that a pivot protrusion 86 is provided on the inner surface of the sleeve within the deformable region 84 . The pivot protrusion 86 contacts the catheter hub, such that pressure on the deformable region 84 distal to the pivot protrusion 86 causes the deformable region 84 to act like a teeter-totter about the pivot protrusion, such that the detent 88 translates away from the axis of the sleeve and disengages from annular flange 28 .
Each of the described embodiments permits the introducer catheter assembly to be withdrawn from the sleeve with little or no resistance. The sleeve could be injection molded or formed in any other conventional means. In one embodiment, the entry sleeve is integrally formed as one continuous unit. Notably, the sleeves described above with the grooves, are suitable for many types of catheters, including both winged and wingless catheters. Thus, a single sleeve design can be used for a wide variety of different catheters, thereby reducing the tooling and manufacturing costs which would otherwise be necessary to produce the several different sleeve types.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes can be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. Therefore, the scope of the invention should be limited only by the appended claims.
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A positive engagement/disengagement catheter sleeve to reduce risks of needle sticks. The sleeve has a base and a body which define a pair of grooves. The grooves define a deformable region of the sleeve therebetween. At least one detent is provided inside the base within the deformable region. A mechanism is provided to cause the detent to disengage when the mechanism is actuated.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 10/450,005, filed Oct. 17, 2003 (371 date), now allowed, which is a U.S. National Stage of PCT/AU01/001627, filed Dec. 18, 2001, which claims priority to Australian Application No. PR2137/00, filed Dec. 18, 2000; these applications are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to antiviral agents, in particular to compounds useful in the treatment of infections caused by Picomaviridae, such as human rhinovirus (HRV), and methods for their preparation. The invention also relates to the use of these compounds in the treatment of picomavirus infections and to intermediates useful in the preparation of these compounds. The compounds of the invention are especially suitable for use in the treatment of HRV and accordingly it will be convenient to describe the invention in connection with these viruses. However, it is to be understood that the invention is also applicable to other viruses of the Picornavirus family.
[0004] 2. Description of the Related Art
[0005] Human rhinoviruses are a member of the genus Rhinovirus of the picornavirus family and are believed to be responsible for between 40 and 50% of common cold infections. Human rhinoviruses comprise a group of over 100 serotypically distinct viruses and accordingly antiviral activity for multiple serotypes and potency are considered to be equally important factors in drug design.
[0006] Two cellular receptors have been identified to which almost all typed HRVs bind. The major group, which comprises 91 of the more than 100 typed serotypes, binds to the intracellular adhesion molecule-1 (ICAM-1) while the minor group, which comprises the rest of typed serotypes with the exception of HRV87, binds to the low density lipoprotein receptor family of proteins.
[0007] Another genus of the Picornaviridae family is represented by the Enteroviruses. This genus includes polioviruses 1-3, coxsackieviruses A (23 serotypes) and B (6 serotypes), echoviruses (31 serotypes) and numbered enteroviruses 68-71. The clinical syndromes caused by enteroviruses include poliomyelitis, meningitis, encephalitis, pleurodynia, herpangina, hand foot and mouth disease, conjunctivitis, myocarditis and neonatal diseases such as respiratory illnesses and febrile illnesses.
[0008] Viruses of the Picornavirus family are characterized by a single stranded (+) RNA genome encapsidated by a protein shell (or capsid) having pseudo icosahedral symmetry. The surface of the capsid contains “canyons” which surround each of the icosahedral fivefold axes, and it is believed that the cellular receptors bind to residues on the canyon floor.
[0009] A hydrophobic pocket lies underneath the canyon within which a number of antiviral compounds are capable of binding, sometimes with consequential conformational changes. Some of these compounds have been shown to inhibit the uncoating of HRVs and, for some of the major receptor group viruses, inhibition of cell receptor binding has also been demonstrated. It has also been shown that when a compound is bound within the hydrophobic capsid pocket, HRVs are more stable to denaturation by heat or acids.
[0010] Examples of antipicornaviral compounds believed to act by binding within the hydrophobic pockets of the picornavirus capsid are described in U.S. Pat. Nos. 4,857,539, 4,992,433, 5,026,848, 5,051,515, 5,100,893, 5,112,825, 5,070,090, and Australian Patent No. 628172. One compound that has been the subject of recent human clinical trials is ethyl 4-[2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]-ethoxy]benzoate, otherwise known as “Pirodavir”. (“Intranasal Pirodavir (R77,975) Treatment of Rhinovirus Colds” F. G. Hayden, et al., Antimicrobial Agents and Chemotherapy, 39, 290-294, 1995.)
BRIEF SUMMARY OF THE INVENTION
[0011] A novel class of antiviral compounds has now been discovered which has been found to exhibit particularly favorable antipicornaviral properties.
[0012] Accordingly the present invention provides a compound of formula I
its salts, and pharmaceutically acceptable derivatives thereof where:
[0013] Het is an optionally substituted 5- or 6-membered monocyclic heterocyclic radical or an optionally substituted 9- or 1 0-membered bicyclic heterocyclic radical;
[0014] A is O, S, NH, N(C 1-6 alkyl), CH 2 O, a direct bond or a bivalent heterocyclic radical of the formula
where one or more of the carbon atoms within the radicals (b-1) to (b-4) may be optionally substituted with C 1-6 alkyl or two carbon atoms in the radicals (b-1) to (b-4) may be bridged with a C 2-4 alkylene radical, m and n are each independently integers of 1 to 4 inclusive with the proviso that the sum of m and n in radicals (b-1) to (b-4) is 3, 4 or 5;
[0015] Z is N or CR 6 where R 6 is hydrogen, hydroxy, C 1-6 alkyl, C 1-6 alkoxy or amino;
[0016] ZN is O, S, CHR 7 or NR 8 where R 7 is hydrogen, hydroxy, C 1-6 alkyl,
[0017] C 1-6 alkoxy or amino and R 8 is hydrogen or C 1-6 alkyl;
[0018] R 4 is hydrogen or C 1-6 alkyl; and
[0019] R 5 is hydrogen, hydroxy, C 1-6 alkyl or C 1-6 alkoxy;
[0020] Alk is C 1-7 alkylene or a direct bond;
[0021] W is O, S, OCH 2 , a direct bond or NR 9 where R 9 is hydrogen or C 1-6 alkyl;
[0022] X 1 , X 2 and X 3 are each independently selected from N and CR, where R is hydrogen, halogen, hydroxy, C 1-6 alkyl or C 1-6 alkoxy and
[0023] B is a five or six membered unsaturated heterocyclic ring, substituted with at least one substituent selected from, R 10 , OR 10 , SR 10 and NR 9 R 10 where R 10 is C 1-6 alkyl, haloC 1-6 alkyl, C 1-6 alkenyl, haloC 1-6 alkenyl, C 1-6 alkynyl or haloC 1-6 alkynyl,
[0024] with the proviso that when Alk is a direct bond and A is O, S, CH 2 O or a direct bond, then W is not O, S, OCH 2 or a direct bond.
[0025] The term “heterocyclic radical” as used herein refers to mono or bicyclic rings or ring systems which include one or more heteroatoms selected from N, S and O. The rings or ring systems generally include 1 to 9 carbon atoms in addition to the heteroatom(s) and may be saturated, unsaturated, aromatic or pseudoaromatic.
[0026] Examples of 5-membered monocyclic heterocycles include furyl, thienyl, pyrrolyl, oxazolyl, thiazolyl, isoxazolyl, isothiazolyl, pyrazolyl, imidazolyl, triazolyl, tetrazolyl, oxadiazolyl, thiadiazolyl and examples of 6-membered monocyclic heterocycles include pyridyl, pyrimidinyl, pyridazinyl, pyrazinyl and triazinyl, each of which may be optionally substituted with C 1-6 alkyl, C 1-6 alkoxy, C 3-6 alkynyl, C 3-6 alkynyl, halo, hydroxy, mercapto, trifluoromethyl, amino, cyano or mono or di(C 1-6 alkyl) amino. Examples of 9 and 10-membered bicyclic heterocycles include indolyl, benzofuranyl, benzothienyl, benzoxazolyl, benzothiazolyl, benzisoxazolyl, benzisothiazolyl, indazolyl, isoquinolinyl, quinolinyl, quinoxalinyl, cinnolinyl, phthalazinyl, quinazolinyl, benzotriazinyl and the like, each of which may be optionally substituted with C 1-6 alkyl, C 1-6 alkoxy, C 3-6 alkynyl, C 3-6 alkynyl, halo, hydroxy, mercapto, trifluoromethyl, amino, cyano or mono or di(C 1-6 alkyl) amino. Examples of preferred heterocyclic radicals include (optionally substituted) isoxazoles, isothiazoles, 1,3,4-oxadiazoles, 1,3,4-thiadiazoles, 1,2,4-oxadiazoles, 1,2,4-thiadiazoles, oxazoles, thiazoles, pyridines, pyridazines, pyrimidines, pyrazines, 1,2,4-triazines, 1,3,5-triazines, benzoxazoles, benzothiazoles, benzisoxazoles, benzisothiazoles, quinolines and quinoxalines. Particular examples of the group Het are radicals of formula (a-1) to (a-14) below:
[0027] wherein R 1 is hydrogen, C 1-6 alkyl, halo, hydroxy, mercapto, haloC 1-6 alkyl, amino, mono or di(C 1-6 alkyl)amino, cyano, formyl, C 1-6 alkoxy, hydroxyC 1-4 alkyl, C 1-4 alkoxyC 1-4 alkyl, C 1-6 haloalkoxy, aryloxy, C 1-6 alkylthio, arylthio, C 1-6 alkylsulphinyl, C 1-6 alkylsulphonyl, arylsulphinyl, arylsulphonyl, —CH═NO—C 1-4 alkyl, C 1-6 alkyloxycarbonyl, C 1-6 alkylcarbonyl or aryl;
[0028] R 2 and R 3 are each independently selected from hydrogen, C 1-6 alkyl,
[0029] C 1-6 alkoxy, halo or, in radicals (a-1), (a-4), (a-7) and (a-13), R 1 and R 2 , or R 2 and R 3 combined may represent a bivalent radical of formula —CH═CH—CH═CH— or (CH 2 ) p where p is an integer from 2 to 4;
[0030] Y is O or S; and
[0031] YN is O, S, SO or SO 2 .
[0032] The term “unsaturated five or six membered heterocyclic ring” as used herein for ring B refers to a 5 or 6 membered heterocyclic radical fused to the six-membered ring as depicted in Formula I. The ring includes one or more heteroatoms selected from N, S and O and will include 2 to 5 carbon atoms in addition to the heteroatom(s). Two of these carbon atoms are derived from the six-membered ring to which it is attached. The ring may be partially or fully saturated, and may be aromatic. The ring must contain at least one substituent selected from R 10 , OR 10 , SR 10 and NR 9 R 10 , where R 9 and R 10 are as defined above. Examples of unsaturated 5-membered heterocyclic rings include oxazole, thiazole, imidazole, 1,2,3-triazole, isoxazole, isothiazole, pyrazole, furan, thiophene and pyrrole, each of which in addition to the defined substituent may be optionally substituted with C 1-6 alkyl, C 1-6 alkoxy, C 3-6 alkenyl, C 3-6 alkynyl, halo, hydroxy, mercapto, trifluoromethyl, amino, cyano or mono or di(C 1-6 alkyl) amino. Examples of unsaturated 6-membered heterocyclic rings include pyridine, pyrimidine, pyrazine, pyridazine and 1,2,4-triazine, each of which in addition to the defined substituent may be optionally substituted with C 1-6 alkyl, C 1-6 alkoxy, C 3-6 alkenyl, C 3-6 alkynyl, halo, hydroxy, mercapto, trifluoromethyl, amino, cyano or mono or di(C 1-6 alkyl) amino. Particular examples of unsaturated five or six membered heterocyclic rings include radicals (c-1) to (c-11) below:
where Y is O, S or NR 9 ; and R 11 is R 10 , OR 10 , SR 10 or NR 9 R 10 , where R 9 and R 10 are as previously defined.
[0033] In some preferred embodiments of the invention one or more of the following definitions apply:
[0034] Het is a radical of formula (a-1), (a-2) or (a-8);
[0035] R 1 is hydrogen, methyl, ethyl, chloro, methoxy or trifluoromethyl;
[0036] R 2 and R 3 are each independently hydrogen, chloro or methyl;
[0037] Y is O or S;
[0038] A is O, NH, NMe, a bond, or a radical of formula (b-1);
[0039] Z is CH or N;
[0040] Alk is C 1-6 alkylene or a direct bond;
[0041] W is O;
[0042] X 1 , x 2 and X 3 are CH; and
[0043] B is (c-1) or (c-2).
[0044] As used herein, the term “C 1-6 alkyl” as used alone or as part of a group such as “di(C 1-6 alkyl)amino” refers to straight chain, branched or cyclic alkyl groups having from 1 to 6 carbon atoms. Examples of such alkyl groups include methyl, ethyl, n -propyl, isopropyl, n -butyl, cyclopentyl and cyclohexyl. Similarly, C 1-4 alkyl refers to such groups having from 1 to 4 carbon atoms.
[0045] As used herein, the term “halo” as used alone or as part of a group such as “C 3-6 halo alkenyl” refers to fluoro, chloro, bromo and iodo groups.
[0046] As used herein, the terms “C 1-6 alkoxy” and “C 1-6 alkyloxy” refer to straight chain or branched alkoxy groups having from 1 to 6 carbon atoms. Examples of C 1-6 alkoxy include methoxy, ethoxy, n -propoxy, isopropoxy, and the different butoxy isomers.
[0047] As used herein, the term “C 3-6 alkenyl” refers to groups formed from C 3-6 straight chain, branched or cyclic alkenes. Examples of C 3-6 alkenyl include allyl, 1-methylvinyl, butenyl, iso-butenyl, 3-methyl-2-butenyl, 1-pentenyl, cyclopentenyl, 1-methyl-cyclopentenyl, 1-hexenyl, 3-hexenyl, cyclohexenyl, 1,3-butadienyl, 1-4,pentadienyl, 1,3-cyclopentadienyl, 1,3-hexadienyl, 1,4-hexadienyl, 1,3-cyclohexadienyl and 1,4-cyclohexadienyl.
[0048] As used herein, the term “C 3-6 alkynyl” refers to groups formed from C 3-6 straight chain or branched groups as previously defined which contain a triple bond. Examples of C 3-6 alkynyl include 2,3-propynyl and 2,3- or 3,4-butynyl.
[0049] The term “optionally substituted” as used herein means that a group may include one or more substituents which do not interfere with the binding activity of the compound of formula I. In some instances the substituent may be selected to improve binding. Examples of optional substituents include halo, C 1-4 alkyl, C 2-4 alkenyl, C 2-4 alkynyl, C 1-4 alkoxy, haloC 1-4 alkyl, hydroxyC 1-4 alkyl, C 1-4 alkoxy, C 1-4 alkyl, hydroxy, aryl, amino, cyano, mercapto, C 1-4 alkylamino, C 1-4 dialkylamino, aryloxy, formyl, C 1-4 alkylcarbonyl and C 1-4 alkoxycarbonyl.
[0050] A particular group of compounds of the invention has the formula II:
wherein:
[0051] R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, mercapto, trifluoromethyl, amino, mono or
[0052] di(C 1-4 alkyl)amino, cyano, formyl, —CH═NO—C 1-4 alkyl, C 1-4 alkoxy, C 1-4 haloalkoxy, aryloxy, C 1-4 alkylthio, or aryl;
[0053] Y is O, S, NH or NMe;
[0054] Z is CH or N;
[0055] Alk is C 1-6 alkylene; and
[0056] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0057] Another particular set of compounds of the invention has the formula III:
wherein:
[0058] R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, mercapto, trifluoromethyl, amino, mono or di(C 1-4 alkyl)amino, cyano, formyl, —CH═NO—C 1-4 alkyl, C 1-4 alkoxy, C 1-4 haloalkoxy, aryloxy, C 1-4 alkylthio, or aryl;
[0059] Y is O, S, NH or NMe;
[0060] Z is CH or N;
[0061] Alk is C 1-6 alkylene; and
[0062] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0063] Another particular set of compounds of the invention has the formula IV:
wherein:
[0064] R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, mercapto, trifluoromethyl, amino, mono or di(C 1-4 alkyl)amino, cyano, formyl, —CH═NO—C 1-4 alkyl, C 1-4 alkoxy, C 1-4 alkoxyC 1-4 alkoxy, C 1 1-4 haloalkoxy, aryloxy, C 1-4 alkylthio, or aryl;
[0065] A is a bond or CH 2 O;
[0066] Y is O, S, NH or NMe;
[0067] Alk is C 1-7 alkylene;
[0068] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl; and
[0069] R 12 and R 13 are each independently hydrogen, halogen, C 1-4 alkyl or C 1-4 alkoxy.
[0070] A particular group of compounds of the invention has the formula V
wherein:
[0071] R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, mercapto, trifluoromethyl, amino, mono or di(C 1-4 alkyl)amino, cyano, formyl, —CH═NO—C 1-4 alkyl, C 1-4 alkoxy, C 1-4 haloalkoxy, aryloxy, C 1-4 alkylthio, or aryl;
[0072] Y is O, S, NH or NMe;
[0073] Z is CH or N;
[0074] Alk is C 1-6 alkylene; and
[0075] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0076] A particular group of compounds of the invention has the formula VI:
wherein:
[0077] R 1 is hydrogen, C 1-4 alkyl, halo, hydroxy, mercapto, trifluoromethyl, amino, mono or di(C 1-4 alkyl)amino, cyano, formyl, —CH═NO—C 1-4 alkyl, C 1-4 alkoxy, C 1-4 haloalkoxy, aryloxy, C 1-4 alkylthio, or aryl;
[0078] Y is O, S, NH or NMe;
[0079] Z is CH or N;
[0080] Alk is C 1-6 alkylene; and
[0081] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0082] A particular group of compounds of the invention has the formula VII
wherein:
[0083] Het is pyridyl, pyrazinyl, thiadiazolyl, benzoxazolyl, 1,3,5-triazinyl, pyrimidinyl or quinoxalinyl, each of which may be optionally substituted with 1 to 3 substituents selected from halo, trifluoromethyl, C 1-4 alkyl, C 1-4 alkoxy or hydroxy;
[0084] Y is O, S, NH or NMe;
[0085] Z is CH or N;
[0086] Alk is C 1-6 alkylene; and
[0087] R 11 is OR 10 or SR 10 where R 10 is C 1-4 alkyl.
[0088] A particular group of groups of the invention has the formula VIII:
wherein:
[0089] Het is pyridyl, pyrazinyl, thiadiazolyl, benzoxazolyl, 1,3,5-triazinyl, pyrimidinyl or quinoxalinyl, each of which may be optionally substituted with 1 to 3 substituents selected from halo, trifluoromethyl, C 1-4 alkyl, C 1-4 alkoxy or hydroxy;
[0090] Y is O, S, NH or NMe;
[0091] Z is CH or N;
[0092] Alk is C 1-6 alkylene; and
[0093] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0094] Another group of compounds of the invention has the formula IX
wherein:
[0095] Het is pyridyl, pyridazinyl, pyrazinyl, thiadiazolyl, benzoxazolyl, 1,2,4-triazinyl, 1,3,5-triazinyl, pyrimidinyl or quinoxalinyl, each of which may be optionally substituted with 1 to 3 substituents selected from halo, trifluoromethyl, C 1-4 alkyl, C 1-4 alkoxy or hydroxy;
[0096] A is a direct bond, O, NH or NMe;
[0097] Y is O, S, NH or NMe;
[0098] Alk is C 1-6 alkylene; and
[0099] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0100] Yet another group of compounds of the invention has the formula X:
wherein:
[0101] Het is pyridyl, pyridazinyl, pyrazinyl, thiadiazolyl, benzoxazolyl, 1,2,4-triazinyl, 1,3,5-triazinyl, pyrimidinyl or quinoxalinyl, each of which may be optionally substituted with 1 to 3 substituents selected from halo, trifluoromethyl, C 1-4 alkyl, C 1-4 alkoxy or hydroxy;
[0102] A is a direct bond, O, NH or NMe;
[0103] Y is O, S, NH or NMc;
[0104] Alk is C 1-6 alkylene; and
[0105] R 11 is OR 10 or SR 10 , where R 10 is C 1-4 alkyl.
[0106] Examples of specific compounds within the scope of the present invention are shown in Tables 1 and 5 below.
TABLE 1 Position of linkage to benz- Compd azole X Y- No. Heterocycle ring Group Substituent 1 6-Me-3-Pyridazinyl 6 O Methyl 2 6-Me-3-Pyridazinyl 5 O Methyl 3 6-Me-3-Pyridazinyl 6 O Ethyl 4 6-Me-3-Pyridazinyl 6 O Methylthio 5 6-Me-3-Pyridazinyl 6 O Ethoxy 6 6-Cl-3-Pyridazinyl 6 O Methylthio 7 6-Me-3-Pyridazinyl 6 O Ethylthio 8 6-Cl-3-Pyridazinyl 6 O Ethylthio 9 5-Methyl-1,3,4-Thiadiazolyl 6 O Ethylthio 10 5-Methyl-1,3,4-Thiadiazolyl 6 O Ethoxy 11 6-Me-3-Pyridazinyl 6 O n-Propoxy 12 6-Me-3-Pyridazinyl 6 O Methoxy 13 6-Cl-3-Pyridazinyl 6 O Ethoxy 14 6-Me-3-Pyridazinyl 6 S Methoxy 15 6-Me-3-Pyridazinyl 6 S Ethoxy 16 6-Me-3-Pyridazinyl 5/6 NMe Ethylthio 19 6-Me-3-Pyridazinyl 5 S Ethylthio 20 6-Me-3-Pyridazinyl 5 S n-Propoxy 21 6-Me-3-Pyridazinyl 5 S Ethoxy 22 6-Me-3-Pyridazinyl 5 O Ethylthio 23 6-Me-3-Pyridazinyl 5 O Ethoxy 24 6-Me-3-Pyridazinyl 6 S n- Propylamino 25 6-Me-3-Pyridazinyl 5 NH Ethylthio 26 6-Me-3-Pyridazinyl 6 O n-Butyl 27 6-Me-3-Pyridazinyl 6 O n-Propyl 28 5,6-Me2-3-Pyridazinyl 6 O Ethoxy 29 3-Me-1,2,4-Thiadiazol-5-yl 6 O Ethoxy 30 5,6-Me 2 -1,2,4-Triazin-3-yl 6 O Ethoxy 31 1-Me-Tetrazol-5-yl 6 O Ethoxy 32 6-Cl-5-Me-3-Pyridazinyl 6 O Ethoxy 33 5-Me-3-Pyridazinyl 6 O Ethoxy
[0107]
TABLE 2
Compound Number
Alkylene chain length n
Y Substituent
17
3
Ethylthio
18
3
Ethoxy
34
5
Ethoxy
[0108]
TABLE 3
Alkylene
Compound
R
chain
Number
Substituent
Group A
length n
Atom X
Group Y
35
Methyl
CH
2
O
Ethoxy
36
Methyl
CH
2
O
Ethyl
37
Chloro
CH
2
O
Ethoxy
38
Methyl
CH
2
O
n-Propoxy
39
Methyl
CH
2
O
n-Propyl
40
Methyl
CH
2
S
Ethoxy
41
Chloro
CH
3
O
Ethoxy
42
Methyl
N
2
O
Ethoxy
[0109]
TABLE 4
Compound Number
X Substituent
Y Substituent
43
Ethoxy
H
44
Chloro
Chloro
45
Ethoxy
Ethoxy
46
H
Ethoxy
[0110]
TABLE 5
Compound
Number
Structure
47
48
49
50
51
52
53
54
55
56
57
58
[0111] The compounds of the present invention may be prepared using methods analogous to those described in the prior art. For example, compounds in which the Het radical is of formula (a-1) may be prepared using methodology analogous to the processes described in U.S. Pat. Nos. 4,992,433, 5,112,825 and 5,100,893. Similarly, compounds in which Het is (a-2), (a-3), (a-4), (a-5) or (a-6) may be prepared using methodology similar to that described in U.S. Pat. No. 5,070,090 and Australian Patent No. 629172, and compounds in which Het is (a-7) or (a-8) may be prepared in accordance with methodology similar to that described in U.S. Pat. No. 5,364,865.
[0112] In one method the compounds of the present invention are prepared via an intermediate of formula XI:
where A, Alk, W, Ar, X 1 , X 2 , X 3 and B are as described above.
[0113] This intermediate may be prepared using methodology similar to that described in U.S. Pat. No. 5,231,184. In one example intermediates of formula XI, when W is O, are prepared by the reaction of compounds of the formula P-A-Alk-OH or P-A-Alk-L with hydroxy aromatic compounds of formula XII.
where Ar, X 1 , X 2 , X 3 and B are as defined above, P is H or a protecting group, and L is a leaving group. Removal of the protecting group P in the reaction product affords the reactive intermediates of formula XI.
[0114] Examples of suitable protecting groups P in compounds of formula P-A-Alk-OH or P-A-Alk-L include benzyl or acyl moieties which can be introduced and removed by standard methods (see, “Protective Groups in Organic Synthesis”, Theodora Green, Wiley Interscience, 1981).
[0115] The intermediate of formula XI may be reacted with a compound of formula Het-L, where Het is as defined above and L is a suitable leaving group to afford a compound of formula I. Where this reaction is an N-alkylation reaction, it can be conducted using procedures known to the art, such as under the conditions described in U.S. Pat. No. 5,231,184 for performing analogous N-alkylations. In performing the reaction described above it may be necessary to protect one or more substituents on groups such as X 1 , X 2 , X 3 or B.
[0116] Some of the intermediates of formula XI and XII are novel and represent a further aspect of the present invention.
[0117] Examples of suitable leaving groups include halogen, such as fluoro, chloro, bromo and iodo, and halogen-like groups such as p-toluenesulphonyloxy and methanesulphonyloxy.
[0118] An additional method of preparing certain compounds of the invention of formula Ia (Compounds for formula I where W=O) involves condensing a compound of formula XIII with a suitable precursor of formula XII:
using Mitsunobu Reaction conditions (see Chemical Syntheses, Vol. 42, p 335, 1992) and where Het, A, Alk, X 1 , X 2 , X 3 and B are as defined for formula I.
[0119] Intermediates of formula XII may often be prepared from protected forms of the hydroxy compound. For example compounds of formula XII wherein X 1 -X 3 are CH (hereinafter referred to as compounds of formula (XIIa)) can be made from the corresponding compounds which have an alkoxy or benzyloxy substituent which can be converted to OH by routine deprotection reagents including HBr or BBr 3 .
[0120] The chemical literature contains many references to the preparation of compounds of formula (XIIb) including, for example, U.S. Pat. No. 5,919,807 and J. Org. Chem., 61, 3289 (1996). Compounds of formula (XIIb) can generally be prepared from the corresponding compounds (XIIc), which have a leaving group L available for displacement by R 11 when R 11 is OR 10 , SR 10 or NR 9 R 10 . There are several references in the literature to the preparation of examples of compounds of general formula (XIIc), for example in U.S. Pat. Nos. 5,919,807 and 5,747,498 and J. Med. Chem., 24, 93 (1981).
[0121] Several references, including U.S. Pat. Nos. 5,112,825 and 5,242,924, describe methods for the preparation of various compounds of formula XIII.
[0122] The compounds of the present invention are useful in the prevention or treatment of picomoviral infections in mammals, particularly humans.
[0123] Accordingly, in a further aspect the invention provides a method for the treatment or prophylaxis of a picomaviral infection in a mammal including the step of administering an effective amount of a compound of formula I.
[0124] The picomavirus infection may be caused by any virus of the family Picornaviridae. Representative family members include human rhinoviruses, polioviruses, enteroviruses including coxsackieviruses and echoviruses, hepatovirus, cardioviruses, apthovirus, hepatitis A and other picornaviruses not yet assigned to a particular genus, including one or more of the serotypes of these viruses. Preferably the invention is used in the prevention or treatment of infection caused by one or more serotypes of rhinovirus.
[0125] Without wishing to be limited by theory, it is believed that the heteroatoms in the fused heterocyclic moiety of the compound of formula I may be involved in hydrogen bonding with an asparagine residue generally present near the opening of the hydrophobic pocket, and that this interaction enhances the binding of the compounds in the capsid pocket, relative to the prior art compounds. It is further believed that the fused heterocyclic moiety may be more resistant to hydrolysis and esterase activity than the ester bond of pirodavir, and that this may allow more flexibility in the methods of administration of the compound to the site of activity, than available for readily hydrolysable pirodavir. In particular it may allow oral administration of the compounds or reduce metabolism in the nasal mucosa following topical administration.
[0126] The salts of the compound of formula I are preferably pharmaceutically acceptable, but it will be appreciated that non-pharmaceutically acceptable salts also fall within the scope of the present invention, since these are useful as intermediates in the preparation of pharmaceutically acceptable salts. The pharmaceutically acceptable salts may include conventional non-toxic salts or quartenary ammonium salts of these compounds, which may be formed, e.g., from organic or inorganic acids or bases. Examples of such acid addition salts include, but are not limited to, those formed with pharmaceutically acceptable acids such as acetic, propionic, citric, lactic, methanesulphonic, toluenesulphonic, benzenesulphonic, salicyclic, ascorbic, hydrochloric, orthophosphoric, sulphuric and hydrobromic acids. Base salts includes, but is not limited to, those formed with pharmaceutically acceptable cations, such as sodium, potassium, lithium, calcium magnesium, ammonium and alkylammonium. Also, basic nitrogen-containing groups may be quaternised with such agents as lower alkyl halides, such as methyl, ethyl, propyl, and butyl chlorides, bromides and iodides; dialkyl sulfates like dimethyl and diethyl sulfate; and others.
[0127] The compounds of the invention may be in crystalline form or as solvates (e.g., hydrates) and it is intended that both forms are within the scope of the present invention. Methods of solvation are generally known within the art.
[0128] Pharmaceutically acceptable derivatives may include any pharmaceutically acceptable salt, hydrate or any other compound or prodrug which, upon administration to a subject, is capable of providing (directly or indirectly) a compound of formula I or an antivirally active metabolite or residue thereof.
[0129] Any compound that is a prodrug of a compound of formula I is within the scope and spirit of the invention. The term “pro-drug” is used in its broadest sense and encompasses those derivatives that are converted in vivo to the compounds of the invention. Such derivatives would readily occur to those skilled in the art, and include, for example, compounds where a free hydroxy group is converted into an ester derivative or a ring nitrogen atom is converted to an N-oxide. Examples of ester derivatives include alkyl esters, phosphate esters and those formed from amino acids, preferably valine.
[0130] It will be appreciated that some derivatives of the compound of formula I may have an asymmetric center, and therefore are capable of existing in more than one stereoisomeric form. The invention extends to each of these forms individually and to mixtures thereof, including racemates. The isomers may be separated conventionally by chromatographic methods or using a resolving agent. Alternatively the individual isomers may be prepared by asymmetric synthesis using chiral intermediates.
[0131] The invention also provides the use of a compound of formula I in the manufacture of a medicament for the treatment or prophylaxis of picornavirus infection.
[0132] While it is possible that, for use in therapy, a compound of the invention may be administered as the neat chemical, it is preferable to present the active ingredient as a pharmaceutical formulation.
[0133] In view of the general lipophilic nature of the compounds, they are particularly suitable to oral forms of administration; however, other forms of administration are also envisaged.
[0134] The invention thus further provides pharmaceutical formulations comprising a compound of the invention or a pharmaceutically acceptable salt or derivative thereof together with one or more pharmaceutically acceptable carriers therefor 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 deleterious to the recipient thereof.
[0135] The compounds of this invention may also be useful in combination with known anti-viral or anti-retroviral agents or other pharmaceuticals used in the treatment of viral infections. Representative examples of these additional pharmaceuticals include immunomodulators, immunostimulants, antibiotics and anti-inflammatory agents. Exemplary anti-viral agents include zanamivir, rimantidine, amantidine, ribavirin, AZT, 3TC, (−) FTC, acyclovir, famciclovir, penciclovir, ddI, ddC, ganciclovir, saquanivir, loviride, other non-nucleotide reverse transcriptase (RT) inhibitors and protease inhibitors, antiviral and antireceptor antibodies and receptor analogues, such as ICAM-1. Exemplary immunomodulators and immunostimulants include various interleukins, cytokines and antibody preparations. Exemplary antibiotics include antifungal agents and antibacterial agents. Exemplary anti-inflammatory agents include glucocorticoids and non-steroidal anti-inflammatory compounds.
[0136] Pharmaceutical formulations include those suitable for oral, rectal, nasal, topical (including buccal and sub-lingual), vaginal or parenteral (including intramuscular, subcutaneous and intravenous) administration or in a form suitable for administration by inhalation or insufflation. The compounds of the invention, together with a conventional adjuvant, carrier, or diluent, may thus be placed into the form of pharmaceutical compositions and unit dosages thereof, and in such form may be employed as solids, such as tablets or filled capsules, or liquids such as solutions, suspensions, emulsions, elixirs, or capsules filled with the same, all for oral use, in the form of suppositories for rectal administration; or in the form of sterile injectable solutions for parenteral (including subcutaneous) use. Such pharmaceutical compositions and unit dosage forms thereof may comprise conventional ingredients in conventional proportions, with or without additional active compounds or principles, and such unit dosage forms may contain any suitable effective amount of the active ingredient commensurate with the intended daily dosage range to be employed. Formulations containing ten (10) milligrams of active ingredient or, more broadly, 0.1 to two hundred (200) milligrams, per tablet, are accordingly suitable representative unit dosage forms. The compounds of the present invention can be administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise, as the active component, either a compound of the invention or a pharmaceutically acceptable salt of a compound of the invention.
[0137] For preparing pharmaceutical compositions from the compounds of the present invention, 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, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
[0138] In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
[0139] 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.
[0140] The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. 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.
[0141] For preparing suppositories, a low melting wax, such as admixture of fatty acid glycerides 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 molds, allowed to cool, and thereby to solidify.
[0142] Formulations 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.
[0143] Liquid form 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.
[0144] 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 formulatory agents such as suspending, stabilizing 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.
[0145] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents, as desired.
[0146] 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.
[0147] Also included are solid form preparations that 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, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0148] For topical administration to the epidermis, the compounds according to the invention may be formulated as ointments, creams or lotions, or as a transdermal patch. 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, stabilizing agents, dispersing agents, suspending agents, thickening agents, or coloring agents.
[0149] Formulations suitable for topical administration in the mouth include lozenges comprising the active agent in a flavored base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerin or sucrose and acacia; and mouthwashes comprising the active ingredient in a suitable liquid carrier.
[0150] Solutions or suspensions are applied directly to the nasal cavity by conventional means, for example with a dropper, pipette or spray. The formulations may be provided in single or multidose 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 atomizing spray pump. To improve nasal delivery and retention, the compounds according to the invention may be encapsulated with cyclodextrins, or formulated with their agents expected to enhance delivery and retention in the nasal mucosa.
[0151] Administration to the respiratory tract may also be achieved by means of an aerosol formulation in which the active ingredient is provided in a pressurized 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.
[0152] 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).
[0153] 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.
[0154] In formulations intended for administration to the respiratory tract, including intranasal formulations, the compound will generally have a small particle size, for example of the order of 1 to 10 microns or less. Such a particle size may be obtained by means known in the art, for example by micronization.
[0155] When desired, formulations adapted to give sustained release of the active ingredient may be employed.
[0156] 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 packeted 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.
[0157] Liquids or powders for intranasal administration, tablets or capsules for oral administration and liquids for intravenous administration are preferred compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0158] The invention will now be described with reference to the following examples which illustrate some preferred aspects of the present invention. However, it is to be understood that the particularity of the following description of the invention is not to supersede the generality of the preceding description of the invention.
EXAMPLES
Example 1
Preparation of 6-{2-[1-(6-Methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-2-methylthiobenzoxazole (Compound 4 from Table 1)
[0000] (a) Preparation of 2-mercapto-6-hydroxybenzoxazole (see also J. Org.Chem., 19, 758)
[0159] A mixture of aminoresorcinol hydrochloride (1.1 g), potassium ethyl xanthate (1.2 g) and potassium carbonate (1.0 g) was dissolved in ethanol/water (1:1, 20 ml) and (under an argon balloon) heated under reflux for 3 hours. The pale yellow solution was cooled to RT and then acetic acid (2 ml) was added to make the solution slightly acidic (gas evolution). A cream precipitate soon formed and the sealed flask was kept in the fridge overnight. The cream solid was collected by filtration and the damp product (0.9 g) was used immediately in the next step.
[0000] (b) Preparation of 6-hydroxy-2-methylthiobenzoxazole
[0160] A mixture of 6-hydroxy-2-mercaptobenzoxazole (165 mg), sodium bicarbonate (84 mg) and dimethyl sulfate (94 μl) was dissolved in water (2 ml) with stirring and under an argon atmosphere. The reaction mixture was stirred at RT overnight and HPLC showed that all starting material was gone. The reaction mixture was evaporated to dryness to give a dark brown solid (one can also extract the reaction mixture with chloroform to give the crude product). Chromatography on silica gel using 10% ethyl acetate/hexane gave the pure product as a near-white crystalline solid (45 mg, 25%).
[0000] (c) Preparation of 2-Methylthio-6-[N-(6-methyl-3-pyridazinyl)piperidinyl-4-ethoxy]benzoxazole (Compound 4)
[0161] A mixture of 6-hydroxy-2-methylthiobenzoxazole (100 mg), 3-[4-(2-chloroethyl)-1-piperidinyl]-6-methylpyridazine (130 mg) and potassium carbonate (100 mg) was heated and stirred in DMF (3 ml) at 90-100° under argon for 20 hr. Tlc showed that the reaction was virtually complete and the DMF was removed under reduced pressure and the residue was partitioned between water and chloroform. The chloroform extracts were evaporated and the residue was chromatographed on silica/chloroform to give the product as a pale cream solid (110 mg, 50%). The 1 H nmr spectrum is summarized in Table 6 below.
Example 2
Preparation of 2-Ethoxy-6-{2-[N-(6-methyl-3-pyridazinyl)piperidinyl]-4-ethoxy}benzoxazole (Compound No 5)
[0162] Sodium metal (100 mg) was dissolved in ethanol (5 ml) and the solution was added to a solution of the methylthiobenzoxazole (compound No. 4) (74 mg) in THF (2 ml). The resultant solution was stirred at RT for 24 hr when hplc indicated that all starting material had disappeared. The reaction mixture was evaporated to dryness and the residue was partitioned between water and dichloromethane. The crude organic product was purified by chromatography on silica/CH 2 Cl 2 to give Compound No. 5 as a pale cream solid (46 mg). The 1 H nmr and MS data are recorded in Table 6 below.
Example 3
[0163] Compounds No 1, 2, 3, 6, 7, 8, 9, 17, 19, 22, 25, 26, 27 were prepared by reacting the appropriate Het-A-Alk-Cl or Het-A-Alk-OH with the required 2-substituted 5- or 6-hydroxybenz-azole (benzoxazole, benzothiazole or benzimidazole) following similar conditions to those described in Example 1 part (c). The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 4
[0164] The 2-alkoxybenz-azole derivatives, Compounds No 10, 11, 12, 13, 14, 15, 18, 20, 21, 23 were prepared from the corresponding 2-methylthio or 2-ethylthiobenzoxazole or benzothiazole by reaction with the appropriate sodium alkoxide following essentially the same conditions as described in Example 2. The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 5
Preparation of a mixture of 2-Ethylthio-3-Methyl-6-{2-[N-(6-methyl-3-pyridazinyl)piperidinyl]-4-ethoxy}benzimidazole and 2-Ethylthio-3-Methyl-5-{2-[N -(6-methyl-3-pyridazinyl)piperidinyl]-4-ethoxy}benzimidazole (Compound No 16)
[0165] Methylation of 2-ethylthio-5-hydroxybenzimidazole gave an approximately 1:1 mixture of 2-ethylthio-3-methyl-5-hydroxybenzimidazole and 2-ethylthio-3-methyl-6-hydroxybenzimidazole which could not be easily separated. Reaction of this mixture of hydroxy compounds with 3-[4-(2-chloroethyl)-1-piperidinyl]-6-methylpyridazine, following the method described in Example 1, gave a 1:1 mixture of isomeric products (Compound No 16).
Example 6
Preparation of 6-{2-[1-(6-Methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-3-ethoxy-1,2-benzisoxazole (Compound 35 from Table 3)
[0000] (a) Preparation of 2-hydroxy-4-methoxybenzohydroxamic acid according to literature procedure Chem. Ber. 100, 954-960 (1967)
[0166] An hydroxylamine solution was prepared by addition of aqueous sodium hydroxide (393 mg, 9.82 mmol)/water (1.6 ml) to a stirred solution of hydroxylamine hydrochloride (292 mg, 4.21 mmol) in water (3.5 ml). Immediately slowly added a solution of methyl 2-hydroxy-4-methoxybenzoate (511 mg, 2.81 mmol) in 1,4-dioxane (1.5 ml). The resulting reaction mixture was stirred at room temperature for 18 hours, under an argon atmosphere. The reaction mixture was concentrated on a rotary evaporator to half the original volume, and the product precipitated by addition of concentrated hydrochloric acid, keeping flask cool in an ice bath. Filtered the suspension to give 2-hydroxy-4-methoxybenzohydroxamic acid (476 mg, 92%) as a pale brown solid.
[0167] 1 H nmr spectrum (CDCl 3 ) δ (ppm): 3.72 (s, 3H); 6.36 (m, 2H); 7.41 (d, 1H).
[0000] (b) Preparation of 3-hydroxy-6-methoxy-1,2-benzisoxazole
[0168] A solution of carbonyl diimidazole (1.07 g, 6.57 mmol) in anhydrous THF (8 ml) was added to a stirred boiling solution of the hydroxamic acid (602 mg, 3.29 mmol) in THF (6 ml). The resulting solution was heated at reflux for approx. 8-10 hours, then allowed to cool to room temperature and stirred overnight under an argon atmosphere. Thin layer chromatography (tlc) (silica; 1:1 hexane/ethyl acetate) showed minimal starting material and new non polar material. The solution was evaporated on a rotary evaporator to give an orange colored oil. Water (6 ml) was added, and contents cooled (ice bath) and acidified to pH 2 with concentrated hydrochloric acid. The crude, damp 3-hydroxy-6-methoxy-1,2-benzisoxazole precipitated as a cream orange solid (645 mg).
[0169] 1 H nmr spectrum (CDCl 3 ) δ (ppm): 3.82 (s, 3H); 6.73 (fd, 1H); 6.80 (dd, 1H); 7.52 (d, 1H). LCMS (ESI) 166 (M+1) +
[0000] (c) Preparation of 3-ethoxy-6-methoxy- 1,2-benzisoxazole
[0170] Benzisoxazole from part (b) (193 mg, 1.17 mmol), ethanol (75 μl, 1.29 mmol) and triphenylphosphine (460 mg, 1.75 mmol) were dissolved in anhydrous THF (4 ml) and cooled (0°). Diisopropylazodicarboxylate (345 μl, 1.75 mmol) was added slowly and after 10-15 min the reaction flask was removed from the ice bath and the reaction mixture was stirred at room temperature overnight under an argon atmosphere. The solution was evaporated to dryness and the residue pre-absorbed onto silica, and chromatographed on silica (19 g); eluent: hexane (300 ml), 10-30% ethyl acetate/hexane to give 3-ethoxy-6-methoxy-1,2-benzisoxazole (101 mg, 44%) as white crystals.
[0171] 1 H nmr spectrum (CDCl 3 ) δ (ppm): 1.50 (t, 3H); 3.87 (s, 3H); 4.47 (q, 2H); 6.86 (m, 2H), 7.47 (d, 1H). LCMS (ESI) 194 (M+1) +
[0000] (d) Preparation of 3-ethoxy-6-hydroxy-1,2-benzisoxazole
[0172] Boron tribromide (1.0M solution in dichloromethane; 1.39 ml, 1.39 mmol) was added to a stirred, −78° cooled solution of benzisoxazole from part (c) (179 mg, 928 μmol) in dichloromethane (4 ml) under an argon atmosphere. The reaction mixture was gradually warmed to room temperature over approx. 2 hours, and stirred overnight. Tlc (silica, 2:1 hexane/ethyl acetate) showed new polar material as well as unreacted starting material. The reaction was worked up by adding water (5 ml) and ice. The aqueous phase was neutralized by addition of saturated NaHCO 3 solution, and saturated with NaCl. The aqueous phase was extracted into dichloromethane (3×60 ml), then the organic extracts combined and washed with brine (10 ml) and dried (NaSO 4 ). The product was purified by chromatography on silica (18 g; eluent 2.5%, 5%, then 15% ethyl acetate/hexane). The first compound to elute was unreacted 3-ethoxy-6-methoxy-1,2-benzisoxazole, (46 mg), followed by 3-ethoxy-6-hydroxy-1,2-benzisoxazole 108 mg (65%).
[0173] 1 H nmr spectrum (CDCl 3 ) δ (ppm): 1.45 (t, 3H); 4.40 (q, 2H); 6.74 (m, 2H); 7.38 (m, 1H). LCMS (ESI) 180 (M+1) +
[0000] (e) Preparation of Compound 35
[0174] A mixture of 2-[-1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethanol (42 mg, 188 μmol), benzisoxazole from part (d) (28 mg, 156 μmol) and polymer-supported triphenylphosphine (145 mg, 234 μmol) in anhydrous THF (3 ml) was cooled (0°) and stirred under an argon atmosphere. Neat diisopropylazodicarboxylate (46 μml, 234 μmol) was added slowly and the reaction mixture was allowed to warm to room temperature and stir overnight. The reaction mixture was filtered, then pre-adsorbed onto silica and chromatographed on silica (approx. 5 g); using firstly 2:1 hexane/ethyl acetate as eluent, then gradually increased to 70% ethyl acetate/hexane to afford Compound 35 (44 mg; 73%) as a white powder. The 1 H nmr and MS data are recorded in Table 6 below.
Example 7
[0175] Compounds No 36, 37, 38, 39, 40, 41, 42, 49, 50, 56 and 57 were prepared by reacting the appropriate Het-A-Alk-Cl or Het-A-Alk-OH with the required 3-substituted 6-hydroxy-1,2-benzisoxazole (or 1,2-benzisothiazole) following similar conditions to those described in Example 6. The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 8
[0176] The n-propylaminobenzothiazole derivative, Compound No 24, was prepared from the corresponding 2-methoxy-benzothiazole (Compound 14) by heating with excess n-propylamine. The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 9
Preparation of 2-Ethoxy-6-{2-[N-(5,6-dimethyl-3-pyridazinyl)piperidinyl]-4-ethoxy}benzoxazole (Compound No 28)
[0000] (a) Preparation of 2-ethoxy-6-hydroxybenzoxazole
[0177] A mixture of equivalent amounts of 4-aminoresorcinol hydrochloride and anhydrous sodium acetate in anhydrous ethanol was stirred for 16 hours at room temperature with a slight excess of tetraethyl orthocarbonate to give 2-ethoxy-6-hydroxybenzoxazole in 60% yield.
[0178] (b) Reaction of 2-ethoxy-6-hydroxybenzoxazole with 2-[-1-(5,6-dimethyl-3-pyridazinyl)-4-piperidinyl]ethanol was carried out using a Mitsunobu coupling and similar conditions to those described in Example 6 part (e). The 1 H nmr and/or MS data for Compound 28 are recorded in Table 6 below.
Example 10
[0179] Compounds No 29, 30, 31, 32, 33, 34, 47 and 48 were prepared by reacting the appropriate Het-A-Alk-Cl or Het-A-Alk-OH with 2-ethoxy-6-hydroxybenzoxazole following similar conditions to those described in Example 1, part (c) or Example 6 part (e). The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 11
Preparation of 6-{2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-4-ethoxy-cinnoline (Compound 53 from Table 5)
[0000] (a) Preparation of 4-chloro-6-methoxycinnoline
[0180] 6-Methoxy-4-hydroxycinnoline (Osborn, A. R. and Schofield, K. J. Chem. Soc., 1955, 2100) was prepared from 2-amino-5-methoxyacetophenone by diazotisation.
[0181] Phosphorous oxychloride (5 ml) was added to a mix of dimethylaniline (157 mg, 1.3 mmol) and 6-methoxy-4-hydroxycinnoline (208 mg, 1.2 mmol). The reaction was heated at reflux for 15 min, then cooled and concentrated under vacuum. The residue was partitioned between chloroform (100 ml) and water (30 ml), then the organic layer was washed with brine and dried (Na 2 SO 4 ). Chromatography of the residue adsorbed onto silica gel (3 g) on silica gel (15 g) eluent CH 2 Cl 2 to 10% Ethylacetate/CH 2 Cl 2 gave 6-methoxy-4-chlorocinnoline (135 mg, 0.7 mmol) in 59% yield as white yellow solid. δ H (CDCl 3 )=4.03 (s, 3H); 7.28 (d, 1H); 7.51 (dd, 1H); 8.41 (d, 1H) and 9.22 (br s, 1H). MS (ESI) (M+H) + 195.
[0000] (b) Preparation of 4-chloro-6-hydroxycinnoline
[0182] A solution of 6-methoxy-4-chlorocinnoline (135 mg, 0.7 mmol) in toluene (7 ml) was added to a stirred suspension of aluminium trichloride (231 mg, 1.73 mmol) in toluene (7 ml) and the red brown suspension was refluxed for 1 hr. The solvent was removed under vacuum and the residue was partitioned between water (20 ml) and 10% ethanol/chloroform (2×100 ml). The organic layer was washed with brine and dried (Na 2 SO 4 ). Removal of the solvent under vacuum gave 6-hydroxy-4-chlorocinnoline (154 mg) as a single component by TLC (1:1 ethylacetate/hexanes). δ H (CD 3 OD)=7.33 (d, 1H); 7.56 (dd, 1H); 8.32 (d, 1H) and 9.15 (br s 1H). MS (ESI) (M+H) + 181.
[0000] (c) Preparation of 6-{2-[(1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy)}-4-chlorocinnoline
[0183] A solution of DIAD (42 mg, 0.21 mmol) in THF (0.4 ml) was added slowly to a suspension containing 6-hydroxy-4-chlorocinnoline (30 mg, 0.17 mmol), triphenylphosphine (65 mg, 0.25 mmol) and 1-(6-methyl-3-pyridazinyl)-4-(2-hydroxyethyl) -piperidine (40 mg, 0.18 mmol) in THF (5 ml) and the suspension cleared. The reaction was left to stir overnight, then the reaction was adsorbed onto silica (1.5 g) and chromatography on silica gel (8 g) eluent ethylacetate gave the product (50 mg, 0.13 mmol) in 72% yield. 1 H nmr δ H (CD 3 OD)=1.35 (m, 2H); 1.9 (m, 5H); 2.46 (s, 3H); 2.95 (m, 2H); 4.34 (m, 4H); 7.19 (d, 1H); 7.26 (d, 1H); 7.42 (d, 1H); 7.64 (dd, 1H); 8.34 (d 1H) and 9.24 (br s 1H). MS (ESI) (M+H) + 384.
[0000] (d) Preparation of Compound No 53
[0184] A solution of sodium ethoxide (0.3 mmol) in ethanol (0.15 ml) was added dropwise to a solution of the above (part c) 4-chlorocinnoline (23 mg, 60 μmol) in dry ethanol (3 ml) and the reaction was allowed to stir for 2 hr. The reaction was quenched with saturated ammonium chloride/brine (1 ml) and solvents removed under vacuum. The residue was partitioned between brine (5 ml) and 5% ethanol/ethylacetate (2×30 ml), dried (Na 2 SO 4 ) and adsorbed onto silica (1 g) under vacuum. Chromatography on silica gel (8 g) eluent 5% methanol/ethylacetate gave Compound No 53 (15 mg, 38 μmol) in 63% yield.
Example 12
Preparation of 7-{2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-4-ethoxy-cinnoline (Compound 52 from Table 5)
[0185] 4-Hydroxy-7-methoxy-cinnoline (Osborn, A. R. and Schofield, K. J. Chem. Soc. (1955) 2100) was prepared following a similar method to that described in Example 11 for the 6-isomer. This compound was converted to Compound 52 in a similar manner to that described in Example 11 for the 6-isomer. The 1 H nmr and MS data are recorded in Table 6 below
Example 13
Preparation of 7-{2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-4-ethoxy-quinazoline (Compound 51 from Table 5)
[0000] (a) Synthesis of 7-nitroquinazolin-4-one
[0186] A mixture of 4-nitroanthranilic acid (2.17 g, 11.91 mmol) and formamide (1.5 mL, 38.43 mmol) was heated at 165° C. for 4 hours. The warm reaction mixture was poured into ice/water (30 mL) and the resulting precipitate was collected via filtration, to give an orange solid (2.16 g, 95% yield) which was dried over P 2 O 5 . This was used without further purification.
[0187] 1 H nmr; 8.24 (d, 1H), 8.32 (s, 1H), 8.34 (s, 1H), 8.35 (d, 1H).
[0000] (b) Synthesis of 7-Aminoquinazolin-4-one
[0188] Pd/C (100 mg) was added as a single portion to a degassed and flushed (3×Ar) suspension of 7-nitroquinazolin-4-one (1.15 g, 6.02 mmol) in methanol(150 mL). The resulting black mixture was degassed, flushed with hydrogen and allowed to stir for 4 hours. The mixture was filtered through celite, washed well with methanol, and the filtrate concentrated to give a tanned solid. This was purified by column chromatography (silica) using 10% methanol/ethyl acetate as the eluent. Combined fractions gave a beige solid (949 mg, 98% yield).
[0189] 1 H nmr; 6.68 (s, 1H), 6.87 (d, 1H), 7.73 (d, 1H), 7.83 (s, 1H), 11.40 (bs, 1H).
[0000] (c) Synthesis of 7-Hydroxyquinazolin-4-one
[0190] A solution of sodium nitrite (1.40 g, 20.32 mmol) in water (17 mL) was added dropwise to a cooled suspension of 7-aminoquinazolin-4-one (712 mg, 4.42 mmol) in sulfuric acid/water (4.4 mL, 18 mL), keeping the temperature at approx. 0° C. The mixture was stirred at room temperature for 2 hours, diluted with water (15 mL) and heated at reflux for 15 minutes. The cooled mixture was neutralized and the precipitate was collected via filtration, and purified by column chromatography (silica) using 10% methanol/ethyl acetate as the eluent. The combined fractions gave an orange solid (541 mg, 76%).
[0191] 1 H nmr; 6.85-6.91 (m, 2H), 7.87 (s, 1H), 7.92 (s, 1H).
[0000] (d) Synthesis of 7-Hydroxy-4-ethoxyquinazoline
[0192] A mixture of 7-hydroxyquinazolin-4-one (105 mg, 648 μmol), phosphorous oxychloride (2 ml), and dimethylaniline (85 μl, 671 μmol) was heated at reflux for 15 minutes in an argon atmosphere. The cooled mixture was concentrated under vacuum, and kept in an argon atmosphere to avoid hydrolysis. This residue was dissolved in ethanol (anhydrous, 3 mL), and a solution of sodium (283 mg, 12.34 mmol) in ethanol (3 ml) was added dropwise. The resulting yellow mixture was stirred at room temperature under argon for 2 hours, acidified to pH 6 using NaH 2 PO 4 and extracted with ethyl acetate (3×50 mL). The combined extracts were dried (MgSO 4 ), filtered and concentrated. The white solid (156 mg) was used without further purification.
[0193] 1 H nmr; 1.49 (t, 3H), 4.78 (q, 2H), 7.26 (d, 1H), 7.43 (s, 1H), 8.11 (d, 1H), 8.83 (s, 1H).
[0000] (e) Preparation of Compound No. 51
[0194] A mixture of 3-[4-(2-chloroethyl)-1-piperidinyl]-6-methyl pyridazine (76 mg, 318 μmol), 7-hydroxy-4-ethoxyquinazoline (100 mg, 526 μmol), potassium carbonate (109 mg, 789 μmol) and potassium iodide (53 mg, 319 μmol) in DMF (5 mL) was heated at 90° C. overnight in an argon atmosphere. The mixture was concentrated, and the residue partitioned between ethyl acetate (100 mL), and water (20 mL). The organic phase was dried (MgSO 4 ), filtered, concentrated and purified by column chromatography (silica), using gradient elution (ethyl acetate—methanol/EA). The combined fractions gave a white solid (22 mg, 18%). The 1 H nmr data are recorded in Table 6 below.
Example 14
[0195] Compounds No 54 and 55 were prepared by reacting 3-[4-(2-chloroethyl)-1-piperidinyl]-6-methyl pyridazine with the appropriate 6-hydroxyquinazoline following similar conditions to those described in Example 13, part (e). The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 15
Preparation of 6-{2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-2-ethoxy-cluinoxaline (Compound 43 from Table 4)
[0000] (a) Preparation of 2-chloro-6-hydroxyquinoxaline
[0196] Aluminium trichloride (85 mg, 638 μmol) was added as a single portion to a stirred mixture of 2-chloro-6-methoxyquinoxaline (73 mg, 375 μmol) and anhydrous toluene (3 ml) under an Argon atmosphere. The reaction mixture was heated at reflux for approx. 1 hr, then allowed to stir overnight at room temperature. Tlc (silica; 2:1 hexane/ethyl acetate) showed no remaining starting material and new polar material. Water (1 ml) and ice were added and the mixture stirred. The contents were partitioned between water (5 ml) and ethyl acetate (100 ml). The aqueous phase was extracted into ethyl acetate (50 ml), then the organic extracts combined and washed with water (10 ml), followed by brine (10 ml) and dried (Na 2 SO 4 ). Concentration gave a brown solid, which was pre-adsorbed onto silica, then chromatographed on silica (9 g); eluent: 20% ethyl acetate in hexane then 25% ethyl acetate in hexane to give 2-chloro-6-hydroxyquinoxaline 54 mg (79%).
[0000] (b) Preparation of 2-chloro-6- {2-[1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethoxy}-quinoxaline
[0197] A mixture of 2-chloro-6-hydroxyquinoxaline (52 mg, 288 μmol), 3-[-4-(2-chloroethyl)-1-piperidinyl]-6-methyl pyridazine (76 mg, 317 μmol), potassium iodide (53 mg, 317 μmol) and potassium carbonate (199 mg, 1.44 mmol) in anhydrous dimethylformamide (2 ml) was heated at 90° under an Argon atmosphere for 2 days. Tlc (silica;ethyl acetate) showed new polar material. Removal of the solvent under high vacuum and then chromatography on silica (5 g; eluent: 30% hexane in ethyl acetate) gave the product as a white solid 68 mg (61%).
[0000] (c) Preparation of Compound 43
[0198] Sodium (78 mg, 3.39 mmol) was added portionwise to anhydrous ethanol (2 ml). The resulting sodium ethoxide solution was added to a stirred solution of the chloroquinoxaline from part (b) (65 mg, 169 μmol) in anhydrous tetrahydrofuran (2 ml) under an Argon atmosphere. The reaction mixture was heated at reflux for several hours then allowed to stir at room temperature overnight. The reaction mixture was quenched with saturated ammonium chloride solution (1 ml), then the contents partitioned between water (3 ml) and dichloromethane (50 ml). The aqueous phase was extracted into dichloromethane (50 ml), the organic extracts combined and washed with brine then dried (Na 2 SO 4 ). The crude product was pre-adsorbed onto silica then chromatographed on silica (11 g; eluent 2:1 ethyl acetate/hexane) to give Compound 43 as a white solid (57 mg 86%).
Example 16
[0199] Compounds No 44, 45 and 46 were prepared by reacting 3-[4-(2-chloroethyl)-1-piperidinyl]-6-methyl pyridazine or 2-[-1-(6-methyl-3-pyridazinyl)-4-piperidinyl]ethanol with the appropriate 6-hydroxyquinoxaline following similar conditions to those described in earlier examples. The 1 H nmr and/or MS data are recorded in Table 6 below.
Example 17
[0200] The compounds of the invention which are listed in Tables 1 to 5 were generally purified by chromatography on silica gel and were isolated as solids and characterised by 1 H nmr and mass spectroscopy. For convenience, the nmr and ms data are recorded in Table 6 below.
TABLE 6 Compound MS data NMR data: Proton Chemical Shift d in ppm No. (ESI) (CDCl 3 unless otherwise noted) 19 415 1.35 (m, 1H), 1.49 (t, 3H), 1.80-1.90 (m, 6H), (M + 1) + 2.64 (s, 3H), 2.99 (m, 2H), 3.34 (q, 2H), 4.10 (t, 2H), 4.37 (m, 2H), 6.93 (dd, 1H), 7.05 (d, 1H), 7.21 (d, 1H), 7.38 (s, 1H), 7.59 (d, 1H). 20 413 1.05 (t, 3H), 1.33 (m, 1H), 1.88 (m, 8H), 2.79 (M + 1) + (s, 3H), 3.10 (m, 2H), 4.07 (t, 2H), 4.40 (m, 2H), 4.50 (t, 2H), 6.84 (dd, 1H), 7.22 (s, 1H), 7.25 (d, 1H), 7.42 (d, 1H), 7.48 (m, 1H) 21 399 1.33 (m, 1H), 1.48 (t, 3H), 1.79 (m, 2H), 1.92 (M + 1) + (m, 4H), 2.73 (s, 3H), 3.04 (m, 2H), 4.07 (t, 2H), 4.39 (m, 2H), 4.60 (q, 2H), 6.84 (dd, 1H), 7.22 (s, 1H), 7.25 (d, 1H), 7.36 (d, 1H), 7.48 (d, 1H) 22 Not 1.35 (m, 1H), 1.49 (t, 3H), 1.80-1.90 (m, 6H), recorded 2.58 (s, 3H), 2.99 (m, 2H), 3.32 (q, 2H), 4.05 (t, 2H), 4.37 (m, 2H), 6.85 (dd, 1H), 6.95 (d, 1H), 7.1 (m, 2H), 7.35 (d, 1H). 23 Not 1.35 (m, 1H), 1.53 (t, 3H), 1.80-1.90 (m, 6H), recorded 2.58 (s, 3H), 2.99 (m, 2H), 4.05 (t, 2H), 4.37 (m, 2H), 4.60 (q, 2H), 6.76 (dd, 1H), 6.95 (d, 1H), 7.0-7.1 (m, 2H), 7.15-7.25 (m, 2H). 24 412 1.01 (t, 3H), 1.35 (m, 3H), 1.68-1.88 (m, 6H), (M + 1) + 2.54 (s, 3H), 2.92 (m, 2H), 3.37 (t, 2H), 4.02 (t, 2H), 4.33 (m, 2H), 6.87-6.92 (m, 2H), 7.08 (d, 1H), 7.12 (s, 1H), 7.42 (d, 1H) 25 398 1.31 (m, 1H), 1.39-1.42 (2x t, 3H), 1.68-1.85 (M + 1) + (m, 6H), 2.52 (s, 3H), 2.90 (m, 2H), 3.27-3.43 (2 x q, 2H), 4.02-4.14 (m, 2H), 4.25 (m, 2H), 6.75-6.85 (m, 1-2H), 6.95-7.21 (m, 3H) 26 Not 0.98 (t, 3H); 1.25-1.55 (m, 3H), 1.80-1.95 recorded (m, 6H), 2.61 (s, 3H), 2.85-3.0 (m, 4H), 4.06 (t, 2H), 4.37 (m, 2H), 6.88 (dd, 1H), 6.95-7.05 (m, 2H), 7.17 (d, 1H), 7.54 (d, 1H) 27 Not 1.06 (t, 3H); 1.35 (m, 1H), 1.80-1.95 (m, 8H), recorded 2.61 (s, 3H), 2.85-3.0 (m, 4H), 4.06 (t, 2H), 4.37 (m, 2H), 6.88-6.94 (m, 2H), 7.03 (d, 1H), 7.10 (d, 1H), 7.54 (d, 1H) 28 Not 1.25-1.35 (m, 2H), 1.50 (t, 3H), 1.73-1.88 (m, recorded 5H), 2.23 (s, 3H), 2.54 (s, 3H), 2.90 (t, 2H), 4.03 (t, 2H), 4.32-4.37 (m, 2H), 4.58 (q, 2H), 6.78-6.83 (m, 2H), 6.93 (fd, 1H), 7.32 (d, 1H) 29 Not 1.25-1.27 (m, 2H), 1.39 (t, 3H), 1.76-1.91 recorded (m, 5H), 2.42 (s, 3H), 3.18 (t, 2H), 3.89-3.93 (m, 2H), 4.01 (t, 2H), 4.57 (q, 2H), 6.82 (dd, 1H), 6.92 (fd, 1H), 7.33 (d, 1H) 30 398 1.24-1.29 (m, 2H), 1.49 (t, 3H), 1.75-1.86 (M + 1) + (m, 5H), 2.33 (s, 3H), 2.46 (s, 3H), 2.92 (t, 2H), 4.03 (t, 2H), 4.58 (q, 2H), 4.78-4.83 (m, 2H), 6.81 (dd, 1H), 6.92 (fd, 1H), 7.33 (d, 1H) 31 373 1.46-1.52 (m, 5H), 1.78-1.90 (m, 5H), 3.03 (M + 1) + (t, 2H), 3.55-3.59 (m, 2H), 3.85 (s, 3H), 4.03 (t, 2H), 4.50 (q, 2H), 6.79 (dd, 1H), 6.91 (bd, 1H), 7.32 (d, 1H) 32 Not 1.39-1.43 (m, 2H), 1.50 (t, 3H), 1.77-2.00 recorded (m, 5H), 2.36 (s, 3H), 3.08-3.14 (m, 2H), 4.01 (t, 2H), 4.45-4.49 (m, 2H), 4.57 (q, 2H), 6.79 (dd, 1H), 6.91 (bd, 1H), 6.98 (s, 1H), 7.35 (d, 1H) 33 Not 1.27-1.34 (m, 2H), 1.51 (s, 3H), 1.73-1.88 recorded (m, 5H), 2.24 (s, 3H), 2.94 (t, 2H), 4.02 (t, 2H), 4.37-4.42 (m, 2H), 4.58 (q, 2H), 6.72 (bs, 1H), 6.83 (dd, 1H), 6.91 (fd, 1H), 7.33 (d, 1H), 8.39 (bs, 1H). 34 Not 1.45-1.55 (m, 5H), 1.69-1.82 (m, 4H), 2.23 recorded (s, 3H), 2.72 (t, 2H), 3.93 (t, 2H), 4.57 (q, 2H), 5.79 (s, 1H), 6.77 (dd, 1H), 6.89 (fd, 1H), 7.31 (d, 1H) 35 383 1.34 (m, 1H); 1.50 (t, 3H); 1.80-1.95 (m, 6H); (M + 1) + 2.74 (s, 3H); 3.05 (m, 2H); 4.08 (t, 2H); 4.40 (m, 2H); 4.46 (q, 2H); 6.85 (m, 2H); 7.24 (bd, 1H); 7.37 (bd, 1H); 7.47 (d, 1H) 36 367 1.34 (m, 2H), 1.43 (t, 3H), 1.82-1.94 (m, 5H), (M + 1) + 2.74 (s, 3H), 2.96 (q, 2H), 3.05 (m, 2H), 4.10 (t, 2H), 4.40 (m, 2H), 6.89 (dd, 1H), 6.97 (fd, 1H), 7.22 (d, 1H), 7.35 (d, 1H), 7.50 (d, 1H) 37 403 1.37 (m, 1H), 1.50 (t, 3H), 1.91 (m, 4H), 3.03 (M + 1) + (bt, 2H), 4.08 (t, 2H), 4.39 (bd, 2H), 4.46 (q, 2H), 6.82-6.86 (m, 2H), 6.97 (bd, 1H), 7.21 (bd, 1H), 7.47 (d, 1H) 38 397 1.06 (t, 3H), 1.34 (m, 3H), 1.81-1.97 (m, 6H), (M + 1) + 2.72 (s, 3H), 3.12 (m, 2H), 4.08 (t, 2H), 4.36 (t, 2H), 6.84 (m, 2H), 7.24 (m, 1H), 7.41-7.49 (m, 2H) 39 381 1.03 (t, 3H), 1.35 (m, 2H), 1.81-1.94 (m, 7H), (M + 1) + 2.69 (s, 3H), 2.90 (t, 2H), 3.03 (t, 2H), 4.10 (t, 2H), 4.36 (m, 2H), 6.89 (bd, 1H), 6.96 (s, 1H), 7.14 (bd, 1H), 7.29 (bd, 1H), 7.49 (bd, 1H) 40 399 1.36 (m, 2H), 1.48 (t, 3H), 1.79-1.91 (m, 5H), (M + 1) + 2.60 (s, 3H), 2.97 (dt, 2H), 4.11 (t, 2H), 4.36 (m, 2H), 4.56 (q, 2H), 6.95 (dd, 1H), 6.99 (bd, 1H), 7.14 (fd, 1H), 7.16 (bd, 1H), 7.76 (bd, 1H) 41 Not 1.30-1.34 (m, 2H), 1.48 (t, 3H), 1.60-1.70 (m, recorded 1H), 1.84-1.91 (m, 4H), 3.04 (t, 2H), 4.01 (t, 2H), 4.39-4.49 (m, 4H), 6.82-6.86 (m, 2H), 6.99 (d, 1H), 7.23 (d, 1H), 7.47 (d, 1H) 42 384 1.43 (t, 3H), 2.46 (s, 3H), 2.76 (t, 4H), 2.93 (M + 1) + (t, 2H), 3.62 (t, 4H), 4.18 (t, 2H), 4.38 (q, 2H), 6.8 (m, 2H), 6.89 (d, 1H), 7.09 (d, 1H), 7.42 (d, 1H) 43 Not 1.37 (m, 1H), 1.46 (t, 3H), 1.85-1.92 (m, 6H), recorded 2.66 (s, 3H), 3.01 (t, 2H), 4.16 (t, 2H), 4.38 (m, 2H), 4.51 (q, 2H), 7.08 (bd, 1H), 7.22-7.26 (m, 1H), 7.32 (m, 1H), 7.34 (fd, 1H), 7.72 (d, 1H), 8.40 (s, 1H) 44 418 1.37 (m, 1H), 1.86-1.96 (m, 6H), 2.74 (s, 3H), (M + 1) + 3.06 (t, 2H), 4.19 (t, 2H), 4.41 (m, 2H), 7.22 (bd, 1H), 7.29 (fd, 1H), 7.35 (bd, 1H), 7.43 (dd, 1H), 7.91 (d, 1H) 45 Not 1.36 (m, 1H), 1.50 (2 x t, 6H), 1.80-1.94 (m, recorded 6H), 2.68 (s, 3H), 3.02 (m, 2H), 4.13 (t, 2H), 4.38 (m, 2H), 4.59 (2 x q, 4H), 7.09 (dd, 1H), 7.11-7.15 (m, 1H), 7.15 (fd, 1H), 7.27 (bd, 1H), 7.62 (d, 1H) 46 394 1.37 (m, 2H), 1.47 (t, 3H), 1.82-1.95 (m, 5H), (M + 1) + 2.69 (s, 3H), 3.03 (m, 2H), 4.18 (t, 2H), 4.39 (m, 2H), 4.52 (q, 2H), 7.13 (bd, 1H), 7.15 (s, 1H), 7.15-7.19 (m, 1H), 7.27 (bd, 1H), 7.87 (d, 1H), 8.29 (s, 1H) 47 Not 1.50 (t, 3H), 1.55-1.89 (m, 5H), 2.99 (t, 2H), recorded 3.96 (t, 3H), 4.35-4.39 (m, 2H), 4.56 (q, 2H), 6.79 (dd, 1H), 6.91-6.96 (m, 2H), 7.21 (d, 1H), 7.35 (d, 1H) 48 384 1.49 (t, 3H), 2.54 (s, 3H), 2.81 (m, 4H), 2.95 (M + 1) + (t, 2H), 3.71 (m, 4H), 4.21 (t, 2H), 4.58 (q, 2H), 6.84 (dd, 1H), 6.86 (d, 1H), 6.95 (fd, 1H), 7.09 (bd, 1H), 7.34 (bd, 1H) 49 Not 1.46-1.57 (m, 5H), 1.73-1.85 (m, 4H), 2.25 recorded (s, 3H), 2.73 (t, 2H), 3.99 (t, 2H), 4.45 (q, 2H), 5.80 (s, 1H), 6.81-6.84 (m, 2H), 7.43 (d, 1H). 50 Not 1.42-1.44 (m, 2H), 1.49 (t, 3H), 1.79-1.86 recorded (m, 5H), 2.56 (s, 3H), 3.08-3.15 (m, 2H), 3.91-3.94 (m, 2H), 4.06 (t, 2H), 4.45 (q, 2H), 6.82-6.85 (m, 2H), 7.45 (d, 1H) 51 Not 1.22-1.37 (m, 2H), 1.48 (t, 3H), 1.51-1.88 recorded (m, 3H), 2.53 (s, 3H), 2.93 (t, 2H), 4.14 (t, 2H), 4.31-4.35 (m, 2H), 4.59 (q, 2H), 6.88 (d, 1H), 7.06 (d, 1H), 7.13 (d, 1H), 7.22 (d, 1H), 8.04 (d, 1H), 8.69 (s, 1H) 52 394 (CD 3 OD) 1.4 (m, 2H); 1.62 (t, 3H); 1.93 (m, (M + H) − 5H); 2.51 (s, 3H); 2.99 (m, 2H); 4.35 (m, 4H); 4.52 (q, 2H); 7.24 (d, 1H); 7.31 (d, 1H); 7.47 (dd, 1H); 7.64 (d, 1H); 8.19 (d, 1H) and 8.99 (br s 1H) 53 394 (CD 3 OD) 1.3 (m, 2H); 1.62 (t, 3H); 1.93 (m, (M + H) − 5H); 2.51 (s, 3H); 2.99 (m, 2H); 4.32 (m, 2H); 4.38 (m, 2H); 4.52 (q, 2H); 7.23 (d, 1H); 7.31 (d, 1H); 7.47 (d, 1H); 7.58 (dd, 1H); 8.27 (d, 1H) and 8.95 (br s 1H) 54 Not 1.31-1.43 (m, 2H), 1.52 (t, 3H), 1.82-1.91 (m, recorded 3H), 2.55 (s, 3H), 2.95 (t, 2H), 4.16 (t, 2H), 4.32-4.37 (m, 2H), 4.65 (q, 2H), 6.87-6.93 (m, 1H), 7.05-7.11 (m, 1H), 7.39 (s, 1H), 7.45 (d, 1H), 7.84 (d, 1H), 8.67 (s, 1H) 55 Not 1.29-1.33 (m, 2H), 1.42-1.53 (m, 6H), 1.78- recorded 1.89 (m, 5H), 2.52 (s, 3H), 2.93 (t, 2H), 4.08- 4.14 (m, 2H), 4.31-4.35 (m, 2H), 4.44 (q, 2H), 4.63 (q, 2H), 6.89 (d, 1H), 7.06 (d, 1H), 7.32- 7.37 (m, 2H), 7.58 (d, 1H) 56 384 1.34-1.38 (m, 2H), 1.36 (t, 3H), 1.79-1.89 (M + 1) + (m, 5H), 2.59 (s, 3H), 2.96 (dt, 2H), 4.02 (q, 2H), 4.08 (t, 2H), 4.36 (m, 2H), 6.64 (fd, 1H), 6.81 (dd, 1H), 6.98 (bd, 1H), 7.15 (bd, 1H), 7.67 (d, 1H) 57 397 0.98 (t, 3H), 1.35 (m, 2H), 1.78-1.96 (m, 7H), (M + 1) + 2.78 (s, 3H), 3.08 (t, 2H), 3.95 (t, 2H), 4.09 (t, 2H), 4.41 (m, 2H), 6.64 (fd, 1H), 6.81 (dd, 1H), 7.50 (bd, 1H), 7.41 (bd, 1H), 7.69 (d, 1H) 58 Not 0.96 (t, 3H), 1.4 (m, 3H), 1.68-1.88 (m, 6H), recorded 2.11 (q, 2H), 2.52 (s, 3H), 2.92 (m, 2H), 4.06 (t, 2H), 4.33 (m, 2H), 4.60 (t, 2H), 6.86 (d, 1H), 7.0-7.1 (m, 3H), 7.08 (d, 1H), 7.70 (d, 1H)
Example 18
Anti-HRV activity in mammalian cell culture assays Inhibition of viral cytopathic effect (CPE) and measurement of cytotoxicity
[0201] The ability of compounds to suppress virus replication and thereby protect cells from HRV-induced CPE was measured using human embryo lung (MRC-5cells infected with HRV type 1A. Cells grown in 96 well tissue culture plates using conventional mammalian tissue culture medium (such as minimum essential medium) supplemented with fetal calf serum were used in an assay essentially similar to that described by Sidwell and Huffman ( Applied Microbiology, 22, 797-801 (1971)). Test compounds were dissolved in 100% anhydrous dimethyl sulfoxide and serially diluted in tissue culture medium. The antiviral potency of the test compounds was assessed by exposing replicate tissue culture wells to a selected dilution series of between 6 and 7 compound concentrations in the presence of sufficient test virus to invoke significant CPE over the course of the assay. Control cells were also exposed to identical concentrations of compounds in the absence of virus or were infected with virus under the same conditions but in the absence of compounds. Compounds of established anti-HRV efficacy (enviroxime, ribavirin and pirodavir) were assayed by identical procedures in parallel to the test compounds. Tissue culture media were identically supplemented to maintain cell viability and support viral growth while suppressing bacterial growth over the period of the assay (supplements: 2% fetal calf serum, 0.01% sodium bicarbonate, 50 μg/ml gentamicin, 5 μM magnesium chloride, 10 mM of zinc chloride). The assays were incubated at 37° C. in a 5% CO 2 atmosphere until significant CPE was observed by microscopic examination of the untreated, HRV infected control cells (generally between 5 and 8 days). At this time all infected cultures were examined by eye using a light microscope and CPE scored on a scale of 0 (no CPE) to 4 (maximum CPE). Uninfected treated cultures were similarly scored for cytotoxic effects (e.g., cell enlargement, granularity, rounding, detachment). These scores were used to generate EC 50 (concentration of compound yielding 50% antiviral efficacy) and CC 50 (concentration of compound yielding 50% cytotoxicity) values by line regression analysis from plots of compound concentration versus % CPE or % cytotoxicity, respectively. As an alternative to a CC 50 value, cytoxicity in some cases was expressed as the Minimum Toxic Concentration (MTC). The MTC corresponds to the lowest compound concentration at which cytotoxic effects were observed.
[0202] In some cases the visual scoring system described above was validated by vital dye staining to measure cell viability. The vital dye technique used was a modification of the method described by McManus ( Appl. Environment. Microbiol, 31, 35-38, 1976). After the assay had been scored by eye with the aid of a microscope, 100 μl of neutral red (NR) solution (0.34% NR in phosphate buffered saline (PBS)) was added to each well and mixed gently. The assays were returned to the 37° C. incubator for 2 hours to facilitate uptake of the NR by viable cells. The medium/NR mixture was then aspirated from the surface of the cells, which were washed twice with PBS. 0.25 ml of absolute ethanol containing Sorensen's citrate buffer I, was added with gentle mixing and the assays incubated at room temperature in the dark for 30 minutes to dissolve the NR. NR staining of viable cells was then quantified spectrophotometrically by measuring the color density of the NR solution using a BioTek EL-309 microplate reader at dual wavelengths of 540 and 405 nm. The differences in the two readings were automatically determined to eliminate background errors. EC 50 and CC 50 values were determined by regression analysis matching compound concentration to NR staining.
[0203] The results are shown in the Tables 7 and 8 below. Selectivity indices (SI) are the CC 50 or MTC divided by the EC 50 . Tables 7 and 8 also show IC 50 data for the testing of the compounds of the invention against HRV strains 2 and 14. These results were obtained using a similar CPE method to that described above for HRV1A.
TABLE 7 IC 50 (μg/ml) IC 50 (μg/ml) Compound No HRV1A CC 50 HRV2 HRV14 1 0.179 >1 >0.50 >0.50 2 0.120 >1 >0.50 >0.50 3 0.060 >1 0.144 0.130 4 0.006 >1 0.099 0.047 5 0.003 0.007 6 0.067 0.146 7 0.002 0.006 8 0.008 0.020 9 0.061 0.056 10 0.065 0.056 11 0.002 0.020 12 0.159 0.099 13 0.004 0.015 14 0.024 0.006 15 0.007 0.006
[0204]
TABLE 8
IC 50 (μg/ml)
Compound No
HRV2
HRV14
16
0.10
0.169
19
0.165
0.049
20
0.166
0.041
21
0.104
0.014
22
0.004
0.050
23
0.045
—
24
0.131
>0.250
26
0.130
0.082
27
0.075
0.028
28
0.101
0.040
30
>0.250
0.198
31
0.237
>0.250
32
0.012
0.039
33
0.167
0.166
34
0.209
0.118
35
0.001
0.005
36
0.024
0.088
37
0.003
0.019
38
0.003
0.029
39
0.084
0.013
40
0.003
0.029
41
0.003
0.009
43
0.012
0.012
46
0.084
0.013
47
0.004
0.010
48
0.069
0.011
49
0.035
0.012
50
0.007
0.005
51
0.027
0.120
52
0.190
0.200
56
0.246
>0.250
57
0.133
0.237
58
0.032
0.139
[0205] Throughout this specification and the claims that follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
[0206] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications. The invention also includes all of the steps, features, compositions and compounds referred to or indicated in this specification, individually or collectively, and any and all combinations of any two or more of said steps or features.
[0207] All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.
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This invention relates to compounds of formula I
their salts, and pharmaceutically acceptable derivatives thereof, pharmaceutical compositions comprising these compounds and their use in the treatment of picornavirus infections in mammals, as well as novel intermediates useful in the preparation of the compounds of formula I.
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CROSS-REFERENCED TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to: Provisional Patent Application No. 61/189,528, filed Aug. 19, 2008; Provisional Patent Application No. 61/198,935, filed Nov. 12, 2008; and Provisional Application No. 61/153,636, filed Feb. 18, 2009; the contents of which are each hereby expressly incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] Among other things, one or more embodiments of the present invention relate generally to conjugates comprising a small interfering nucleic acid (siNA) and a polymer. In addition, the invention relates to (among other things) compositions comprising conjugates, methods for synthesizing conjugates, and methods of administering a composition.
BACKGROUND OF THE INVENTION
[0003] RNA interference is currently recognized as a highly specific mechanism of sequence-specific gene silencing. See deFougerolles et al. (2007) Nature Reviews 6:443-453. The mechanism allows for the specific and profound reduction of proteins and mRNA.
[0004] Briefly, double-stranded RNA (dsRNA) is synthesized with a sequence complementary to a gene of interest and introduced into a cell or organism, where the dsRNA is recognized as exogenous genetic material and activates the RNAi pathway. If the exogenous dsRNA is relatively long, it will be cleaved into small interfering RNAs (siRNAs). Alternatively, if the exogenous dsRNA is relatively short (about 30 base pairs or less), cleavage does not occur, the exogenous dsRNA itself acts as the siRNA substrate, and complications arising from activation of innate immunity defenses are avoided. In both cases, the siRNA becomes incorporated into an RNA-induced silencing complex (RISC) followed by unwinding of the double stranded siRNA into two strands. One of these strands, the “sense” strand (also known as the “passenger” strand), is discarded. The other strand, the “guide” strand (also known as the “antisense” strand) recognizes target sites to direct mRNA cleavage, thereby silencing its message. A similar RNAi mechanism involves microRNAs (miRNAs) deriving from imperfectly paired non-coding hairpin RNA structures.
[0005] Through the specific targeting of genes, RNAi-based therapies have the ability to substantially block the production of undesired proteins. Thus, in diseases and conditions attributable to the undesired or over expression of certain proteins, RNAi-based therapies represent a potentially powerful and important approach.
[0006] Despite the great promise of RNAi-based therapies, there remains a problem of the relative short half life of these therapeutics in vivo. There remains a need for better and improved versions of siNA in order to bring the RNAi-based therapies to fruition.
SUMMARY OF THE INVENTION
[0007] Accordingly, in one or more embodiments of the invention, a conjugate is provided, the conjugate comprising a residue of a siNA covalently attached to a water-soluble polymer.
[0008] In one or more embodiments of the invention, a conjugate is provided, the conjugate comprising a residue of a siNA covalently attached, either directly or through a spacer moiety comprised of one or more atoms, to a water-soluble polymer, wherein the siNA is attached to the water-soluble polymer or spacer moiety via an amine linkage.
[0009] In one or more embodiments of the invention, a conjugate is provided, the conjugate comprising a residue of a siNA covalently attached, either directly or through a spacer moiety comprised of one or more atoms, to a water-soluble polymer, wherein the siNA is attached to the water-soluble polymer or spacer moiety via an amide linkage.
[0010] In further embodiments of the above-described embodiments, the conjugates comprise a targeting moiety that delivers the conjugate to the targeted site in the body.
[0011] In one or more embodiments of the invention, a method for delivering a conjugate is provided, the method comprising the step of subcutaneously administering to the patient a composition comprised of a conjugate of a residue of a siNA and a water-soluble polymer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a representation of a gel as further described in Example 1.
[0013] FIG. 2 is a representation of a gel as further described in Example 2.
[0014] FIG. 3 , FIG. 4 , FIG. 5A and FIG. 5B are representations of gel as further described in Examples 3a-3f.
[0015] FIG. 6A , FIG. 6B and FIG. 6C are representations of chromatograms as further described in Examples 3a-3f.
[0016] FIG. 7 is a representation of a chromatogram as further described in Example 4.
[0017] FIG. 8 is a representation of a chromatogram as further described in Examples 5a and 5b and FIG. 9 is a representation of mass spectrometry results as further described in Examples 5a and 5b.
[0018] FIG. 10 is a representation of a chromatogram as further described in Example 6, FIG. 11 is a representation of mass spectrometry results as further described in Example 6. FIG. 12 is a representation of a gel as further described in Example 6.
[0019] FIG. 13 is a representation of a chromatogram as further described in Example 7.
[0020] FIG. 14 is a representation of a chromatogram as further described in Example 8.
[0021] FIG. 15 is a representation of a chromatogram as further described in Example 9.
[0022] FIG. 16 is a representation of a chromatogram as further described in Example 10.
[0023] FIG. 17 is a representation of a chromatogram as further described in Example 11.
[0024] FIG. 18 is a representation of a chromatogram as further described in Example 12.
[0025] FIG. 19 is a representation of a chromatogram as further described in Example 13.
[0026] FIG. 20 is a representation of a chromatogram as further described in Example 14.
[0027] FIG. 21 is a representation of a chromatogram as further described in Example 15.
[0028] FIG. 22 is a representation of a chromatogram as further described in Example 16.
[0029] FIG. 23 is a series of chromatograms showing the release of ssRNA from C2-PEG2-FMOC-20K-ssRNA as further described in Example 18.
[0030] FIG. 24 is a time-concentration plot of PEG-ssRNA conjugates, wherein release kinetics (0.4 M HEPES, pH 7.4, 37° C.) are shown as further described in Example 18.
[0031] FIG. 25 is a representation of a chromatogram as further described in Example 19.
[0032] FIG. 26 is a representation of a chromatogram as further described in Example 20.
[0033] FIG. 27 is a representation of a chromatogram as further described in Example 25.
[0034] FIG. 28 is a representation of a chromatogram as further described in Example 26.
[0035] FIG. 29 shows three panels, A, B and C corresponding to conjugate, antisense and annealed, as further described in Example 34.
[0036] FIG. 30 is a graph as further described in Example 34 and shows the knockdown of SSB RNA expression by conjugates R1 through R5 when transfected using Lipofectamine2000. SSB gene expression relative to untreated cells (bar1), annealed siRNA (bar2), control SSB siRNA (bar3), conjugates R1 through R5 complexed with Lipofectamine2000 (bars 4 through 8).
[0037] FIG. 31 is a graph as further described in Example 34 and shows the SSB gene expression relative to untreated cells (bar1), control SSB siRNA (bar2), conjugates S1 through S3 complexed with Lipofectamine2000 (bars 3 through 5).
[0038] FIG. 32 is a graph as further described in Example 34 and shows the SSB gene expression relative to untreated cells (bar1), cells treated with lipofectamine2000 (bar2),
[0000]
Oligo3 (SEQ ID NO: 186):
5′(C6—S—SC6)-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′,
(bar3)
Oligo5 (SEQ ID NO: 187):
5′(C6—NH2)AmCAmACmAGmACmUUmUAmAUmGUmAA-3′,
(C6—NH2) (bar4)
Oligo28 (SEQ ID NO: 188):
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′,
(C6—NH) (Cy5.5) (bar5)
Oligo31 (SEQ ID NO: 189):
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′,
(C6—NH2) (bar6)
Oligo34 (SEQ ID NO: 190):
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′.
C3—S—S—C3(bar7)
[0039] FIG. 33 and FIG. 34 are representations of gels as further described in Example 35.
DETAILED DESCRIPTION OF THE INVENTION
[0040] As used herein, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “siNA” includes a single siNA as well as two or more of the same or different siNAs, reference to an excipient refers to a single excipient as well as two or more of the same or different excipients, and the like.
[0041] Before further discussion, a definition of the following terms will aid in the understanding of the present invention.
[0042] In describing and claiming one or more embodiments of the present invention, the following terminology will be used in accordance with the definitions described below.
[0043] “PEG,” “polyethylene glycol” and “poly(ethylene glycol)” as used herein, are interchangeable and encompass any nonpeptidic water-soluble poly(ethylene oxide). Typically, PEGs for use in accordance with the invention comprise the following structure “—(OCH 2 CH 2 ) n —” where (n) is 2 to 4000. As used herein, PEG also includes “—CH 2 CH 2 —O(CH 2 CH 2 O) n —CH 2 CH 2 —” and “—(OCH 2 CH 2 ) n O—,” depending upon whether or not the terminal oxygens have been displaced. Throughout the specification and claims, it should be remembered that the term “PEG” includes structures having various terminal or “end capping” groups and so forth. The term “PEG” also means a polymer that contains a majority, that is to say, greater than 50%, of —OCH 2 CH 2 — repeating subunits. With respect to specific forms, the PEG can take any number of a variety of molecular weights, as well as structures or geometries such as “branched,” “linear,” “forked,” “multifunctional,” and the like, to be described in greater detail below.
[0044] The terms “end-capped” and “terminally capped” are interchangeably used herein to refer to a terminal or endpoint of a polymer having an end-capping moiety. Typically, although not necessarily, the end-capping moiety comprises a hydroxy or C 1-20 alkoxy group, more preferably a C 1-10 alkoxy group, and still more preferably a C 1-5 alkoxy group. Thus, examples of end-capping moieties include alkoxy (e.g., methoxy, ethoxy and benzyloxy), as well as aryl, heteroaryl, cyclo, heterocyclo, and the like. It must be remembered that the end-capping moiety may include one or more atoms of the terminal monomer in the polymer [e.g., the end-capping moiety “methoxy” in CH 3 O(CH 2 CH 2 O) n — and CH 3 (OCH 2 CH 2 ) n —]. In addition, saturated, unsaturated, substituted and unsubstituted forms of each of the foregoing are envisioned. Moreover, the end-capping group can also be a silane. The end-capping group can also advantageously comprise a detectable label. When the polymer has an end-capping group comprising a detectable label, the amount or location of the polymer and/or the moiety (e.g., active agent) to which the polymer is coupled can be determined by using a suitable detector. Such labels include, without limitation, fluorescers, chemiluminescers, moieties used in enzyme labeling, colorimetric (e.g., dyes), metal ions, radioactive moieties, and the like. Suitable detectors include photometers, films, spectrometers, and the like. The end-capping group can also advantageously comprise a phospholipid. When the polymer has an end-capping group comprising a phospholipid, unique properties are imparted to the polymer and the resulting conjugate. Exemplary phospholipids include, without limitation, those selected from the class of phospholipids called phosphatidylcholines. Specific phospholipids include, without limitation, those selected from the group consisting of dilauroylphosphatidylcholine, dioleylphosphatidylcholine, dipalmitoylphosphatidylcholine, disteroylphosphatidylcholine, behenoylphosphatidylcholine, arachidoylphosphatidylcholine, and lecithin.
[0045] The term “targeting moiety” is used herein to refer to a molecular structure that increases localization of the conjugate described herein to a targeted area, e.g., enter, permeate, or penetrate a cell, or bind a receptor. Preferably, the targeting moiety comprises of vitamin, cofactor, antibody, antigen, receptor, DNA, RNA, sialyl Lewis X antigen, hyaluronic acid, sugars, cell specific lectins, steroid or steroid derivative, RGD peptide, cell penetrating or cell targeting moiety, ligand for a cell surface receptor, serum component, or combinatorial molecule directed against various intra- or extracellular receptors. The targeting moiety may also comprise a lipid or a phospholipid. Exemplary phospholipids include, without limitation, phosphatidylcholines, phospatidylserine, phospatidylinositol, phospatidylglycerol, and phospatidylethanolamine. These lipids may be in the form of micelles or liposomes and the like. The targeting moiety may further comprise a detectable label or alternately a detectable label may serve as a targeting moiety. When the conjugate has a targeting group comprising a detectable label, the amount and/or distribution/location of the polymer and/or the moiety (e.g., active agent) to which the polymer is coupled can be determined by using a suitable detector. Such labels include, without limitation, fluorescers, chemiluminescers, moieties used in enzyme labeling, colorimetric (e.g., dyes), metal ions, radioactive moieties, gold particles, quantum dots, and the like.
[0046] “Non-naturally occurring” with respect to a polymer as described herein, means a polymer that in its entirety is not found in nature. A non-naturally occurring polymer of the invention may, however, contain one or more monomers or segments of monomers that are naturally occurring, so long as the overall polymer structure is not found in nature.
[0047] The term “water soluble” as in a “water-soluble polymer” polymer is any polymer that is soluble in water at room temperature. Typically, a water-soluble polymer will transmit at least about 75%, more preferably at least about 95%, of light transmitted by the same solution after filtering. On a weight basis, a water-soluble polymer will preferably be at least about 35% (by weight) soluble in water, more preferably at least about 50% (by weight) soluble in water, still more preferably about 70% (by weight) soluble in water, and still more preferably about 85% (by weight) soluble in water. It is most preferred, however, that the water-soluble polymer is about 95% (by weight) soluble in water or completely soluble in water.
[0048] Molecular weight in the context of a water-soluble polymer, such as PEG, can be expressed as either a number average molecular weight or a weight average molecular weight. Unless otherwise indicated, all references to molecular weight herein refer to the weight average molecular weight. Both molecular weight determinations, number average and weight average, can be measured using gel permeation chromatography or other liquid chromatography techniques. Other methods for measuring molecular weight values can also be used, such as the use of end-group analysis or the measurement of colligative properties (e.g., freezing-point depression, boiling-point elevation, or osmotic pressure) to determine number average molecular weight or the use of light scattering techniques, ultracentrifugation or viscometry to determine weight average molecular weight. The polymers of the invention are typically polydisperse (i.e., number average molecular weight and weight average molecular weight of the polymers are not equal), possessing low polydispersity values of preferably less than about 1.2, more preferably less than about 1.15, still more preferably less than about 1.10, yet still more preferably less than about 1.05, and most preferably less than about 1.03.
[0049] The term “active” or “activated” when used in conjunction with a particular functional group, refers to a reactive functional group that reacts readily with an electrophile or a nucleophile on another molecule. This is in contrast to those groups that require strong catalysts or highly impractical reaction conditions in order to react (i.e., a “non-reactive” or “inert” group).
[0050] As used herein, the term “functional group” or any synonym thereof is meant to encompass protected forms thereof as well as unprotected forms.
[0051] The terms “spacer moiety,” “linkage” and “linker” are used herein to refer to an atom or a collection of atoms optionally used to link interconnecting moieties such as a terminus of a polymer segment and a siNA or an electrophile or nucleophile of a siNA. The spacer moiety may be hydrolytically stable or may include a physiologically releasable linkage (e.g., a hydrolyzable or enzymatically releasable linkage). Unless the context clearly dictates otherwise, a spacer moiety optionally exists between any two elements of a compound (e.g., the provided conjugates comprising a residue of siNA and water-soluble polymer can attached directly or indirectly through a spacer moiety).
[0052] “Alkyl” refers to a hydrocarbon chain, typically ranging from about 1 to 15 atoms in length. Such hydrocarbon chains are preferably but not necessarily saturated and may be branched or straight chain, although typically straight chain is preferred. Exemplary alkyl groups include methyl, ethyl, propyl, butyl, pentyl, 3-methylpentyl, and the like. As used herein, “alkyl” includes cycloalkyl as well as cycloalkylene-containing alkyl.
[0053] “Lower alkyl” refers to an alkyl group containing from 1 to 6 carbon atoms, and may be straight chain or branched, as exemplified by methyl, ethyl, n-butyl, i-butyl, and t-butyl.
[0054] “Cycloalkyl” refers to a saturated or unsaturated cyclic hydrocarbon chain, including bridged, fused, or spiro cyclic compounds, preferably made up of 3 to about 12 carbon atoms, more preferably 3 to about 8 carbon atoms. “Cycloalkylene” refers to a cycloalkyl group that is inserted into an alkyl chain by bonding of the chain at any two carbons in the cyclic ring system.
[0055] “Alkoxy” refers to an —O—R group, wherein R is alkyl or substituted alkyl, preferably C 1-6 alkyl (e.g., methoxy, ethoxy, propyloxy, and so forth).
[0056] The term “substituted” as in, for example, “substituted alkyl,” refers to a moiety (e.g., an alkyl group) substituted with one or more noninterfering substituents, such as, but not limited to: alkyl, C 3-8 cycloalkyl, e.g., cyclopropyl, cyclobutyl, and the like; halo, e.g., fluoro, chloro, bromo, and iodo; cyano; alkoxy, lower phenyl; substituted phenyl; and the like. “Substituted aryl” is aryl having one or more noninterfering groups as a substituent. For substitutions on a phenyl ring, the substituents may be in any orientation (i.e., ortho, meta, or para).
[0057] “Noninterfering substituents” are those groups that, when present in a molecule, are typically nonreactive with other functional groups contained within the molecule.
[0058] “Aryl” means one or more aromatic rings, each of 5 or 6 core carbon atoms. Aryl includes multiple aryl rings that may be fused, as in naphthyl or unfused, as in biphenyl. Aryl rings may also be fused or unfused with one or more cyclic hydrocarbon, heteroaryl, or heterocyclic rings. As used herein, “aryl” includes heteroaryl.
[0059] “Heteroaryl” is an aryl group containing from one to four heteroatoms, preferably sulfur, oxygen, or nitrogen, or a combination thereof. Heteroaryl rings may also be fused with one or more cyclic hydrocarbon, heterocyclic, aryl, or heteroaryl rings.
[0060] “Heterocycle” or “heterocyclic” means one or more rings of 5-12 atoms, preferably 5-7 atoms, with or without unsaturation or aromatic character and having at least one ring atom that is not a carbon. Preferred heteroatoms include sulfur, oxygen, and nitrogen.
[0061] “Substituted heteroaryl” is heteroaryl having one or more noninterfering groups as substituents.
[0062] “Substituted heterocycle” is a heterocycle having one or more side chains formed from noninterfering substituents.
[0063] An “organic radical” as used herein shall include alkyl, substituted alkyl, aryl, substituted aryl.
[0064] “Electrophile” and “electrophilic group” refer to an ion or atom or collection of atoms, that may be ionic, having an electrophilic center, i.e., a center that is electron seeking, capable of reacting with a nucleophile.
[0065] “Nucleophile” and “nucleophilic group” refers to an ion or atom or collection of atoms that may be ionic having a nucleophilic center, i.e., a center that is seeking an electrophilic center or with an electrophile.
[0066] A “physiologically cleavable” or “releasable” bond is a bond within a single molecular species that cleaves to result in two distinct molecular species. An exemplary releasable bond is a hydrolysable bond, which reacts with water (i.e., is hydrolyzed) under physiological conditions. The tendency of a bond to hydrolyze in water will depend not only on the general type of linkage connecting two central atoms but also on the substituents attached to these central atoms.
[0067] An “enzymatically degradable linkage” means a linkage that is subject to degradation by one or more enzymes.
[0068] A “hydrolytically stable” linkage or bond refers to a chemical bond, typically a covalent bond, that is substantially stable in water, that is to say, does not undergo hydrolysis under physiological conditions to any appreciable extent over an extended period of time. Examples of hydrolytically stable linkages include, but are not limited to, the following: carbon-carbon bonds (e.g., in aliphatic chains), ethers, amides, urethanes, and the like. Generally, a hydrolytically stable linkage is one that exhibits a rate of hydrolysis of less than about 1-2% per day under physiological conditions. Hydrolysis rates of representative chemical bonds can be found in most standard chemistry textbooks.
[0069] Pharmaceutically acceptable excipient or carrier” refers to an excipient that may optionally be included in the compositions of the invention and that causes no significant adverse toxicological effects to the patient. “Pharmacologically effective amount,” “physiologically effective amount,” and “therapeutically effective amount” are used interchangeably herein to mean the amount of a polymer-siNA conjugate that is needed to provide a desired level of the conjugate (or corresponding unconjugated siNA) in the bloodstream or in the target tissue. The precise amount will depend upon numerous factors, e.g., the particular siNA, the components and physical characteristics of the therapeutic composition, intended patient population, individual patient considerations, and the like, and can readily be determined by one skilled in the art, based upon the information provided herein.
[0070] “Multi-functional” means a polymer having three or more functional groups contained therein, where the functional groups may be the same or different. Multi-functional polymeric reagents of the invention will typically contain from about 3-100 functional groups, or from 3-50 functional groups, or from 3-25 functional groups, or from 3-15 functional groups, or from 3 to 10 functional groups, or will contain 3, 4, 5, 6, 7, 8, 9 or 10 functional groups within the polymer backbone.
[0071] The term “siNA,” as used herein, refers to a moiety having human siNA activity. The siNA will also have at least one electrophilic group or nucleophilic group suitable for reaction with a polymeric reagent. In addition, the term “siNA” encompasses both the siNA prior to conjugation as well as the siNA residue following conjugation. As will be explained in further detail below, one of ordinary skill in the art can determine whether any given moiety has siNA activity. Further, the term “siNA” includes any nucleic acid molecule capable of mediating RNA interference (“RNAi”) or gene silencing. The siNA includes, without limitation, a “short interfering nucleic acid” and includes short interfering RNA (siRNA), double-stranded RNA (dsRNA), micro-RNA (miRNA), short hairpin RNA (shRNA), short interfering oligonucleotide, short interfering nucleic acid, short interfering modified oligonucleotide, chemically-modified siRNA, and post-transcriptional gene silencing RNA (ptgsRNA). For example, the siRNA can be a double-stranded oligonucleotide molecule comprising a sense oligonucleotide and an antisense oligonucleotide, wherein the antisense region comprises complementarity to a target nucleic acid molecule. The siRNA can be a single-stranded hairpin oligonucleotide having self-complementary sense and antisense regions, wherein the antisense region comprises complementarity to a target nucleic acid molecule. As used herein, siRNA molecules need not be limited to those molecules containing only RNA, but further encompasses chemically-modified nucleotides and non-nucleotides. In certain embodiments, the short interfering nucleic acid molecules of the invention lack 2′-hydroxy (2′-OH) containing nucleotides. In certain embodiments, short interfering nucleic acids do not require the presence of nucleotides having a 2′-hydroxy group for mediating RNAi and as such, short interfering nucleic acid molecules of the invention optionally do not contain any ribonucleotides (e.g., nucleotides having a 2′-OH group). The microRNAs can be of an agonist or antagonist and including, for example, antagomirs (as described in Krützfeldt et al. (2005) Nature 438(7068): 685-689). The siNA can be single stranded, double stranded or triple stranded.
[0072] In some instances, the siNA can be a sequence listed in the SEQUENCE LISTING included herewith.
[0073] In some instances, the siNA comprises a first sequence, for example, the antisense sequence of the siNA construct, complementary to a sequence or portion of sequence comprising a sequence represented by GenBank Accession Nos. shown in Table I of U.S. Patent Application Publication No. 2007/0160980 A1, or other sequence listed in that publication.
[0074] Further exemplary siNA is a siNA described in one or more of WO07/121947, WO07/121956, WO07/084684, WO06/069782, WO06/023544, WO05/105152, WO05/000320, WO04/035615, European Patent and/or Application Nos. EP1857547, EP1771206, EP1527176, EP1638580, EP1551868, EP1536827, EP1527176, U.S. Patent Application Publication Nos. 2004/0180351 and 2005/0043263.
[0075] Still further exemplary siNA is siNA described in one or more of U.S. Pat. Nos. 5,898,031, 6,107,094, 7,056,704, 7,078,196, European Patent and Application Nos. EP1144623, EP1214945, EP1352061, German Patent 20023125, and U.S. Patent Application Publication Nos. 2005/0176667, 2005/0186591, 2005/0288244, 2006/0008822, 2006/0035254, 2006/0287260, 2007/0054279, 2007/0161595, 2007/0185050, 2007/0197460, 2007/0213292, 2007/0275465 and 2008/0194512.
[0076] Still further exemplary siNA is siNA described in one or more of the following U.S. Patent Application Publication Nos. 2005/0244858, 2005/0277610 and 2007/0265220.
[0077] Still further exemplary siNA is siNA described in one or more of the following publications Rose et al. (2005) Nucleic Acid Res. 33(13):4140-4156, Kim et al. (2005) Nat Biotechnol. 23(2):222-226 and Amarzguioui et al. (2006) Nature Protocol 1(2):508-517.
[0078] Still further exemplary siNA is siNA described in one or more of the following U.S. Patent Application Publication Nos. 2002/0086356, 2003/0108923, 2007/0229266, 2004/0259247, 2004/0259248, 2005/0026278, 2005/0059005, 2005/0182005, 2005/0227934, 2005/0234006, 2005/0234007, 2006/0166910, 2006/0212950, 2007/0003960, 2007/0003961, 2007/0003962, 2007/0003963, 2007/0093445 and 2007/0287179.
[0079] Still further exemplary siNA is siNA described in one or more of the following U.S. Patent Application Publication Nos. 2003/0190654, 2004/0001811, 2004/0038921, 2004/0053875, 2004/0072779, 2004/0091457, 2004/0102408, 2004/0121348, 2004/0126791, 2004/0175703, 2005/0074757, 2005/0100907 and 2008/0070856.
[0080] Still further exemplary siNA is siNA described in one or more of the following U.S. Patent Application Publication Nos. 2006/0014289, 2006/0035815, 2006/0122137, 2006/0142230, 2006/0160123, 2007/0155658, 2007/0172430, 2007/0213257, 2007/0213293, 2007/0254362, 2007/0269892, 2007/0275923, 2007/0276134, 2007/0281900, 2007/0293449, 2007/0293657 and 2008/0076701.
[0081] By “inhibit” or “down regulate” it is meant that the activity of a gene expression product or level of RNAs or equivalent RNAs encoding one or more gene products is reduced below that observed in the absence of the nucleic acid molecule. In one embodiment, inhibition with a siRNA molecule preferably is below that level observed in the presence of an inactive or attenuated molecule that is unable to mediate an RNAi response. In another embodiment, inhibition of gene expression with the siRNA molecule included as part of the instant invention is greater in the presence of the siRNA molecule than in its absence.
[0082] By “RNA” is meant a molecule comprising at least one ribonucleotide residue. By “ribonucleotide” is meant a nucleotide with a hydroxyl group at the 2′ position of a β-D-ribo-furanose moiety. The terms include triple-stranded RNA, double-stranded RNA, single-stranded RNA, isolated RNA such as partially purified RNA, essentially pure RNA, synthetic RNA, recombinantly produced RNA, as well as altered RNA that differs from naturally occurring RNA by the addition, deletion, substitution and/or alteration of one or more nucleotides. Such alterations can include addition of non-nucleotide material, such as to the end(s) of a siRNA or internally (e.g. capped structures), for example, at one or more nucleotides of the RNA. Nucleotides in the RNA molecules of the instant invention can also comprise non-standard nucleotides, such as non-naturally occurring nucleotides or chemically synthesized nucleotides or deoxynucleotides. These altered RNAs can be referred to as analogs or analogs of naturally-occurring RNA.
[0083] By “gene” and “target gene” and “target nucleic acid” is meant, a nucleic acid that encodes an RNA, for example, nucleic acid sequences including, but not limited to, structural genes encoding a polypeptide. The target gene can be a gene derived from a cell, an endogenous gene, a transgene, or exogenous genes such as genes of a pathogen, for example a virus, which is present in the cell after infection thereof. The cell containing the target gene can be derived from or contained in any organism, for example a plant, animal, protozoan, virus, bacterium, or fungus.
[0084] “Optional” and “optionally” means that the subsequently described circumstance may or may not occur, so that the description includes instances where the circumstance occurs and instances where it does not. Thus, for example, a composition comprising an “optional excipient” includes compositions comprising one or more excipient as well as compositions any excipient.
[0085] The term “patient,” refers to a living organism suffering from or prone to a condition that can be prevented or treated by administration of an active agent (e.g., siNA-containing conjugate), and includes both humans and animals. The term “subject” refers to a living organism suffering from or prone to a condition that can be prevented or treated through RNAi.
[0086] “Optional” or “optionally” means that the subsequently described circumstance may or may not occur, so that the description includes instances where the circumstance occurs and instances where it does not.
[0087] As used herein, an “excipient” is a component of a pharmaceutical composition that does not have RNAi activity. Further, “excipients” such as buffers, sugars, amino acids, and so forth are intended components of a pharmaceutical composition and stand in contrast to unintended components of a composition such as impurities.
[0088] A “therapeutically effective amount” is an amount of siNA (e.g., sirNA) construct required to provide a desired therapeutic effect. The exact amount required will vary from subject to subject and will otherwise be influenced by a number of factors, as will be explained in further detail below. An appropriate “therapeutically effective amount,” however, in any individual case can be determined by one of ordinary skill in the art.
[0089] The term “substantially” refers to a system in which greater than 50% of the stated condition is satisfied. For instance, greater than 85%, greater than 92%, or greater than 96% of the condition may be satisfied.
[0090] Turning to one or more embodiments of the invention, a conjugate is provided, the conjugate comprising a residue of siNA covalently attached (either directly or through a spacer moiety) to a water-soluble polymer. The conjugates of the invention will have one or more of the following features.
[0091] siNAs
[0092] Turning to exemplary aspects of the invention, the compositions include one or more siNA, which may take several forms. siNAs may be of a length of about 7 to 50 nucleotides (each strand of a single stranded, double stranded and triple stranded siNA is independently of from about 7 to 50 nucleotides in length), e.g., one of the following nucleotide lengths: 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, and 50. In some instances, the nucleotide length satisfies one or more of the following ranges: from 10 to 30; from 15 to 25; from 15 to 30; from 26 to 28; from 15 to 26; from 27 to 50; from 27 to 30; and from 10 to 20. Many siNAs are known in the art. siNAs, particularly in their single-stranded form and individual strands of a double-stranded or triple stranded siNA, generally have the ability to bind to a target with a K D of about 0.1 nM to about 100 nM.
[0093] In one or more embodiments, the siNA is a siRNA comprising a double-stranded structure whereby the double-stranded structure comprises a first strand and a second strand, whereby the first strand comprises a first stretch of contiguous nucleotides and whereby said first stretch is at least partially complementary to a target nucleic acid, and the second strand comprises a second stretch of contiguous nucleotides, whereby said second stretch is at least partially identical to a target nucleic acid, and, optionally, one or more of the following apply: (i) the first stretch and/or the second stretch have a length of 15 to 23 nucleotides (e.g., 15, 16, 17, 18, 19, 20, 21 or 23 nucleotides); (ii) at least one of the two strands has an overhang of at least one nucleotide at the 5′-end or the 3′-end (preferably consisting of at least one nucleotide which is selected from the group comprising ribonucleotides and desoxyribonucleotides); (iii) a 2′ modification (preferably selected from the group comprising amino, fluoro, methoxy, alkoxy and alkyl modifications; (iv) a 3′ modification (preferably an inverted nucleotide); (v) said first strand and/or said second strand comprises a plurality of groups of modified nucleotides having a modification at the 2′-position whereby within the strand each group of modified nucleotides is flanked on one or both sides by a flanking group of nucleotides whereby the flanking nucleotides forming the flanking group of nucleotides is either an unmodified nucleotide or a nucleotide having a modification different from the modification of the modified nucleotides; (vi) the first strand and the target nucleic acid comprises at least 15 nucleotides wherein there is one mismatch or two mismatches between said first strand and the target nucleic acid forming said double-stranded structure; (vii) the first strand and the second strand are linked by a loop structure. In some instances, it is preferred that the double-stranded structure is blunt ended on both sides of a double-stranded structure. In other instances, it is preferred that the double-stranded structure is blunt ended on the double-stranded structure which is defined by the 5′-end of the first strand and the 3′-end of the second strand. In still other instances, it is preferred that the double-stranded structure is blunt ended on the double stranded structure which is defined by the 3′-end of the first strand and the 5′-end of the second strand.
[0094] In one or more embodiments of the invention, the modification(s) included within an oligonucleotide that is an siNA can be present such that a pattern of the modification(s) is apparent or can be present such that a pattern of the modification(s) is not apparent. As would be understood, it is not possible to understand whether a pattern of modification(s) within an oligonucleotide is present based on only modification(s) of a single nucleotide within the oligonucleotide; consequently, it is necessary to demonstrate any pattern within a stretch of oligonucleotides.
[0095] This discussion of a pattern (and lack of a pattern) of modifications will focus on a modified nucleotide wherein a methoxy group is formed via methylation of the 2′-OH-group of the ribose moiety of the nucleotide (i.e., a 2′-O-methyl modification); this disclosure relating to patterns (or lack of patterns) of modifications, however, applies to any given modification as in the context of discussing the pattern (or lack of the pattern), any modification can be substituted for 2′-O-methyl modification).
[0096] In one or more embodiments, a pattern arises within a stretch of oligonucleotides such that each nucleotide within a stretch of nucleotides within the siNA alternates between 2′-O-methyl modified and non-2′-O-methyl modified. In one or more embodiments, however, a stretch of oligonucleotides will not demonstrate a pattern wherein a stretch of nucleotides within the siNA alternates between 2′-O-methyl modified and non-2′-O-methyl modified nucleotides. In an convention wherein “M” is a 2′-O-methyl modified nucleotide and “0” is a non-2′-O-methyl modified nucleotide, the following arrangement is considered as exhibiting a pattern: MOMOMOMOM, while the following arrangements are considered as not exhibiting a pattern: MOOOMOMOM; MOMOOOMOM; MOMOMOMOO; MOOOOOMOM; MOMOOOOOO; MOOOOOMOM; MOMOOOOOO; MMOMMOMMO; MOOMMOMMO; MOMOOOMMO; MOMOMOOOM; MMMOMOMOM; MOMMMOMOM; MOMOMMMOM; MOMOMOMMO; MOMOMOMOO; MMMOOMOMO; MMMOOOMOM; MMMOOOOMO; MMMOOOOOM; MMOOOMMOO; MMOMOMMOM; MMMMOMMMM; MMOMMMOMM; MOMMOMMMO; MOMOMMOMM; MOMOMMMOO; MOMOMMMOM; MOOMOOOMM; MOMOOMMMO; MOMOOOOMM; MMOOOMOMM; MOOOMMOMO; MMMMMMOMM; MOMMMMMOM; OOMOMOMOM; OOOOMOMOM; OOMOOOMOM; OOMOMOMOO; OOOOOOMOM; OOMOOOOOO; OOOOOOMOM; OOMOOOOOO; OMOMMOMMO; OOOMMOMMO; OOMOOOMMO; OOMOMOOOM; OMMOMOMOM; OOMMMOMOM; OOMOMMMOM; OOMOMOMMO; OOMOMOMOO; OMMOOMOMO; OMMOOOMOM; OMMOOOOMO; OMMOOOOOM; OMOOOMMOO; OMOMOMMOM; OMMMOMMMM; OMOMMMOMM; OOMMOMMMO; OOMOMMOMM; OOMOMMMOO; OOMOMMMOM; OOOMOOOMM; OOMOOMMMO; OOMOOOOMM; OMOOOMOMM; OOOOMMOMO; OMMMMMOMM; and OOMMMMMOM. Of course, other arrangements are possible that similarly do not evidence a pattern. In another embodiment, the modified nucleotide comprises a 2′-fluro modification.
[0097] The siNA is preferably targeted against a gene (i.e., the “target gene” or “target nucleic acid”) selected from the group comprising structural genes, housekeeping genes, transcription factors, motility factors, cell cycle factors, cell cycle inhibitors, enzymes, growth factors, cytokines and tumor suppressors.
[0098] As will be explained in further detail below, the invention relates to polymer conjugates of siNAs. The polymer selected is typically water soluble so that the siNA to which it is attached does not precipitate in an aqueous environment, such as a physiological environment. The polymer selected is usually modified to have a one or more reactive groups, such as an active ester, carbonate or aldehyde. The polymer may be of any molecular weight, and typically between a weight-average molecular weight of 500 Daltons and a weight-average molecular weight of about 100,000 Daltons (the term “about” indicating that in preparations of a water soluble polymer, some molecules will weigh more, some less, than the stated molecular weight), and may be branched or unbranched. The polymers each typically have a weight-average molecular weight satisfying one or more of the following ranges: from about 2,000 Daltons to about 100,000 Daltons; from about 3,000 Daltons to about 50,000 Daltons; from about 5,000 Da to about 40,000 Daltons; and from about 20,000 Daltons to about 35,000 Daltons.
[0099] Suitable water-soluble polymers or mixtures thereof include, but are not limited to, N-linked or O-linked carbohydrates, sugars, phosphates, carbohydrates; sugars; phosphates; polyethylene glycol (PEG) (including the forms of PEG that have been used to derivatize proteins, including mono-(C1-C10) alkoxy- or aryloxy-polyethylene glycol); monomethoxy-polyethylene glycol; dextran (such as low molecular weight dextran, of, for example about 6,000 Daltons), cellulose; other carbohydrate-based polymers, poly-(N-vinyl pyrrolidone) polyethylene glycol, propylene glycol homopolymers, a polypropylene oxide/ethylene oxide co-polymer, polyoxyethylated polyols (e.g., glycerol) and polyvinyl alcohol. In one or more embodiments, it is preferred that the water-soluble polymer is not lactosylated poly(ethylene glycol) (e.g., a “lactose-PEG-siNA” construct).
[0100] In general, chemical derivatization may be performed under any suitable condition used to react a siNA with an activated polymer molecule. Methods for preparing chemical derivatives of polypeptides will generally comprise (a) reacting the siNA with the activated polymer molecule (such as a reactive ester, carbonate, or aldehyde derivative of the polymer molecule) under conditions whereby the siNA becomes covalently attached to the polymer. In one embodiment, the siNA may have a single polymer molecule attached thereto, although multiple polymers (e.g., two, three, four, and so on) attached to a single siNA are also contemplated.
[0101] siNA may be purchased from a commercial source or may be synthetically produced. For example siRNA can be purchased from Applied Biosystems (Foster City, Calif.) and Thermo Fisher Scientific Inc. (Waltham, Mass.). Those of ordinary skill in the art can prepare synthetic versions of siNA based on the references cited herein and elsewhere in the literature. For further details and a discussion of the synthesis of siRNA molecules in general see, U.S. Patent Application Publication No. 2003/0206887.
[0102] The Water-Soluble Polymer
[0103] As previously discussed, each conjugate comprises a siNA attached to a water-soluble polymer. With respect to the water-soluble polymer, the water-soluble polymer is nonpeptidic, nontoxic, non-naturally occurring and biocompatible. With respect to biocompatibility, a substance is considered biocompatible if the beneficial effects associated with use of the substance alone or with another substance (e.g., an active agent such as an siNA) in connection with living tissues (e.g., administration to a patient) outweighs any deleterious effects as evaluated by a clinician, e.g., a physician. With respect to non-immunogenicity, a substance is considered nonimmunogenic if the intended use of the substance in vivo does not produce an undesired immune response (e.g., the formation of antibodies) or, if an immune response is produced, that such a response is not deemed clinically significant or important as evaluated by a clinician. It is particularly preferred that the nonpeptidic water-soluble polymer is biocompatible and nonimmunogenic.
[0104] Further, the polymer is typically characterized as having from 2 to about 300 termini. Examples of such polymers include, but are not limited to, poly(alkylene glycols) such as polyethylene glycol (“PEG”), poly(propylene glycol) (“PPG”), copolymers of ethylene glycol and propylene glycol and the like, poly(oxyethylated polyol), poly(olefinic alcohol), poly(vinylpyrrolidone), poly(hydroxyalkylmethacrylamide), poly(hydroxyalkylmethacrylate), poly(saccharides), poly(α-hydroxy acid), poly(vinyl alcohol), polyphosphazene, polyoxazoline, poly(N-acryloylmorpholine), hydroxyalkyl starch, and combinations of any of the foregoing.
[0105] With respect to hydroxyalkyl starch (HAS), these sugars represent a water-soluble polymer useful for the present invention. Typical of HAS is hydroxethyl starch, which is a substituted derivative of the carbohydrate polymer amylopectin which occurs in maize starch in a concentration of up to 95%. Amylopectin consists of glucose units, wherein the main chains have α-1,4-glycosidic bonds, but α-1,6-glycosidic bonds are present at the branching sites. Methods for activating hydroxyalkyl starch (such as hydroxyethyl starch) for facile attachment to molecules are described in U.S. Patent Application Publication No. 2006/0188472.
[0106] The polymer is not limited to a particular structure and can be linear (e.g., alkoxy PEG or bifunctional PEG), branched or multi-armed (e.g., forked PEG or PEG attached to a polyol core), dendritic, or with degradable linkages. Moreover, the internal structure of the polymer can be organized in any number of different patterns and can be selected from the group consisting of homopolymer, alternating copolymer, random copolymer, block copolymer, alternating tripolymer, random tripolymer, and block tripolymer.
[0107] Typically, activated PEG and other activated water-soluble polymers (i.e., polymeric reagents) are activated with a suitable activating group appropriate for coupling to a desired site on the siNA. Thus, a polymeric reagent will possess a reactive group for reaction with the siNA. Representative polymeric reagents and methods for conjugating these polymers to an active moiety are known in the art and further described in Zalipsky, S., et al., “ Use of Functionalized Poly(Ethylene Glycols) for Modification of Polypeptides ” in Polyethylene Glycol Chemistry: Biotechnical and Biomedical Applications, J. M. Harris, Plenus Press, New York (1992), and in Zalipsky (1995) Advanced Drug Reviews 16:157-182.
[0108] Typically, the weight-average molecular weight of the water-soluble polymer in the conjugate is from about 100 Daltons to about 150,000 Daltons. Exemplary ranges, however, include weight-average molecular weights in the range of greater than 5,000 Daltons to about 100,000 Daltons, in the range of from about 6,000 Daltons to about 90,000 Daltons, in the range of from about 10,000 Daltons to about 85,000 Daltons, in the range of greater than 10,000 Daltons to about 85,000 Daltons, in the range of from about 20,000 Daltons to about 85,000 Daltons, in the range of from about 53,000 Daltons to about 85,000 Daltons, in the range of from about 25,000 Daltons to about 120,000 Daltons, in the range of from about 29,000 Daltons to about 120,000 Daltons, in the range of from about 35,000 Daltons to about 120,000 Daltons, and in the range of from about 40,000 Daltons to about 120,000 Daltons. For any given water-soluble polymer, PEGs having a molecular weight in one or more of these ranges are preferred.
[0109] Exemplary weight-average molecular weights for the water-soluble polymer include about 100 Daltons, about 200 Daltons, about 300 Daltons, about 400 Daltons, about 500 Daltons, about 600 Daltons, about 700 Daltons, about 750 Daltons, about 800 Daltons, about 900 Daltons, about 1,000 Daltons, about 1,500 Daltons, about 2,000 Daltons, about 2,200 Daltons, about 2,500 Daltons, about 3,000 Daltons, about 4,000 Daltons, about 4,400 Daltons, about 4,500 Daltons, about 5,000 Daltons, about 5,500 Daltons, about 6,000 Daltons, about 7,000 Daltons, about 7,500 Daltons, about 8,000 Daltons, about 9,000 Daltons, about 10,000 Daltons, about 11,000 Daltons, about 12,000 Daltons, about 13,000 Daltons, about 14,000 Daltons, about 15,000 Daltons, about 20,000 Daltons, about 22,500 Daltons, about 25,000 Daltons, about 30,000 Daltons, about 35,000 Daltons, about 40,000 Daltons, about 45,000 Daltons, about 50,000 Daltons, about 55,000 Daltons, about 60,000 Daltons, about 65,000 Daltons, about 70,000 Daltons, and about 75,000 Daltons. Branched versions of the water-soluble polymer (e.g., a branched 40,000 Dalton water-soluble polymer comprised of two 20,000 Dalton polymers) having a total molecular weight of any of the foregoing can also be used. In one or more embodiments, the conjugate will not have any PEG moieties attached, either directly or indirectly, with a PEG having a weight average molecular weight of less than about 6,000 Daltons.
[0110] When used as the polymer, PEGs will typically comprise a number of (OCH 2 CH 2 ) monomers [or (CH 2 CH 2 O) monomers, depending on how the PEG is defined]. As used throughout the description, the number of repeating units is identified by the subscript “n” in “(OCH 2 CH 2 ) n .” Thus, the value of (n) typically falls within one or more of the following ranges: from 2 to about 3400, from about 100 to about 2300, from about 100 to about 2270, from about 136 to about 2050, from about 225 to about 1930, from about 450 to about 1930, from about 1200 to about 1930, from about 568 to about 2727, from about 660 to about 2730, from about 795 to about 2730, from about 795 to about 2730, from about 909 to about 2730, and from about 1,200 to about 1,900. For any given polymer in which the molecular weight is known, it is possible to determine the number of repeating units (i.e., “n”) by dividing the total weight-average molecular weight of the polymer by the molecular weight of the repeating monomer.
[0111] One particularly preferred polymer for use in the invention is an end-capped polymer, that is, a polymer having at least one terminus capped with a relatively inert group, such as a lower C 1-6 alkoxy group, although a hydroxyl group can also be used. When the polymer is PEG, for example, it is preferred to use a methoxy-PEG (commonly referred to as mPEG), which is a linear form of PEG wherein one terminus of the polymer is a methoxy (—OCH 3 ) group (or —CH 3 , again depending on how the PEG is defined), while the other terminus is a hydroxyl or other functional group that can be optionally chemically modified.
[0112] In one form useful in one or more embodiments of the present invention, free or unbound PEG is a linear polymer terminated at each end with hydroxyl groups:
[0000] HO—CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —OH,
[0000] wherein (n) typically ranges from zero to about 4,000.
[0113] The above polymer, alpha-, omega-dihydroxylpoly(ethylene glycol), can be represented in brief form as HO-PEG-OH where it is understood that the -PEG-symbol can represent the following structural unit:
[0000] —CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —,
[0000] wherein (n) is as defined as above.
[0114] Another type of PEG useful in one or more embodiments of the present invention is methoxy-PEG-OH, or mPEG in brief, in which one terminus is the relatively inert methoxy group, while the other terminus is a hydroxyl group. The structure of mPEG is given below:
[0000] CH 3 O—CH 2 CH 2 O—(CH 2 CH 2 O) n —CH 2 CH 2 —OH
[0000] wherein (n) is as described above.
[0115] Multi-armed or branched PEG molecules, such as those described in U.S. Pat. No. 5,932,462, can also be used as the PEG polymer. For example, PEG can have the structure:
[0000]
[0000] wherein:
[0116] poly a and poly b are PEG backbones (either the same or different), such as methoxy poly(ethylene glycol);
[0117] R″ is a nonreactive moiety, such as H, methyl or a PEG backbone; and
[0118] P and Q are nonreactive linkages. In a preferred embodiment, the branched PEG polymer is methoxy poly(ethylene glycol) disubstituted lysine. Depending on the specific siNA used, the reactive ester functional group of the disubstituted lysine may be further modified to form a functional group suitable for reaction with the target group within the siNA.
[0119] In addition, the PEG can comprise a forked PEG. An example of a forked PEG is represented by the following structure:
[0000]
[0000] wherein: X is a spacer moiety of one or more atoms and each Z is an activated terminal group linked to CH by a chain of atoms of defined length. U.S. Pat. No. 7,223,803 discloses various forked PEG structures capable of use in one or more embodiments of the present invention. The chain of atoms linking the Z functional groups to the branching carbon atom serve as a tethering group and may comprise, for example, alkyl chains, ether chains, ester chains, amide chains and combinations thereof.
[0120] The PEG polymer may comprise a pendant PEG molecule having reactive groups, such as carboxyl, covalently attached along the length of the PEG rather than at the end of the PEG chain. The pendant reactive groups can be attached to the PEG directly or through a spacer moiety, such as an alkylene group.
[0121] In addition to the above-described forms of PEG, the polymer can also be prepared with one or more weak or degradable linkages (also referred to as “releasable” linkages”) in the polymer, including any of the above-described polymers. For example, PEG can be prepared with ester linkages in the polymer that are subject to hydrolysis. As shown below, this hydrolysis results in cleavage of the polymer into fragments of lower molecular weight:
[0000] -PEG-CO 2 -PEG-+H 2 O→-PEG-CO 2 H+HO-PEG-
[0122] Other hydrolytically degradable linkages, useful as a degradable linkage within a polymer backbone, include: carbonate linkages; imine linkages resulting, for example, from reaction of an amine and an aldehyde (see, e.g., Ouchi et al. (1997) Polymer Preprints 38(1):582-3); phosphate ester linkages formed, for example, by reacting an alcohol with a phosphate group; hydrazone linkages which are typically formed by reaction of a hydrazide and an aldehyde; acetal linkages that are typically formed by reaction between an aldehyde and an alcohol; orthoester linkages that are, for example, formed by reaction between a formate and an alcohol; amide linkages formed by an amine group, e.g., at an end of a polymer such as PEG, and a carboxyl group of another PEG chain; urethane linkages formed from reaction of, e.g., a PEG with a terminal isocyanate group and a PEG alcohol; peptide linkages formed by an amine group, e.g., at an end of a polymer such as PEG, and a carboxyl group of a peptide; and oligonucleotide linkages formed by, for example, a phosphoramidite group, e.g., a phosphoramidite group introduced at the end of a polymer, and a 5′ hydroxyl group of an oligonucleotide.
[0123] Such optional features of the conjugate, e.g., the introduction of one or more degradable linkages into the polymer chain, may provide for additional control over the final desired pharmacological properties of the conjugate upon administration. For example, a large and relatively inert conjugate (i.e., having one or more high molecular weight PEG chains attached thereto, for example, one or more PEG chains having a molecular weight greater than about 10,000, wherein the conjugate possesses essentially no bioactivity) may be administered, which is hydrolyzed to generate a bioactive conjugate possessing a portion of the original PEG chain. In this way, the properties of the conjugate can be more effectively tailored to balance the bioactivity of the conjugate over time.
[0124] The water-soluble polymer associated with the conjugate can also be “releasable” (also referred to as “cleavable”). That is, the water-soluble polymer is released (either through hydrolysis, enzymatic processes, or otherwise), thereby resulting in the unconjugated siNA. In some instances, releasable polymers detach from the siNA in vivo without leaving any fragment of the water-soluble polymer or spacer moiety. In other instances, releaseable polymers detach from the siNA in vivo leaving a relatively small fragment (e.g., a succinate tag) from the water-soluble polymer. An exemplary releasable polymer includes one that attaches to the siNA via a carbonate linkage.
[0125] Those of ordinary skill in the art will recognize that the foregoing discussion concerning nonpeptidic and water-soluble polymers is by no means exhaustive and is merely illustrative, and that all polymeric materials having the qualities described above are contemplated. As used herein, the term “polymeric reagent” generally refers to an entire molecule, which can comprise a water-soluble polymer segment and a functional group.
[0126] As described above, a conjugate of the invention comprises a water-soluble polymer covalently attached to a siNA. Typically, for any given conjugate, there will be one to three water-soluble polymers covalently attached to one or more siNA. In some instances, however, the conjugate may have 1, 2, 3, 4, 5, 6, 7, 8 or more water-soluble polymers individually attached to a siNA.
[0127] The particular linkage within the moiety having siNA activity and the polymer depends on a number of factors. Such factors include, for example, the particular linkage chemistry employed, the particular siNA, the available functional groups within the siNA (either for attachment to a polymer or conversion to a suitable attachment site), the presence of additional reactive functional groups within the siNA, and the like.
[0128] The conjugates of the invention can be, although not necessarily, prodrugs, meaning that the linkage between the polymer and the siNA is releasable (e.g., hydrolyzable) to allow release of the parent moiety. Such linkages can be readily prepared by appropriate modification of either the siNA and/or the polymeric reagent using coupling methods commonly employed in the art. Most preferred for releasable linkages, however, are hydrolyzable linkages that are readily formed by reaction of a suitably activated polymer with a non-modified functional group contained within the moiety having siNA activity.
[0129] Alternatively, a hydrolytically stable linkage, such as an amide, urethane (also known as carbamate), amine, thioether (also known as sulfide), or urea (also known as carbamide) linkage can also be employed as the linkage for coupling the siNA. Again, preferred hydrolytically stable linkages include amines and amides. In one approach, a water-soluble polymer bearing an activated ester can be reacted with an amine group on the siNA to thereby result in an amide linkage.
[0130] In one or more embodiments, the conjugates of the invention further comprise a targeting moiety. Targeting moiety may comprise of, but is not limited to, an antibody or a fragment of an antibody, a protein or a fragment thereof, a receptor or a subunit thereof, a peptide, a lipid, a carbohydrate, a polymer, a radiolabel, or other suitable targeting moiety. For example, an antibody to a cell surface receptor or the receptor's ligand may be used as a targeting moiety that would deliver the conjugate to cells expressing the receptor on its surface. Similarly, using ApoB protein as target would deliver the siNA-conjugates to cells that express LDL receptor. Other examples of targeting moieties and their targets include: glucose or mannose-terminal glycoproteins for macrophages; galactose-terminal glycoproteins for hepatocytes; phosphovitellogenins for developing oocyte; fibrin for epithelial cells; and insulin and /or other hormones and transferring for various cell types. Once bound to a receptor or to the cell surface, the conjugates of the invention may be endocytosed, either by receptor-mediated endocytosis, pinocytosis, clathrin-mediated endocytosis, caveolae-mediated endocytosis, or some other mechanism. The endosomes (or commonly referred to as “vesicles”), containing the siNA conjugates and the targeting moiety may fuse with other vesicles, such as lysozomes, phagosomes, storage vesicles, or uncoupling vesicles called the compartment of uncoupling receptor and ligand (CURL). CURLs are characterized by an internal pH of ˜5.0. In some embodiments, the conjugates possess a releasable linkage that is susceptible to a low pH and hence release the siNA from the conjugate. In other instances, the releasable linkage of the siNA-polymer conjugate may be susceptible to high or low pH, temperature, reducing or oxidizing environments, enzymes such as proteases, nucleases, esterases, lipases, and others present in the vesicles. Eventually, these vesicles may fuse with other vesicles or dissolve and release their contents in the cytoplasm, thus delivering the siNA to the intended cell and its cytoplasm. Thus, using the various releasable or cleavable linkages that are described herein; siNA-polymer conjugates comprising a targeting moiety are prepared that target and deliver siNA to desired cell type, or tissue.
[0131] The conjugates (as opposed to an unconjugated siNA) may or may not possess a measurable degree of RNAi activity. That is to say, a polymer-siNA conjugate in accordance with the invention will possesses anywhere from about 0.1% to about 100% of the bioactivity of the unmodified parent siNA. In some instances, the polymer-siNA conjugates may possess greater than 100% bioactivity of the unmodified parent siNA. Preferably, conjugates possessing little or no siNA activity contain a releasable linkage connecting the polymer to the moiety, so that regardless of the lack (or relatively lack) of activity in the conjugate, the active parent molecule (or a derivative thereof) is released upon aqueous-induced cleavage of the releasable linkage. Such activity may be determined using a suitable in-vivo or in-vitro model, depending upon the known activity of the particular moiety having RNAi activity being employed.
[0132] For conjugates possessing a hydrolytically stable linkage that couples the moiety having siNA activity to the polymer, the conjugate will typically possess a measurable degree of bioactivity. For instance, such conjugates are typically characterized as having a bioactivity satisfying one or more of the following percentages relative to that of the unconjugated siNA: at least about 2%, at least about 5%, at least about 10%, at least about 15%, at least about 25%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 97%, at least about 100%, and more than 105% (when measured in a suitable model, such as those well known in the art). Preferably, conjugates having a hydrolytically stable linkage (e.g., an amine or amide linkage) will possess at least some degree of the bioactivity of the unmodified parent moiety having siNA activity.
[0133] Exemplary conjugates in accordance with the invention will now be described.
[0134] Amino groups on siNA provide a point of attachment between the siNA and the water-soluble polymer. The siNA can, in some instances, be provided and otherwise manufactured with an amino group (such as having a aminohexyl [i.e., —(CH 2 ) 6 —NH 2 ] or other aminoalkyl group. See, for example, Petrie et al. (1992) Bioconjugate Chemistry 3:85-87.
[0135] There are a number of examples of suitable polymeric reagents useful for forming covalent linkages with available amines of a siNA. Specific examples, along with the corresponding conjugate, are provided in Table 1, below. In the table, the variable (n) represents the number of repeating monomeric units and “—NH—(SiNA)” represents the residue of the siNA following conjugation to the polymeric reagent. While each polymeric portion [e.g., (OCH 2 CH 2 ) n or (CH 2 CH 2 O) n ] presented in Table 1 terminates in a “CH 3 ” group, other groups (such as H and benzyl) can be substituted therefor.
[0000]
TABLE 1
Amine-Selective Polymeric Reagents and the siNA Conjugate Formed Therefrom
Polymeric Reagent
Corresponding Conjugate
mPEG-Oxycarbonylimidazole Reagent
Carbamate Linkage
mPEG Nitrophenyl Reagent
Carbamate Linkage
mPEG-Trichlorophenyl Carbonate Reagent
Carbamate Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
Homobifunctional PEG-Succinimidyl Reagent
Amide Linkages
Heterobifunctional PEG-Succinimidyl Reagent
Amide Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
mPEG-Succinimdyl Reagent
Amide Linkage
mPEG Succinimidyl Reagent
Amide Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
mPEG-Benzotriazole Carbonate Reagent
Carbamate Linkage
mPEG-Succinimidyl Reagent
Carbamate Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
mPEG Succinimidyl Carbonate Reagent
Carbamate Linkage
Branched mPEG2-N-Hydroxysuccinimide Reagent
Amide Linkage
Branched mPEG2-Aldehyde Reagent
Secondary Amine Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
mPEG-Succinimidyl Reagent
Amide Linkage
Homobifunctional PEG-Succinimidyl Reagent
Amide Linkages
mPEG-Succinimidyl Reagent
Amide Linkage
Homobifunctional PEG-Succinimidyl Propionate Reagent
Amide Linkages
mPEG-Succinimidyl Reagent
Amide Linkage
Branched mPEG2-N-Hydroxysuccinimide Reagent
Amide Linkage
Branched mPEG2-N-Hydroxysuccinimide Reagent
Amide linkage
mPEG-Thioester Reagent
Amide Linkage (typically to siNA having an N-terminal cysteine or histidine)
Homobifunctional PEG Propionaldehyde Reagent
Secondary Amine Linkages
mPEG Propionaldehyde Reagent
H 3 C—(OCH 2 CH 2 ) n —O—CH 2 CH 2 —CH 2 —NH—(siNA) Secondary Amine Linkage
Homobifunctional PEG Butyraldehyde Reagent
Secondary Amine Linkage
mPEG Butryaldehyde Reagent
H 3 C—(OCH 2 ) n —O—CH 2 CH 2 CH 2 —CH 2 —NH—(siNA) Secondary Amine Linkages
mPEG Butryaldehyde Reagent
Secondary Amine Linkage
Homobifunctional PEG Butryaldehyde Reagent
Secondary Amine Linkages
Branched mPEG2 Butyraldehyde Reagent
Secondary Amine Linkage
Branched mPEG2 Butyraldehyde Reagent
Secondary Amine Linkage
mPEG Acetal Reagent
H 3 C—(OCH 2 CH 2 ) n —O—CH 2 CH 2 —NH—(sNA) Secondary Amine Linkage
mPEG Piperidone Reagent
Secondary Amine Linkage (to a secondary carbon)
mPEG Methylketone Reagent
secondary amine linkage (to a secondary carbon)
mPEG tresylate Reagent
H 3 CO—(CH 2 CH 2 O) n —CH 2 CH 2 —NH—(siNA) Secondary Amine Linkage
mPEG Maleimide Reagent (under certain reaction conditions such as pH > 8)
Secondary Amine Linkage
mPEG Maleimide Reagent (under certain reaction conditions such as pH > 8)
Secondary Amine Linkage
mPEG Maleimide Reagent (under certain reaction conditions such as pH > 8)
Secondary Amine Linkage
mPEG Forked Maleimide Reagent (under certain reaction conditions such as pH > 8)
Secondary Amine Linkages
branched mPEG2 Maleimide Reagent (under certain reaction conditions such as pH > 8)
Secondary Amine Linkage
Releasable linkage
Releasable Linkage
Releasable Linkage
Releasable Linkage
[0136] Conjugation of a polymeric reagent to an amino group of a siNA can be accomplished by a variety of techniques. In one approach, a siNA can be conjugated to a polymeric reagent functionalized with a succinimidyl derivative (or other activated ester or carbonate group, wherein approaches similar to those described for these alternative activated ester group-containing polymeric reagents can be used). In this approach, the polymer bearing a succinimidyl derivative can be attached to the siNA in an aqueous media at a pH of 7 to 9.0, although using different reaction conditions (e.g., a lower pH such as 6 to 7, or different temperatures and/or less than 15° C.) can result in the attachment of the polymer to a different location on the siNA. In addition, an amide linkage can be formed reacting an amine-terminated nonpeptidic, water-soluble polymer with a siNA bearing an activating a carboxylic acid group.
[0137] An exemplary conjugate comprises the following structure:
[0000]
[0000] wherein:
[0138] (n) is an integer having a value of from 2 to 4000;
[0139] X is a spacer moiety;
[0140] R 1 is H or an organic radical (e.g., lower alkyl); and
[0141] siNA is a residue of a siNA.
[0142] Another exemplary conjugate of the present invention comprises the following structure:
[0000]
[0000] wherein (n) an integer having a value of from 2 to 4000 and siNA is a residue of a siNA.
[0143] Typical of another approach useful for conjugating the siNA to a polymeric reagent is use of reductive amination to conjugate a primary amine of a siNA with a polymeric reagent functionalized with a ketone, aldehyde or a hydrated form thereof (e.g., a ketone hydrate and aldehyde hydrate). In this approach, the primary amine from the siNA reacts with the carbonyl group of the aldehyde or ketone (or the corresponding hydroxyl-containing group of a hydrated aldehyde or ketone), thereby forming a Schiff base. The Schiff base, in turn, can then be reductively converted to a stable conjugate through use of a reducing agent such as sodium borohydride. Selective reactions (e.g., at the N-terminus are possible) are possible, particularly with a polymer functionalized with a ketone or an alpha-methyl branched aldehyde and/or under specific reaction conditions (e.g., reduced pH).
[0144] Exemplary conjugates of the invention wherein the water-soluble polymer is in a branched form, will have the branched form of the water-soluble polymer comprise the following structure:
[0000]
[0000] wherein each (n) is independently an integer having a value of from 2 to 4000.
[0145] Exemplary conjugates of the invention comprise the following structure:
[0000]
[0000] wherein:
[0146] each (n) is independently an integer having a value of from 2 to 4000;
[0147] X is spacer moiety;
[0148] (b) is an integer having a value 2 through 6;
[0149] (c) is an integer having a value 2 through 6;
[0150] R 2 , in each occurrence, is independently H or lower alkyl; and
[0151] siNA is a residue of a siNA.
[0152] An exemplary conjugate of the invention comprises the following structure:
[0000]
[0000] wherein:
[0153] each (n) is independently an integer having a value of from 2 to 4000; and
[0154] siNA is a residue of a siNA.
[0155] Another exemplary conjugate of the invention comprises the following structure:
[0000]
[0156] wherein:
[0157] each (n) is independently an integer having a value of from 2 to 4000;
[0158] (a) is either zero or one;
[0159] X, when present, is a spacer moiety comprised of one or more atoms;
[0160] (b′) is zero or an integer having a value of one through ten;
[0161] (c) is an integer having a value of one through ten;
[0162] R 2 , in each occurrence, is independently H or an organic radical;
[0163] R 3 , in each occurrence, is independently H or an organic radical; and
[0164] siNA is a residue of a siNA.
[0165] An exemplary conjugate of the invention comprises the following structure:
[0000]
[0000] wherein:
[0166] each (n) is independently an integer having a value of from 2 to 4000; and
[0167] siNA is a residue of siNA.
[0168] Carboxyl groups represent another functional group that can serve as a point of attachment on the siNA. Structurally, the conjugate will comprise the following:
[0000]
[0000] where (siNA) and the adjacent carbonyl group corresponds to the carboxyl-containing siNA, X is a linkage, preferably a heteroatom selected from O, N(H), and S, and POLY is a water-soluble polymer such as PEG, optionally terminating in an end-capping moiety.
[0169] The C(O)—X linkage results from the reaction between a polymeric derivative bearing a terminal functional group and a carboxyl-containing siNA. As discussed above, the specific linkage will depend on the type of functional group utilized. If the polymer is end-functionalized or “activated” with a hydroxyl group, the resulting linkage will be a carboxylic acid ester and X will be O. If the polymer backbone is functionalized with a thiol group, the resulting linkage will be a thioester and X will be S. When certain multi-arm, branched or forked polymers are employed, the C(O)X moiety, and in particular the X moiety, may be relatively more complex and may include a longer linkage structure.
[0170] Water-soluble derivatives containing a hydrazide moiety are also useful for conjugation at a carbonyl. Specific examples of water-soluble derivatives containing a hydrazide moiety, along with the corresponding conjugates, are provided in Table 2, below. In addition, any water-soluble derivative containing an activated ester (e.g., a succinimidyl group) can be converted to contain a hydrazide moiety by reacting the water-soluble polymer derivative containing the activated ester with hydrazine (NH 2 —NH 2 ) or tert-butyl carbazate [NH 2 NHCO 2 C(CH 3 ) 3 ]. In the table, the variable (n) represents the number of repeating monomeric units and “=C—(SiNA)” represents the residue of the siNA following conjugation to the polymeric reagent. Optionally, the hydrazone linkage can be reduced using a suitable reducing agent. While each polymeric portion [e.g., (OCH 2 CH 2 ) n or (CH 2 CH 2 O) n ] presented in Table 1 terminates in a “CH 3 ” group, other groups (such as H and benzyl) can be substituted therefor.
[0000]
TABLE 2
Carboxyl-Selective Polymeric Reagents and the siNA Conjugate Formed Therefrom
Polymeric Reagent
Corresponding Conjugate
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
mPEG-Hydrazine Reagent
Hydrazone Linkage
[0171] Thiol groups contained within the siNA can serve as effective sites of attachment for the water-soluble polymer. To the extent that a given siNA does not include a thiol, a thiol can be introduced via techniques known to those of ordinary skill in the art.
[0172] Specific examples of reagents, along with the corresponding conjugate, are provided in Table 3, below. In the table, the variable (n) represents the number of repeating monomeric units and “—S-(siNA)” represents the siNA residue following conjugation to the water-soluble polymer. While each polymeric portion [e.g., (OCH 2 CH 2 ) n or (CH 2 CH 2 O) n ] presented in Table 3 terminates in a “CH 3 ” group, other groups (such as H and benzyl) can be substituted therefor.
[0000]
TABLE 3
Thiol-Selective Polymeric Reagents and the siNA Conjugate Formed Therefrom
Polymeric Reagent
Corresponding Conjugate
mPEG Maleimide Reagent
Thioether Linkage
mPEG Maleimide Reagent
Thioether Linkage
mPEG Maleimide Reagent
Thioether Linkage
Homobifunctional mPEG Maleimide Reagent
Thioether Linkages
mPEG Maleimide Reagent
Thioether Linkage
mPEG Maleimide Reagent
Thioether Linkage
mPEG Maleimide Reagent
Thioether Linkage
mPEG Forked Maleimide Reagent
Thioether Linkage
branched mPEG2 Maleimide Reagent
Thioether Linkage
branched mPEG2 Maleimide Reagent
Thioether Linkage
Branched mPEG2 Forked Maleimide Reagent
Thioether Linkages
Branched mPEG2 Forked Maleimide Reagent
Thioether Linkages
mPEG Vinyl Sulfone Reagent
Thioether Linkage
mPEG Thiol Reagent
Disulfide Linkage
Homobifunctional PEG Thiol Reagent
Disulfide Linkages
mPEG Disulfide Reagent
H 3 CO—(CH 2 CH 2 O) n —CH 2 CH 2 CH 2 CH 2 —S—S—(siNA) Disulfide Linkage
Homobifunctional Disulfide Reagent
(siNA) S—S—CH 2 CH 2 —(CH 2 CH 2 O) n —CH 2 CH 2 CH 2 CH 2 — —S—S—(siNA) Disulfide Linkages
[0173] With respect to conjugates formed from water-soluble polymers bearing one or more maleimide functional groups (regardless of whether the maleimide reacts with an amine or thiol group on the siNA), the corresponding maleamic acid form(s) of the water-soluble polymer can also react with the siNA. Under certain conditions (e.g., a pH of about 7-9 and in the presence of water), the maleimide ring will “open” to form the corresponding maleamic acid. The maleamic acid, in turn, can react with an amine or thiol group of a siNA. Exemplary maleamic acid-based reactions are schematically shown below. POLY represents the water-soluble polymer, and (siNA) represents the siNA.
[0000]
[0174] A representative conjugate in accordance with the invention can have the following structure:
[0000] POLY-L 0,1 -C(O)Z—Y—S—S-(siNA)
[0000] wherein POLY is a water-soluble polymer, L is an optional linker, Z is a heteroatom selected from the group consisting of O, NH, and S, and Y is selected from the group consisting of C 2-10 alkyl, C 2-10 substituted alkyl, aryl, and substituted aryl, and (siNA) is a siNA. Polymeric reagents that can be reacted with a siNA and result in this type of conjugate are described in U.S. Patent Application Publication No. 2005/0014903.
[0175] As previously indicated, exemplary conjugates of the invention wherein the water-soluble polymer is in a branched form, will have the branched form of the water-soluble polymer comprise the following structure:
[0000]
[0000] wherein each (n) is independently an integer having a value of from 2 to 4000.
[0176] Exemplary conjugates having a water-soluble polymer in branched form are prepared using the following reagent:
[0000]
[0000] thereby forming a conjugate having the following structure:
[0000]
[0000] wherein:
[0177] (for each structure) each (n) is independently an integer having a value of from 2 to 4000; and
[0178] (siNA) is a residue of siNA.
[0179] An additional exemplary conjugate can be formed using a reagent:
[0000]
[0000] thereby forming a conjugate having the following structure:
[0000]
[0000] wherein:
[0180] (for each structure) (n) is independently an integer having a value of from 2 to 4000; and
[0181] siNA is a residue of siNA.
[0182] Conjugates can be formed using thiol-specific polymeric reagents in a number of ways and the invention is not limited in this regard. For example, the siNA—optionally in a suitable buffer (including amine-containing buffers, if desired)—is placed in an aqueous media at a pH of about 7-8 and the thiol-specific polymeric reagent is added at a molar excess. The reaction is allowed to proceed for about 0.5 to 2 hours, although reaction times of greater than 2 hours (e.g., 5 hours, 10 hours, 12 hours, and 24 hours) can be useful if PEGylation yields are determined to be relatively low. Exemplary polymeric reagents that can be used in this approach are polymeric reagents bearing a reactive group selected from the group consisting of maleimide, sulfone (e.g., vinyl sulfone), and thiol (e.g., functionalized thiols such as an ortho pyridinyl or “OPSS”).
[0183] The conjugates can be formed from reagents bearing multiple polymer “arms” and functional groups.
[0184] For example, one such multiarm approach has the following formula:
[0000]
[0000] wherein:
[0185] as X 1 , X 2 , X 3 , X 4 , X 5 are each independently optional spacer moieties;
[0186] each POLY 1 is a water-soluble polymer (e.g., a PEG);
[0187] POLY 2 is a positively charged or neutral polymer (e.g., chitosan, polylysine, and polyethylenemine);
[0188] n is 1, 2, or 3;
[0189] R 1 is H or alkyl;
[0190] R 2 is H or alkyl;
[0191] Y 1 is H, lower alkyl, substituted alkyl, a fatty group (optionally substituted) including lipids (e.g., phospholipids, lipophilic vitamins, lipophilic coenzymes, or lipophilic antioxidants); and
[0192] X 1 is an endcapping group or spacer moiety connecting an siNA or a targeting moiety (e.g., folate, pemetrexed, RGD peptide, and cholesterol).
[0193] One specific example of the use of this structure follows. POLY 1 is a branched PEG polymer that includes a lipid or fatty group, Y 1 , at a terminus of a branched PEG (POLY 1 ) and as POLY 2 is the positively charged polymer selected from the group consisting of a polylysine (such as a modified polylysine) and polyethyleneimine. Further, optional spacer moiety, X 5 , is present and is a releasable linker, which, when X 1 is a spacer moiety connecting an siNA, provides for a release of the siNA. In addition, this structure can deliver the siNA as an unbound component in a composition as the negative charges of the siNA would be attracted to the positive charges of POLY 2 . Depending on the complexity of the Y 1 , and the molecular weight of the PEG in this example, the polymeric mixture in water could form a micelle. Micelles are known to have useful drug delivery properties. See Kataoka et al. (1993) J. Controlled Rel. 24:119-132 and Husseini et al. (2002) J. Controlled Rel. 83:302-304.
[0194] An exemplary structure following this approach is provided below.
[0000]
[0195] A second generic structure that will be applicable to siNA delivery is shown below. Methods for preparing the structure are described in U.S. Patent Application Publication No. 2007/0031371. While this structure is shown in a six-arm form which delivers up to six drug molecules, this structural type is also available in other numbers of arms, including two- and four-arm varieties.
[0000]
[0000] wherein:
[0196] X 1 is a degradable or releaseable spacer moiety or linker (e.g., ester, releasable carbamate, releasable disulfide, and releasable thioether);
[0197] each of X 2 , X 3 , X 4 is independently a stable spacer moiety;
[0198] each Z is a residue of a pharmacologically active agent (e.g., a siNA);
[0199] each POLY 1 is a water soluble polymer (e.g., a PEG);
[0200] POLY 2 is a water soluble oligomeric linker (e.g., a PEG, a polycationic polymer, and carbohydrate);
[0201] POLY 3 is a water soluble polymeric linker that is optionally positively charged (e.g., chitosan, polylysine, an polyethyleneimine); and
[0202] each Targeting moiety is an organic or biologically active moiety that can binds to target and is selected to fit a specific delivery application (e.g., folate, pemetrexed and RGD peptide, or cholesterol).
[0203] The residue of the pharmacologically active agent, (Z) can also contain various structural motifs especially for siNA delivery (e.g., Z is a targeting moiety-Xn—Z— or Z—Xn-Targeting moiety-; where Xn may be a stable or releasable spacer moiety). Alternatively spacer moieties (X 1 ) could be polycationic moieties that form non-covalent ionic complex with the siNA drug.
[0204] A third generic multiarm structure is shown below. Methods for preparing the structure are described in U.S. Patent Application Publication No. 2007/0031371. This particular multiarm may have two or more arms depending on the functionality of the polypeptide linker (two or more amino acids, lysines in this example).
[0000]
[0000] wherein:
[0205] Drug is a residue of a pharmacologically active agent drug that is released in vivo;
[0206] each X 1 is a stable spacer moeity;
[0207] X 3 is a stable spacer moeity; p X 2 is a releasable spacer moiety (e.g., ester, releasable carbamate, releasable disulfide, and releasable thioether);
[0208] each POLY 1 is a water soluble polymer (e.g., a PEG);
[0209] POLY 2 is neutral or, optionally, positively charged water soluble polymeric linker (e.g., a PEG, polycationic polymer, and carbohydrate); and
[0210] Targeting moiety is an organic or biologically active moiety that can bind to a target and is selected to fit a specific delivery application.
[0211] Spacer moieties, end groups and targeting groups will include, in some cases, lipid or phospholipids moieties. Positively charged polymers may include polyamines or polymers containing positively charged amine groups. Releaseable linkers may be, for example, FMOC-based structures and esters.
[0212] Note that the pharmacologically active agent moiety (Drug) may also contain various structural motifs especially for siNA delivery (e.g., Drug=TM-Lx-Drug- or Drug-Lx-TM-; where Lx may be a stable or releasable linker and TM is a targeting moiety). Alternatively, linkers (X 2 ) could be polycationic moieties that form non-covalent ionic complex with the siNA drug.
[0213] Additional multiarm approaches are envisioned, an example of which is provided below.
[0000]
[0000] wherein:
[0214] each X 1 is a releaseable spacer moiety;
[0215] each x 2 is a stable spacer moiety;
[0216] X 3 is an optionally stable or releasable spacer moiety (e.g., ester, releasable carbamate, releasable disulfide, and releasable thioether);
[0217] Z is a residue of a pharmacologically active agent (e.g., a siRNA);
[0218] each POLY 1 is a water soluble polymer (e.g., a PEG);
[0219] each TM is a targeting moiety, which is an optional presence on one or more polymer-linked pharmacologically active agent moieties (e.g., folate, pemetrexed, RGD peptide and cholesterol).
[0220] More structures may also be useful for targeted conjugate delivery of siNA. The targeting moieties may optionally be present on one or more of the polymer linked drug moieties and be linked via a stable or releasable linker (when the targeting moiety is stably linked to siNA, conjugation to the passenger or sense strand would be preferred).
[0000] Y-POLY 1 -X 1 -Z—X 3 -TM
[0000] wherein:
[0221] X 1 is a releaseable spacer moiety;
[0222] Y is an end-capping group or spacer moiety containing lower alkyl, alkyl or a lipid and optionally connected to a stable or releasable linked targeting moiety (e.g., folate or pemetrexed);
[0223] X 3 is an optional stable or releasable spacer moiety (e.g., ester, disulfide, releasable carbamate, releasable thioether, cleavable amide and peptide);
[0224] Z is a residue of a pharmacologically active agent (e.g., siRNA)
[0225] POLY 1 is a water soluble polymer (e.g., a PEG); and
[0226] each TM is a targeting moiety (e.g., folate, pemetrexed, RGD peptide, and cholesterol), which is an optional presence on one or more polymer-linked pharmacologically active agent moieties.
[0227] Note that linear and branched PEG architectures may also be used in this context as shown above.
[0228] In the above-described structures, please note that the drug moiety (Z) may also contain various structural motifs especially for siNA delivery (e.g., Z is a targeting moiety-Xn-Z- or Z-Xn-Targeting moiety-; where Xn may be stable or releasable linker). Alternatively linkers (X 1 ) could be polycationic moieties that form non-covalent ionic complex with the siNA drug.
[0229] With respect to polymeric reagents, those described here and elsewhere can be purchased from commercial sources (e.g., Nektar Therapeutics, Huntsville, Ala. and NOF Corporation, Japan). In addition, methods for preparing the polymeric reagents are described in the literature.
[0230] The attachment between the siNA and the non-peptidic, water-soluble polymer can be direct, wherein no intervening atoms are located between the siNA and the polymer, or indirect, wherein one or more atoms are located between the siNA and the polymer. With respect to the indirect attachment, a “spacer moiety” or “linker” serves as a linker between the residue of the siNA and the water-soluble polymer. The one or more atoms making up the spacer moiety can include one or more of carbon atoms, nitrogen atoms, sulfur atoms, oxygen atoms, and combinations thereof The spacer moiety can comprise an amide, secondary amine, carbamate, thioether, and/or disulfide group. Nonlimiting examples of specific spacer moieties include those selected from the group consisting of “—” (a covalent bond), —O—, —S—, —S—S—, —C(O)—, —C(O)—NH—, —NH—C(O)—NH—, —O—C(O)—NH—, —C(S)—, —CH 2 —, —CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —CH 2 —, —O—CH 2 —, —CH 2 —O—, —O—CH 2 —CH 2 —, —CH 2 —O—CH 2 —, —CH 2 —CH 2 —O—, —O—CH 2 —CH 2 —CH 2 —, —CH 2 —O—CH 2 —CH 2 —, —CH 2 —CH 2 —O—CH 2 —, —CH 2 —CH 2 —CH 2 —O—, —O—CH 2 —CH 2 —CH 2 —CH 2 —, —CH 2 —O—CH 2 —CH 2 —CH 2 —, —CH 2 —CH 2 —O—CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —O—CH 2 —, —CH 2 —CH 2 —CH 2 CH 2 —O—, C(O)—NH—CH 2 —, —C(O)—NH—CH 2 —CH 2 —, —CH 2 —C(O)—NH—CH 2 —, —CH 2 —CH 2 —C(O)—NH—, —C(O)—NH—CH 2 —CH 2 —CH 2 —, —CH 2 —C(O)—NH—CH 2 —CH 2 —, —CH 2 —CH 2 —C(O)—NH—CH 2 —, —CH 2 —CH 2 —CH 2 —C(O)—NH—, —C(O)—NH—CH 2 —CH 2 —CH 2 —CH 2 —, —CH 2 —C(O)—NH—CH 2 —CH 2 —CH 2 —, —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —, —CH 2 —CH 2 —CH 2 —CH 2 —C(O)—NH—, —C(O)—O—CH 2 —, —CH 2 —C(O)—O—CH 2 —, —CH 2 —CH 2 —C(O)—O—CH 2 —, —C(O)—O—CH 2 —CH 2 —, —NH—C(O)—CH 2 —, —CH 2 —NH—C(O)—CH 2 —, —CH 2 —CH 2 —NH—C(O)—CH 2 —, —NH—C(O)—CH 2 —CH 2 —, —CH 2 —NH—C(O)—CH 2 —CH 2 —, —CH 2 —CH 2 —NH—C(O)—CH 2 —CH 2 —, —C(O)—NH—CH 2 —, —C(O)—NH—CH 2 —CH 2 —, —O—C(O)—NH—CH 2 —, —O—C(O)—NH—CH 2 —CH 2 —, —NH—CH 2 —, —NH—CH 2 —CH 2 —, —CH 2 —NH—CH 2 —, —CH 2 —CH 2 —NH—CH 2 —, —C(O)—CH 2 —, —C(O)—CH 2 —CH 2 —, —CH 2 —C(O)—CH 2 —, —CH 2 —CH 2 —C(O)—CH 2 —, —CH 2 —CH 2 —C(O)—CH 2 —CH 2 —, —CH 2 —CH 2 —C(O)—, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —NH—, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —NH—C(O)—, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —NH—C(O)—CH 2 —, —CH 2 —CH 2 —CH 2 —C(O)—NH—CH 2 —CH 2 —NH—C(O)—CH 2 —CH 2 —, —O—C(O)—NH—[CH 2 ] h —(OCH 2 CH 2 ) j —, bivalent cycloalkyl group, —O—, —S—, an amino acid, —N(R 6 )—, and combinations of two or more of any of the foregoing, wherein R 6 is H or an organic radical selected from the group consisting of alkyl, substituted alkyl, alkenyl, substituted alkenyl, alkynyl, substituted alkynyl, aryl and substituted aryl, (h) is zero to six, and (j) is zero to 20. Other specific spacer moieties have the following structures: —C(O)—NH—(CH 2 ) 1-6 —NH—C(O)—, —NH—C(O)—NH—(CH 2 ) 1-6 —NH—C(O)—, and —O—C(O)—NH—(CH 2 ) 1-6 —NH—C(O)—, wherein the subscript values following each methylene indicate the number of methylenes contained in the structure, e.g., (CH 2 ) 1-6 means that the structure can contain 1, 2, 3, 4, 5 or 6 methylenes. Additionally, any of the above spacer moieties may further include an ethylene oxide oligomer chain comprising 1 to 20 ethylene oxide monomer units [i.e., —(CH 2 CH 2 O) 1-20 ]. That is, the ethylene oxide oligomer chain can occur before or after the spacer moiety, and optionally in between any two atoms of a spacer moiety comprised of two or more atoms. Also, the oligomer chain would not be considered part of the spacer moiety if the oligomer is adjacent to a polymer segment and merely represent an extension of the polymer segment.
[0231] Compositions
[0232] The conjugates are typically part of a composition. Generally, the composition comprises a plurality of conjugates, preferably although not necessarily, each conjugate is comprised of the same siNA (i.e., within the entire composition, only one type of siNA is found). In addition, the composition can comprise a plurality of conjugates wherein any given conjugate is comprised of a moiety selected from the group consisting of two or more different siNA moieties (i.e., within the entire composition, two or more different siNA moieties are found). Optimally, however, substantially all conjugates in the composition (e.g., 85% or more of the plurality of conjugates in the composition) are each comprised of the same siNA.
[0233] The composition can comprise a single conjugate species (e.g., a monoPEGylated conjugate wherein the single polymer is attached at the same location for substantially all conjugates in the composition) or a mixture of conjugate species (e.g., a mixture of monoPEGylated conjugates where attachment of the polymer occurs at different sites and/or a mixture monPEGylated, diPEGylated and triPEGylated conjugates). The compositions can also comprise other conjugates having four, five, six, seven, eight or more polymers attached to any given moiety having siNA activity. In addition, the invention includes instances wherein the composition comprises a plurality of conjugates, each conjugate comprising one water-soluble polymer covalently attached to one siNA, as well as compositions comprising two, three, four, five, six, seven, eight, or more water-soluble polymers covalently attached to one siNA.
[0234] With respect to the conjugates in the composition, the composition will satisfy one or more of the following characteristics: at least about 85% of the conjugates in the composition will have from one to four polymers attached to the siNA; at least about 85% of the conjugates in the composition will have from one to four polymers attached to the siNA; at least about 85% of the conjugates in the composition will have from one to three polymers attached to the siNA; at least about 85% of the conjugates in the composition will have from one to two polymers attached to the siNA; at least about 85% of the conjugates in the composition will have one polymer attached to the siNA; at least about 95% of the conjugates in the composition will have from one to five polymers attached to the siNA; at least about 95% of the conjugates in the composition will have from one to four polymers attached to the siNA; at least about 95% of the conjugates in the composition will have from one to three polymers attached to the siNA; at least about 95% of the conjugates in the composition will have from one to two polymers attached to the siNA; at least about 95% of the conjugates in the composition will have one polymer attached to the siNA; at least about 99% of the conjugates in the composition will have from one to five polymers attached to the siNA; at least about 99% of the conjugates in the composition will have from one to four polymers attached to the siNA; at least about 99% of the conjugates in the composition will have from one to three polymers attached to the siNA; at least about 99% of the conjugates in the composition will have from one to two polymers attached to the siNA; and at least about 99% of the conjugates in the composition will have one polymer attached to the siNA.
[0235] In one or more embodiments, it is preferred that the conjugate-containing composition is free or substantially free of albumin. It is also preferred that the composition is free or substantially free of macromolecules that do not have siNA activity. Thus, it is preferred that the composition is 85%, more preferably 95%, and most preferably 99% free of albumin. Additionally, it is preferred that the composition is 85%, more preferably 95%, and most preferably 99% free of any protein that does not have siNA activity. To the extent that albumin is present in the composition, exemplary compositions of the invention are substantially free of conjugates comprising a poly(ethylene glycol) polymer linking a residue of a siNA to albumin.
[0236] Control of the desired number of polymers for any given moiety can be achieved by selecting the proper polymeric reagent, the ratio of polymeric reagent to the siNA, temperature, pH conditions, and other aspects of the conjugation reaction. In addition, reduction or elimination of the undesired conjugates (e.g., those conjugates having four or more attached polymers) can be achieved through purification means.
[0237] For example, the polymer-siNA conjugates can be purified to obtain/isolate different conjugated species. Specifically, the product mixture can be purified to obtain an average of anywhere from one, two, three, four, five or more PEGs per siNA, typically one, two or three PEGs per siNA. The strategy for purification of the final conjugate reaction mixture will depend upon a number of factors, including, for example, the molecular weight of the polymeric reagent employed, the particular siNA, the desired dosing regimen, and the residual activity and in vivo properties of the individual conjugate(s).
[0238] If desired, conjugates having different molecular weights can be isolated using gel filtration chromatography and/or ion exchange chromatography. That is to say, gel filtration chromatography is used to fractionate differently numbered polymer-to-siNA ratios (e.g., 1-mer, 2-mer, 3-mer, and so forth, wherein “1-mer” indicates 1 polymer to siNA, “2-mer” indicates two polymers to siNA, and so on) on the basis of their differing molecular weights (where the difference corresponds essentially to the average molecular weight of the water-soluble polymer portion). For example, in an exemplary reaction where a 2,000 Dalton oligopeptide is randomly conjugated to a polymeric reagent having a molecular weight of about 20,000 Daltons, the resulting reaction mixture may contain unmodified oligopeptide (having a molecular weight of about 2,000 Daltons), monoPEGylated oligopeptide (having a molecular weight of about 22,000 Daltons), diPEGylated oligopeptide (having a molecular weight of about 42,000 Daltons), and so forth.
[0239] While this approach can be used to separate PEG and other polymer-siNA conjugates having different molecular weights, this approach is generally ineffective for separating positional isoforms having different polymer attachment sites within the siNA. For example, gel filtration chromatography can be used to separate from each other mixtures of PEG 1-mers, 2-mers, 3-mers, and so forth, although each of the recovered conjugate compositions may contain PEG(s) attached to different reactive groups (e.g., amine residues) within the siNA.
[0240] Gel filtration columns suitable for carrying out this type of separation include Superdex™ and Sephadex™ columns available from Amersham Biosciences (Piscataway, N.J.). Selection of a particular column will depend upon the desired fractionation range desired. Elution is generally carried out using a suitable buffer, such as phosphate, acetate, or the like. The collected fractions may be analyzed by a number of different methods, for example, (i) absorbance at 280 nm for protein content, (ii) dye-based protein analysis using bovine serum albumin (BSA) as a standard, (iii) iodine testing for PEG content (Sims et al. (1980) Anal. Biochem, 107:60-63), (iv) sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS PAGE), followed by staining with barium iodide, and (v) high performance liquid chromatography (HPLC).
[0241] Separation of positional isoforms is carried out by reverse phase chromatography using a reverse phase-high performance liquid chromatography (RP-HPLC) using a suitable column (e.g., a C18 column or C3 column, available commercially from companies such as Amersham Biosciences or Vydac) or by ion exchange chromatography using an ion exchange column, e.g., a Sepharose™ ion exchange column available from Amersham Biosciences. Either approach can be used to separate polymer-active agent isomers having the same molecular weight (i.e., positional isoforms).
[0242] The compositions are preferably substantially free of proteins and other macromolecules that do not have siNA activity. In addition, the compositions preferably are substantially free of all other noncovalently attached water-soluble polymers. In some circumstances, however, the composition can contain a mixture of polymer-siNA conjugates and unconjugated siNA.
[0243] Optionally, the composition of the invention further comprises a pharmaceutically acceptable excipient. If desired, the pharmaceutically acceptable excipient can be added to a conjugate to form a composition.
[0244] Exemplary excipients include, without limitation, those selected from the group consisting of carbohydrates, inorganic salts, antimicrobial agents, antioxidants, surfactants, buffers, acids, bases, and combinations thereof.
[0245] A carbohydrate such as a sugar, a derivatized sugar such as an alditol, aldonic acid, an esterified sugar, and/or a sugar polymer may be present as an excipient. Specific carbohydrate excipients include, for example: monosaccharides, such as fructose, maltose, galactose, glucose, D-mannose, sorbose, and the like; disaccharides, such as lactose, sucrose, trehalose, cellobiose, and the like; polysaccharides, such as raffinose, melezitose, maltodextrins, dextrans, starches, and the like; and alditols, such as mannitol, xylitol, maltitol, lactitol, xylitol, sorbitol (glucitol), pyranosyl sorbitol, myoinositol, and the like.
[0246] The excipient can also include an inorganic salt or buffer such as citric acid, sodium chloride, potassium chloride, sodium sulfate, potassium nitrate, sodium phosphate monobasic, sodium phosphate dibasic, and combinations thereof.
[0247] The composition can also include an antimicrobial agent for preventing or deterring microbial growth. Nonlimiting examples of antimicrobial agents suitable for one or more embodiments of the present invention include benzalkonium chloride, benzethonium chloride, benzyl alcohol, cetylpyridinium chloride, chlorobutanol, phenol, phenylethyl alcohol, phenylmercuric nitrate, thimersol, and combinations thereof.
[0248] An antioxidant can be present in the composition as well. Antioxidants are used to prevent oxidation, thereby preventing the deterioration of the conjugate or other components of the preparation. Suitable antioxidants for use in one or more embodiments of the present invention include, for example, ascorbyl palmitate, butylated hydroxyanisole, butylated hydroxytoluene, hypophosphorous acid, monothioglycerol, propyl gallate, sodium bisulfite, sodium formaldehyde sulfoxylate, sodium metabisulfite, and combinations thereof.
[0249] A surfactant can be present as an excipient. Exemplary surfactants include: polysorbates, such as “Tween 20” and “Tween 80,” and pluronics such as F68 and F88 (both of which are available from BASF, Mount Olive, New Jersey); sorbitan esters; lipids, such as phospholipids such as lecithin and other phosphatidylcholines, phosphatidylethanolamines (although preferably not in liposomal form), fatty acids and fatty esters; steroids, such as cholesterol; and chelating agents, such as EDTA, zinc and other such suitable cations.
[0250] Acids or bases can be present as an excipient in the composition. Nonlimiting examples of acids that can be used include those acids selected from the group consisting of hydrochloric acid, acetic acid, phosphoric acid, citric acid, malic acid, lactic acid, formic acid, trichloroacetic acid, nitric acid, perchloric acid, phosphoric acid, sulfuric acid, fumaric acid, and combinations thereof. Examples of suitable bases include, without limitation, bases selected from the group consisting of sodium hydroxide, sodium acetate, ammonium hydroxide, potassium hydroxide, ammonium acetate, potassium acetate, sodium phosphate, potassium phosphate, sodium citrate, sodium formate, sodium sulfate, potassium sulfate, potassium fumerate, and combinations thereof.
[0251] The amount of the conjugate (i.e., the conjugate formed between the active agent and the polymeric reagent) in the composition will vary depending on a number of factors, but will optimally be a therapeutically effective dose when the composition is stored in a unit dose container (e.g., a vial). In addition, the pharmaceutical preparation can be housed in a syringe. A therapeutically effective dose can be determined experimentally by repeated administration of increasing amounts of the conjugate in order to determine which amount produces a clinically desired endpoint.
[0252] The amount of any individual excipient in the composition will vary depending on the activity of the excipient and particular needs of the composition. Typically, the optimal amount of any individual excipient is determined through routine experimentation, i.e., by preparing compositions containing varying amounts of the excipient (ranging from low to high), examining the stability and other parameters, and then determining the range at which optimal performance is attained with no significant adverse effects.
[0253] Generally, however, the excipient will be present in the composition in an amount of about 1% to about 99% by weight, preferably from about 5% to about 98% by weight, more preferably from about 15 to about 95% by weight of the excipient, with concentrations less than 30% by weight most preferred.
[0254] These foregoing pharmaceutical excipients along with other excipients are described in “Remington: The Science & Practice of Pharmacy”, 19 th ed., Williams & Williams, (1995), the “Physician's Desk Reference”, 52 nd ed., Medical Economics, Montvale, N.J. (1998), and Kibbe, A. H., Handbook of Pharmaceutical Excipients, 3 rd Edition, American Pharmaceutical Association, Washington, D.C., 2000.
[0255] The compositions encompass all types of formulations and in particular those that are suited for injection, e.g., powders or lyophilates that can be reconstituted as well as liquids. Examples of suitable diluents for reconstituting solid compositions prior to injection include bacteriostatic water for injection, dextrose 5% in water, phosphate-buffered saline, Ringer's solution, saline, sterile water, deionized water, and combinations thereof With respect to liquid pharmaceutical compositions, solutions and suspensions are envisioned.
[0256] In some embodiments of the invention, the compositions comprising the polymer-siNA conjugates may further be incorporated into a suitable delivery vehicle. Such delivery vehicles may provide controlled and/or continuous release of the conjugates and may also serve as a targeting moiety. Non-limiting examples of delivery vehicles include, adjuvants, synthetic adjuvants, microcapsules, microparticles, liposomes, and yeast cell wall particles. Yeast cells walls may be variously processed to selectively remove protein component, glucan, or mannan layers, and are referred to as whole glucan particles (WGP), yeast beta-glucan mannan particles (YGMP), yeast glucan particles (YGP), Rhodotorula yeast cell particles (YCP). Yeast cells such as S. cerevisiae and Rhodotorula sp. are preferred; however, any yeast cell may be used. These yeast cells exhibit different properties in terms of hydrodynamic volume and also differ in the target organ where they may release their contents. The methods of manufacture and characterization of these particles are described in U.S. Pat. Nos. 5,741,495; 4,810,646; 4,992,540; 5,028,703; 5,607,677, and U.S. Patent Applications Nos. 2005/0281781, and 2008/0044438. In one or more embodiments, the delivery vehicle is not a liposomal in nature (i.e., lacks liposomes).
[0257] The compositions of one or more embodiments of the present invention are typically, although not necessarily, administered via injection and are therefore generally liquid solutions or suspensions immediately prior to administration. The pharmaceutical preparation can also take other forms such as syrups, creams, ointments, tablets, powders, and the like. Other modes of administration are also included, such as pulmonary, rectal, transdermal, transmucosal, oral, intrathecal, subcutaneous, intra-arterial, and so forth.
[0258] With respect to pulmonary delivery of the conjugates described herein, it is preferred to employ one or more of the approaches described in U.S. Pat. Nos. 6,565,885; 6,946,117; 6,309,623; and 6,433,040; the contents of all of which are hereby incorporated herein by reference in their entirety.
[0259] The invention also provides a method for administering a conjugate as provided herein to a patient suffering from a condition that is responsive to treatment with conjugate. The method comprises administering to a patient, generally via injection, a therapeutically effective amount of the conjugate (preferably provided as part of a pharmaceutical composition). As previously described, the conjugates can be administered injected parenterally by intravenous injection. Advantageously, the conjugate can be administered by intramuscular or by subcutaneous injection. Suitable formulation types for parenteral administration include ready-for-injection solutions, dry powders for combination with a solvent prior to use, suspensions ready for injection, dry insoluble compositions for combination with a vehicle prior to use, and emulsions and liquid concentrates for dilution prior to administration, among others.
[0260] The method of administering may be used to treat any condition that can be remedied or prevented by administration of the conjugate. Those of ordinary skill in the art appreciate which conditions a specific conjugate can effectively treat. Advantageously, the conjugate can be administered to the patient prior to, simultaneously with, or after administration of another active agent.
[0261] The actual dose to be administered will vary depending upon the age, weight, and general condition of the subject as well as the severity of the condition being treated, the judgment of the health care professional, and conjugate being administered. Therapeutically effective amounts are known to those skilled in the art and/or are described in the pertinent reference texts and literature. Generally, a therapeutically effective amount will range from about 0.001 mg to 100 mg, preferably in doses from 0.01 mg/day to 75 mg/day, and more preferably in doses from 0.10 mg/day to 50 mg/day. A given dose can be periodically administered up until, for example, symptoms of organophosphate poisoning lessen and/or are eliminated entirely.
[0262] The unit dosage of any given conjugate (again, preferably provided as part of a pharmaceutical preparation) can be administered in a variety of dosing schedules depending on the judgment of the clinician, needs of the patient, and so forth. The specific dosing schedule will be known by those of ordinary skill in the art or can be determined experimentally using routine methods. Exemplary dosing schedules include, without limitation, administration once daily, three times weekly, twice weekly, once weekly, twice monthly, once monthly, and any combination thereof. Once the clinical endpoint has been achieved, dosing of the composition is halted.
[0263] One advantage of administering certain conjugates described herein is that individual water-soluble polymer portions can be cleaved when a hydrolytically releasable linkage is included between the residue of siNA and water-soluble polymer. Such a result is advantageous when clearance from the body is potentially a problem because of the polymer size. Optimally, cleavage of each water-soluble polymer portion is facilitated through the use of physiologically cleavable and/or enzymatically releasable linkages such as amide, carbamate, carbonate or ester-containing linkages. In this way, clearance of the conjugate (via cleavage of individual water-soluble polymer portions) can be modulated by selecting the polymer molecular size and the type functional group that would provide the desired clearance properties. One of ordinary skill in the art can determine the proper molecular size of the polymer as well as the cleavable functional group. For example, one of ordinary skill in the art, using routine experimentation, can determine a proper molecular size and cleavable functional group by first preparing a variety of polymer derivatives with different polymer weights and cleavable functional groups, and then obtaining the clearance profile (e.g., through periodic blood or urine sampling) by administering the polymer derivative to a patient and taking periodic blood and/or urine sampling. Once a series of clearance profiles have been obtained for each tested conjugate, a suitable conjugate can be identified.
[0264] It is to be understood that while the invention has been described in conjunction with the preferred specific embodiments thereof, that the foregoing description as well as the examples that follow are intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
[0265] All articles, books, patents and other publications referenced herein are hereby incorporated by reference in their entireties.
Experimental
[0266] The practice of the invention will employ, unless otherwise indicated, conventional techniques of organic synthesis and the like, which are within the skill of the art. Such techniques are fully described in the literature. Reagents and materials are commercially available and/or their syntheses (particularly with respect to polymeric reagents) are described in the literature unless specifically stated to the contrary. See, for example, M. B. Smith and J. March, March's Advanced Organic Chemistry: Reactions Mechanisms and Structure, 6th Ed. (New York: Wiley-Interscience, 2007), supra, and Comprehensive Organic Functional Group Transformations II, Volumes 1-7, Second Ed.: A Comprehensive Review of the Synthetic Literature 1995-2003 (Organic Chemistry Series), Eds. Katritsky, A. R., et al., Elsevier Science.
[0267] In the following examples, efforts have been made to ensure accuracy with respect to numbers used (e.g., amounts, temperatures, etc.) but some experimental error and deviation should be accounted for. Unless indicated otherwise, temperature is in degrees C. and pressure is at or near atmospheric pressure at sea level.
[0268] References in this Experimental to polymeric reagents identified by the following designations shall represent the following structure:
[0000]
[0000] wherein, when the polymeric reagent designated as:
[0269] “C2,” R 2 is H and each of R 1 and R 3 is
[0000]
[0270] “G2,” R 2 is H and each of R 1 and R 3 is
[0000]
[0271] “CG,” R 1 is H, R 2 is
[0000]
and R 3 is
[0272]
[0000] and
[0273] “CAC,” R 1 is H, R 2 is
[0000]
and R 3 is
[0274]
[0000] and each m-PEG represents CH 3 O(CH 2 CH 2 O) n —CH 2 CH 2 ˜ and (n) is defined such that both m-PEG moieties in the structure provide the molecular weight stated in the particular example.
[0275] Further, the following structures shall be identified in this Experimental by the designations located adjacent to the structure:
[0000]
[0000] wherein m-PEG represents CH 3 O(CH 2 CH 2 O) n —CH 2 CH 2 ˜ and (n) is defined such that m-PEG moiety in the structure provides the molecular weight stated in the particular example.
[0276] The C2, G2, CG, CAC, SBC and SS polymeric reagents, upon conjugation to the siNA, provide conjugates that are releaseable in vivo (i.e., wherein the polymeric reagent detaches or substantially detaches from the conjugate, thereby releasing the original siNA or an siNA only slightly modified with a small residue from the polymeric reagent), whereas the PEG2-RU-NHS polymeric reagent, upon conjugation to the siNA, provides a substantially stable conjugate. The OPSS polymeric reagent, upon conjugation to the siNA, provides a conjugate that may undergo disulfide exchange. Single- and double-stranded RNA sequences were manufactured by Tri-Link BioTechnologies, San Diego, Calif., Dharmacon RNAi Technologies, Lafayette, Colo., and IDT Inc., Coralville, Iowa. Chitosan was obtained from Kitto Life, Kyongki-Do, Korea. Two forms were used: chitooligosaccharide with average MW about 10,000 Daltons (measured by GPC) and with ˜94% deacetylation (measured by NMR) and chitoooligosaccharide average MW 3,000-5,000 Daltons (measured by GPC) and with ˜86% deacetylation (by NMR). Generally, it is preferred to use chitosan lacking derivatization with side chains of —NH—(CH 2 ) a —(NH(CH 2 ) 2 ) e —NH 2 , where (a) and (e) are independently 1 to 5. Generally, it is also preferred to use chitosan with a molecular weight of less than about 100,000 Daltons, more preferably less than about 60,000 Daltons, still more preferably less than 30,000 Daltons, with less than 20,000 Daltons being most preferred.
[0277] Further, the following siNAs (single-stranded oligonucleotide sequences are identified with SEQ ID NOs), shall be identified in this Experimental by the SEQ ID NOs located adjacent to the sequence or corresponding oligonucleotide (oligo) number:
[0000]
SEQ ID
Sequence
Name
NO:
5′ (C6—NH2) AmCAmACmAGmACmUUmUAmAUmGUmAA-3′
Oligo 13
183
5′(C6—NH2) AmCAmACmAGmACmUUmUAmAUmGUmAA-3′(C6—SH)(Cy5.5)
Oligo 14
184
5′ (C6—NH2)AmCAmACmAGmACmUUmUAmAUmGUmAA-3′(cholesteryl-TEG)
Oligo 18
185
5′(C6—S—SC6)-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′
Oligo 3
186
5′(C6—NH2)AmCAmACmAGmACmUUmUAmAUmGUmAA-3′(C6—NH)
Oligo 5
187
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′ (C6—NH) (Cy5.5)
Oligo 28
188
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′ C6—NH2)
Oligo 31
189
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′ C3—S—S—C3
Oligo 34
190
5′ AmCAmACmAGmACmUUmUAmAUmGUmAA-3′
Sense
191
5′mUUmACmAUmUAmAAmGUmCUmGUmUGmU-3′
Antisense
192
Ai2FCAAi2FCAGAi2FCTi2FUTAATGTAAmUmU
Sense
193
5′-rUmUrAmCAi2FUmUAmAAmGmUi2FCi2FUmGi2FUmUmGi2FUmUmU
Antisense
194
EXAMPLE 1
Conjugation of Double-Stranded siRNA with a 5′-aminoC6 Linker with: 1a) CAC 20K Polymeric Reagent [“9-hydroxymethyl-4-(mPEG(10,000)-carboxyamide)-7-(3-(mPEG(10,000)carbamoyl-propyl)-fluorene-N-hydroxysuccinimide” or “4,7-CAC-PEG2-FMOC-NHS 20K”]and
1b) GC 20K Polymeric Reagent [“9-hydroxymethyl-4-(mPEG(10,000)-carboxyamide)-7-(3-(mPEG(10,000) amidoglutaric amide)-fluorene-N-hydroxysuccinimide” or “4,7-CG-PEG2-FMOC-NHS 20K”]
[0278] Sodium phosphate buffer (25 mM; pH 7.5) was prepared. A stock solution (280 μM) of double-stranded siRNA with a 5′-aminoC6 linker on the sense strand (SEQ ID NO: 183:SEQ ID NO: 192) (IDT Inc., Coralville, Iowa) was prepared in 1× siRNA buffer (diluted from 5× siRNA buffer, pH 7.5, Dharmacon Lafayette, Colo.). The reactions were run by dissolution of the indicated polymeric reagent CAC or GC (4 mg, 0.2 μmol) in a mixture of siRNA stock solution (27 μl, 0.0075 μmol) and the indicated sodium phosphate buffer (25 mM, 173 μl). The reaction mixtures were stirred and incubated at room temperature for three hours. Aliquots (2 μl) were taken, quenched with 0.1 M glycine (2 μl) and diluted with RNAse free water and 6× loading buffer (comprised of 10 mM pH 7.6 Tris buffer, 60 mM EDTA, 60% glycerol, 0.03% bromophenol blue and 0.03% xylene cyanol). The samples were loaded on a non-denaturing PAGE gel (Invitrogen 20% TBE gel) and run at 100 V for 120 min. The gels were removed, stained with ethidium bromide (BioChemika, Sigma) for 30 minutes and then destained for more than one hour.
[0279] The gel is provided in FIG. 1 , wherein lanes 1 and 2 correspond to siRNA-CAC conjugate, lane 3 corresponds to siRNA, and lanes 4 and 5 correspond to siRNA-CG conjugate.
EXAMPLE 2
Conjugation of Double-Stranded siRNA and Single-Stranded siRNA with 2a) m-PEG-SBA 5K [“mPEG-succinimidyl butanoate 5K” and
2b) m-PEG-SPA 5K [or “mPEG-succinimidyl propionate 5K”]
[0280] Preparation of Conjugates with a Double-Stranded siRNA
[0281] Sodium phosphate buffer (100 mM; pH 8.0) was prepared. A stock solution (280 μM) of double-stranded siRNA with a 5′-aminoC6 linker on the sense strand (SEQ ID NO: 183:SEQ ID NO: 192) (IDT Inc., Coralville, Iowa) was prepared in 1×siRNA buffer (diluted from 5× siRNA buffer, pH 7.5, Dharmacon, Lafayette, Colo.). The reactions in were run by dissolution of the indicated polymeric reagent (1 mg, 0.2 μmol) in a mixture of siRNA stock solution (10 μl, 0.0028 μmol) and the indicated sodium phosphate buffer (100 mM, 90 μl). The reaction mixtures were stirred and incubated at room temperature for three hours. Aliquots (2 μl) were taken, quenched with 0.1 M glycine (2 μl) and diluted with RNAse free water and loading buffer.
[0282] Preparation of Conjugates with a Single-Stranded siRNA
[0283] A stock solution (1000 μM) of siRNA sense-strand with a 5′-aminoC6 linker (SEQ ID NO: 183) (IDT Inc., Coralville, Iowa) was prepared in 1× siRNA buffer. The reactions were run by dissolution of mPEG-SBA 5K reagent (1 mg, 0.2 μmol) in a mixture of siRNA stock solution (10 μl, 0.01 μmol) and the indicated sodium phosphate buffer (100 mM, 90 μl). The reaction mixtures were stirred and incubated at room temperature for three hours. Aliquots (2 μl) were taken, quenched with 0.1 M glycine (2 μl) and diluted with RNAse free water and loading buffer.
[0284] The samples were loaded on a non-denaturing PAGE gel (Invitrogen 20% TBE gel) and run at 100 V for 120 minutes. The gels were removed, stained with ethidium bromide (BioChemika, Sigma) for 30 minutes and then destained for more than one hour.
[0285] The gel is provided in FIG. 2 , showing native PAGE 5′-aminoC6 double-stranded siRNA (280 μM)+mPEG-SBA 5K or mPEG-SPA 5K (70×) comparisons with 5′-aminoC6 siRNA sense strain (1000 μM)+mPEG-SBA 5K (20×) at pH 8.0 in 100 mM phosphate buffer for three hours. Lane corresponds to a 10 by DNA ladder, lane 2 corresponds to double-stranded siRNA, lane 3 corresponds to double-stranded siRNA-mPEG-SBA 5K conjugate, lane 4 corresponds to double-stranded siRNA-mPEG-SPA 5K conjugate, lane 5 corresponds to siRNA sense strain-mPEG-SBA 5K conjugate, lane 6 corresponds to double-stranded siRNA-mPEG-SBA 5K conjugate, lane 7 corresponds to double-stranded siRNA-mPEG-SPA 5K conjugate, lane 8 corresponds to siRNA sense strain-mPEG-SBA 5K, conjugate, and 9 corresponds to double-stranded siRNA.
EXAMPLE 3a-3f
Conjugation of Double-Stranded siRNA (ds-siRNA) and Single-Stranded siRNA (ss-siRNA) with Polymeric Reagents
3a) and 3b) m-PEG2-RU-NHS 20K [“Reversed-urethane Branched PEG NHS 20K”], 3c) and 3d) m-PEG-SC 20K [“mPEG succinimido carbonate 20K”], and
3e) and 3f) CAC [“9-hydroxymethyl-4-(mPEG(10,000)-carboxyamide)-7-(3-(mPEG(10,000)carbamoyl-propyl)-fluorene-N-hydroxysuccinimide” or “4,7-CAC-PEG2-FMOC-NHS 20K”]
[0286] The reaction parameters were set up according to Table 4. The polymeric reagents were dissolved in 2 mM HCl (100 mg/ml) and used immediately. Each portion of PEG reagent was added every 30 minutes. The concentration of 5′-AminoC6 double-stranded (SEQ ID NO: 183:SEQ ID NO: 192) or single stranded siRNA (SEQ ID NO: 183) in the reaction solution was 28 μM. The reaction mixtures were incubated at ambient temperature (22 C) with stirring. At 3 hours, 10 μl reaction mixtures were mixed with 2.5 μl 0.2 M glycine (unbuffered) to quench the reaction. The reaction mixtures were analyzed by 20% non-denaturing PAGE and 4-20% native PAGE gels. See FIG. 3 , FIG. 4 , FIG. 5A and FIG. 5B .
[0000]
TABLE 4
Reaction Parameters for Examples 3a-3f
Polymeric
500 mM
RNAse
Total
Reagent
EPPS buffer,
free water
volume
Example
100 mg/mL, μl
pH 8.5, μl
siRNA
(μl)
(μl)
Ratio
3a
m-PEG2-RU-NHS
40
ds-5′ AminoC6, 0.28
60
200
60:1
20K, 85%, 20 μl ×
mM in siRNA buffer,
4 (340 nmole)
20 μl (5.6 nmole)
3b
m-PEG2-RU-NHS
40
ss-5′ AminoC6, 1.0
74.4
200
60:1
20K, 85%, 20 μl ×
mM in siRNA buffer,
4 (336 nmole)
5.6 μl (5.6 nmole)
3c
mPEG-SC 20K,
40
ds-5′ AminoC6, 0.28
60
200
60:1
85%, 20 μl × 4
mM in siRNA buffer,
(340 nmole)
20 μl (5.6 nmole)
3d
mPEG-SC 20K,
40
ss-5′ AminoC6, 1.0
74.4
200
60:1
85%, 20 μl × 4
mM in siRNA buffer,
(340 nmole)
5.6 μl (5.6 nmole)
3e
4,7-CAC-mPEG-
40
ds-5′ AminoC6, 0.28
60
200
60:1
FMOC-NHS, 87%,
mM in siRNA buffer,
20 μl × 4 (340
20 μl (5.6 nmole)
nmole)
3f
4,7-CAC-PEG2-
40
ss-5′ AminoC6, 1.0
74.4
200
60:1
FMOC-NHS, 87%
mM in siRNA buffer,
20 μl × 4 (340
5.6 μl (5.6 nmole)
nmole)
[0287] A gel is provided in FIG. 3 , showing native 20% PAGE 5′-aminoC6 ds-siRNA +indicated polymeric reagent (60×) comparisons with 5′-aminoC6 ss-siRNA at pH 8.5 in 100 mM EPPS buffer for three hours. Lane 1 corresponds to a 10 by DNA ladder, lane 2 corresponds to ds-siRNA-m-PEG2-RU-NHS 20K conjugate, 1 and 3 corresponds to ss-siRNA-m-PEG2-RU-NHS conjugate, lane 4 corresponds to ds-siRNA-m-PEG-SC 20K conjugate, lane 5 corresponds to ss-siRNA-m-PEG-SC 20K conjugate, lane 6 corresponds to ds-siRNA-CAC 20K conjugate, lane 7 corresponds to ss-siRNA-4,7-CAC 20K conjugate (although the bands crossed over to lane 6). The conversion yields of ds-siRNA conjugation were estimated with density scanning: all were roughly 50%. FIG. 4 represents the gel of FIG. 3 stained with iodine, thereby showing the PEG components.
[0288] A gel is provided in FIG. 5A , showing igure native 4-20% gradient PAGE 5′-aminoC6 double-stranded siRNA+indicated polymeric reagent comparisons with 5′-aminoC6 siRNA sense strain at pH 8.5 in 100 mM EPPS buffer for three hours. Lanes 1 and 2 correspond to a 10 bp DNA ladder, lane 3 corresponds to ds-siRNA, lane 4 corresponds to ds-siRNA-m-PEG2-RU-NHS 20K conjugate, lane 5 corresponds to ss-siRNA-m-PEG2-RU-NHS 20K conjugate, lane 6 corresponds to ds-siRNA-m-PEG-SC 20K conjugate, lane 7 corresponds to ss-siRNA-m-PEG-SC 20K conjugate, lane 8 corresponds to ds-siRNA-4,7-CAC 20K conjugate, lane 9 corresponds to ss-siRNA-4,7-CAC 20K conjugate (although the bands crossed over to lane 6), lane 10 corresponds to mPEG2-RU-NHS 20K, lane 11 corresponds to mPEG-SC 20K, lane 12 corresponds to CAC 20K. Conversion yields of ds-siRNA conjugation were estimated by density scanning: all were roughly 50%. FIG. 5B represents the gel of FIG. 5A stained with iodine, thereby showing the PEG components.
[0289] Single stranded siRNA conjugation mixtures were analyzed by RP- HPLC (reversed phase-high performance liquid chromatography), results shown in FIG. 6A , FIG. 6B and FIG. 6C , wherein the chromatogram provided in FIG. 6A corresponds to the product resulting from the reaction parameters for Example 3b, 74% conversion, FIG. 6B corresponds to the product resulting from the reaction parameters for Example 3d, 63.8% conversion, and FIG. 6C corresponds to the product resulting from the reaction parameters for Example 3f, complete conversion detected.
EXAMPLE 4
Conjugation of 5′AminoC6 Tetramer with m-PEG2-RU-NHS 20K [“Reversed-urethane Branched PEG NHS 20K”]
[0290] EPPS buffer (500 mM) was prepared at pH 8.5. A stock solution (14.723 mM) of 5′-aminoC6 ACAA tetramer (Trilink Biotechnology, San Diego, Calif.) was prepared in 1× siRNA buffer (diluted from 5× siRNA buffer, pH 7.5, Dharmacon, Lafayette, Colo.). The reaction was run by dissolution of the indicated polymeric reagent (36.8 mg, 85%) in a mixture of siRNA stock solution (10 μl) and the indicated EPPS buffer (500 mM, 490 μl). The reaction mixture was stirred and incubated at room temperature for three hours. Aliquot (2 μl) was taken, quenched with 0.1 M glycine (2 μl) and diluted with RNAse free water. The sample was analyzed on RP-HPLC, wherein the chromatogram provided in FIG. 7 corresponds to this example and shows a conversion yield of 97%.
EXAMPLE 5a AND 5b
Conjugation of ss-siRNA with m-PEG-SC 20K [“mPEG succinimido carbonate 20K”]
[0291] The mPEG reagent was dissolved in 2 mM HCl (100 mg/ml) and used immediately. A stock solution (10.0 mM) of 5′-AminoC6 siRNA sense strain (SEQ ID NO: 183) (Trilink Biotechnology, San Diego, Calif.) was prepared. The reaction was conducted using the reaction parameters set forth in Table 5. The reaction mixtures were incubated at ambient temperature (22° C.). At 15, 30, 60, 90 minutes, 2 μl reaction mixtures were mixed with 2 μl 0.2 M glycine (unbuffered) to quench the reaction. The samples were analyzed via RP-HPLC (results provided in Table 6). The reaction mixture was subjected to purification on FPLC system equipped with Hi-Trap Q HP anion-exchange cartridge. Pure conjugate was obtained, as shown in the chromatogram provided in FIG. 8 while FIG. 9 provides mass spectrometry results (MALDI-MS) of the m-PEG-SC-(ss-siRNA) conjugate.
[0000]
TABLE 5
Reaction Parameters for Example 5a and Example 5b
Example 5a
Example 5b
m-PEG-SC 20K (90%, 100 mg/ml), μl
14.12
28.24
ss-siRNA (96%, 10 mM), μl
1
1
EPPS buffer (1M, pH 8.5), μl
3.33
3.33
RNAse free water, μl
14.88
0.76
Total Volume, μl
33.33
33.33
Ratio
6:1
12:1
[0000]
TABLE 6
Results at Time Points 15, 30, 60 and 90
minutes for Example 5a and Example 5b
Time
Conversion Yield, %
Point
Example 5a
Example 5b
(minutes)
6:1
12:1
15
49.0
67
30
59.3
76.8
60
64.0
85.4
90
63.3
88.0
EXAMPLE 6
Conjugation of ss-siRNA with CAC 20K Polymeric Reagent [“4,7-CAC-PEG2-FMOC-NHS 20K”]
[0292] The reaction was conducted in a manner similar to those of the previous examples, using the reaction parameters set forth in Table 7. The reaction mixtures were incubated at ambient temperature (22° C.). At 15, 30, 60, 90, and 180 minutes, 2 μl reaction mixtures were mixed with 2 μl 0.2 M glycine (unbuffered) to quench the reaction. The samples were analyzed on RP-HPLC (results provided in Table 8). The reaction mixture was subjected to purification on FPLC system equipped with Hi-Trap Q HP anion-exchange cartridge. The pure product was obtained. The RP-HPLC chromatogram of the product is provided in FIG. 10 while FIG. 11 provides mass spectrometry results (MALDI-MS) of the CAC-(ss-siRNA) conjugate.
[0000]
TABLE 7
Reaction Parameters for Example 6a and Example 6b
Example 6a
Example 6b
CAC 20K (90%, 100 mg/ml), μl
14.12
28.24
ss-siRNA (96%, 10 mM), μl
1
1
EPPS buffer (1M, pH 8.5), μl
3.33
3.33
RNAse free water, μl
14.88
0.76
Total Volume, μl
33.33
33.33
Ratio
6:1
12:1
[0000]
TABLE 8
Results at Time Points 15, 30, 60, 90 and
180 minutes for Example 6a and Example 6b
Time
Conversion Yield, %
Point
Example 6a
Example 6b
(minutes)
6:1
12:1
15
37.8
54.0
30
50.3
69.1
60
55.0
77.8
90
56.3
80.4
180
56.4
79.6
[0293] Further analysis via a native gel analysis for the reaction conducted for 180 minutes were performed by mixing 0.5 μl of the reaction mixture with 1 μl 0.2 M glycine (unbuffered) to quench the reaction. The reaction mixtures were analyzed by 4-20% native PAGE gel as shown in FIG. 12 . In FIG. 12 , lane 1 corresponds to a 10 bp DNA ladder, lane 2 corresponds to ss-siRNA, lane 3 corresponds to m-PEG-SC 20K-ss-siRNA conjugate (6:1), lane 4 corresponds to m-PEG-SC 20K-ss-siRNA conjugate (12:1), lane 5 corresponds to CAC 20K-ss-siRNA (6:1) conjugate, lane 6 corresponds to CAC 20K-ss-siRNA conjugate (12:1).
EXAMPLE 7
PEGylation and Purification of CAC 20K-ssRNA Conjugate [“CAC-PEG2-FMOC-20K-ssRNA conjugate”]
[0294] CAC-ssRNA conjugate was produced in a 0.3-mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009-ML 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL CAC 20K polymeric reagent. The CAC 20K reagent, the last reactive component added to the mixture, was dissolved in RNAse-free water to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-mL with 20 mM Bis-tris buffer, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (5 column volumes). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes at the elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 13 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 8
PEGylation and Purification of CG 20K-ssRNA Conjugate [“CG-PEG2-FMOC-20K-ssRNA Conjugate”]
[0295] CG 20K-ssRNA conjugate was produced in a 0.3-mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009-ML 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL CG 20K polymeric reagent. The CG 20K reagent, the last reactive component added to the mixture, was dissolved in RNAse-free water to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-ML with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow ratio 1 mL/min and then the column was washed with the buffer A (5 column volumes). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes at the elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 14 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was determined by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 9
PEGylation and Purification of C2 20K-ssRNA Conjugate [“C2-PEG2-FMOC 20K-ssRNA Conjugate”]
[0296] C2 20K-ssRNA conjugate was produced in a 0.3-mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009-ML 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL C2 20K polymeric reagent. The C2 20K reagent, the last reactive component added to the mixture, was dissolved in RNAse-free water to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow ratio 1 mL/min and then the column was washed with a 5 column volume of the buffer A. The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes at the elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 15 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 10
PEGylation and Purification of m-PEG-SS 20K-ssRNA Conjugate
[0297] m-PEG-SS 20K-ssRNA conjugate was produced in a 0.3-mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009-ML 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL m-PEG-SS 20K polymeric reagent. The m-PEG-SS 20K reagent, the last reactive component added to the mixture, was dissolved in RNAse-free water to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (5 column volumes). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 16 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 11
PEGylation and Purification of m-PEG-SBC 30K-ssRNA Conjugate
[0298] m-PEG-SBC 30K-ssRNA conjugate was produced in a 0.3-mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009-ML 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml RNAse free water. The m-PEG-SBC 30K polymeric reagent (31.5 mg) was added into the RNA with three portions within 20 minutes. After the last addition of the m-PEG-SBC 30K reagent, the reaction mixture was further incubated at 25° C. for 20 minutes; then 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 17 . The concentration of the conjugate as determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate
EXAMPLE 12
PEGylation and Purification of m-PEG-OPSS 5K-ssRNA Conjugate
[0299] m-PEG-OPSS 5K-ssRNA conjugate was produced by the reduction of 5′capped-RNA (5′-C6-S-SC6-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 186) with Tris (2-Carboxyethyl) phosphine hydrochloride (TCEP HCl) followed by PEGylation with m-PEG-OPSS 5K. To reduce 5′-capped-RNA, a 0.03 mL solution containing 0.002 mL of 5′capped-RNA, 0.006 mL,1 M, EPPS buffer, pH 8.5 and 0.022-mL 18 mM TCEP HCl was incubated at 25° C. without stirring for 60 minutes. After 60 minutes incubation, 0.03 mL reaction mixture was loaded on a desalting column (pre-equilibrated with 20 mM HEPES, 50 mM NaCl, pH 7.4) and rinsed with 0.03 mL buffer (20 mM HEPES, 50 mM NaCl, pH 7.4). A total of 0.06 mL solution containing RNA with free thiol group (5′-HSC6-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′) was collected. To PEGylate free thiol-ss-RNA, 7.2 mg m-PEG-OPSS 5K was added into the 0.06-ML solution containing RNA with free thiol group. After incubation at 25° C. without stirring for three hours, the reaction mixture was diluted to a final volume of 1 mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow ratio 1 mL/min and then the column was washed with the buffer A (a 5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 18 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 13
PEGylation and Purification of Di-C2 20K-ssRNA Conjugate [or “Di-C2-mPEG2-FMOC-20K-ssRNA Conjugate”]
[0300] Di-C2 20K-ssRNA conjugate was produced in a 0.033 mL reaction mixture consisting of 0.003 mL 1 M EPPS buffer, pH 8.5, 0.001 mL 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-C6-NH 2 -3′, SEQ ID NO: 183) and 0.0281 ml of 100 mg/mL C2 20K polymeric reagent. The C2 20K reagent, the last reactive component added to the mixture, was dissolved in RNAse-free water to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.005 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1 mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at 1 mL/min and then the column was washed with the buffer A (a 5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 19 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 14
PEGylation and Purification of m-PEG2-RU-NHS 20K-ssRNA Conjugate [or “ruPEG2-20K-ssRNA Conjugate]
[0301] m-PEG2-RU-NHS 20K-ssRNA conjugate was produced in a 0.3 mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009 mL 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL m-PEG2-RU-NHS 20K polymeric reagent. The m-PEG2-RU-NHS 20K reagent, the last reactive component added to the mixture, was dissolved in 2 mM HCl to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1 mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (a 5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 20 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 15
PEGylation and Purification of mPEG-SBA 5K-ssRNA Conjugate
[0302] m-PEG-SBA 5K-ssRNA conjugate was produced in a 0.3 mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009 mL 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL m-PEG-SBA 5K polymeric reagent. The m-PEG-SBA 5K reagent, the last reactive component added to the mixture, was dissolved in 2 mM HCl to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1-ML with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from the unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (a 5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 21 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 16
PEGylation and Purification of m-PEG-SC 20K-ssRNA Conjugate
[0303] m-PEG-SC 20K-ssRNA conjugate was produced in a 0.3 mL reaction mixture consisting of 0.030 mL 1 M EPPS buffer, pH 8.5, 0.009 mL 10 mM ssRNA (sequence: 5′-C6-NH 2 -AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 183) and 0.261 ml of 100 mg/mL mPEG-SC 20K polymeric reagent. The mPEG-SC 20K reagent, the last reactive component added to the mixture, was dissolved in 2 mM HCl to a final concentration of 100 mg/mL immediately before use. The reaction mixture was incubated at 25° C. without stirring for 60 minutes. After 60 minutes, 0.05 mL 0.4 M glycine (unbuffered) was added into the reaction mixture to quench the unreacted polymeric reagent. After an additional 30 minutes of incubation at 25° C., the reaction mixture was diluted to a final volume of 1 mL with 20 mM Bis-tris, pH 6.8 and purified by anion exchange chromatography (HiTrap Q HP; 1 mL). A linear salt gradient separated the PEGylated ss-RNA from unreacted polymeric reagent and unreacted ssRNA. Purification buffers were as follows: A: 20 mM Bis-tris, pH 6.8, and B: 20 mM Bis-tris, 1.0 M sodium chloride, pH 6.8. The diluted reaction mixture was loaded at the flow rate 1 mL/min and then the column was washed with the buffer A (a 5 column volume). The linear gradient consisted of 10 to 80% of the buffer B over the twenty column volumes of the eluate at an elution flow rate of 1 mL/min. The chromatogram of the reaction mixture is provided in FIG. 22 . The concentration of the conjugate was determined by UV spectrophotometry. The purity of the conjugate was confirmed by ion-exchange HPLC. MALDI-TOF analysis was performed to confirm the molecular weight of the conjugate.
EXAMPLE 17
Comparison of Conjugates
[0304] A comparison of some of the analytical data of the conjugates prepared in Examples 7 through 16 is provided in Table 9. Purity % was determined by anion exchange HPLC while observed molecular weight (MW) was established using MALDI.
[0305] Anion exchange HPLC was carried out using a DIONEX BioLC DNAPac PA-10 column (P/N: 043010, Ser #: 007409; Lot #: 008-20-009) having dimensions of 4 mm×250 mm. Flow rate was set at 1.5 mL/min with a column temperature of 25° C. The detection wavelength was 260 nm. Eluent buffer A was 25 mM Tris/0.5% ACN, pH 8.0/HCl and eluent buffer B was 25 mM Tris/0.5% ACN, NH 4 Cl: 1.6M, pH 8.0/NH 4 OH. The eluent profile for the approach designated as “IEX-6” is set forth in Table 10a and the eluent profile for the approach designated as “IEX-8” is set forth in Table 10b.
[0000]
TABLE 9
Comparison of Conjugates Prepared in Example 7 through 16
Purity
Calculated
Observed
Conjugates
(%)
MW (kD)
MW (kD)
CAC 20K-ssRNA (Example 7)
97
26.3
27.7
CG 20K-ssRNA (Example 8)
>99
26.3
27.3
C2 20K-ssRNA (Example 9)
97
26.3
27.8
m-PEG-SS 20K-ssRNA (Example 10)
93
26.3
26.8
m-PEG-SBC 30K-ssRNA (Example 11)
90
36.3
33.7
m-PEG-OPSS 5K-ssRNA (Example 12)
>99
11.3
12.2
Di-C2 20K-ssRNA (Example 13)
>99
46.3
48.7
m-PEG2-RU-NHS 20K-ssRNA
97
26.3
27.6
(Example 14)
m-PEG-SBA 5K-ssRNA (Example 15)
93
11.3
11.9
m-PEG-SC 20K-ssRNA (Example 16)
92
26.3
26.7
[0000]
TABLE 10a
Eluent Profile for IEX-6 Approach
Time
(minutes)
A
B
−10
85
15
0
85
15
3
85
15
20
66.5
33.5
20.1
0
100
26
0
100
26.1
85
15
26.2
Stop
[0000]
TABLE 10b
Eluent Profile for IEX-6 Approach
Time
(minutes)
A
B
−10
95
5
0
95
5
3
95
5
29.3
66.5
33.5
29.4
0
100
36.4
0
100
36.5
95
5
36.6
Stop
EXAMPLE 18
PEG-ssRNA Conjugate Release Kinetics
[0306] NH 2 —C6-ssRNA release from C2-PEG2-FMOC-20K-ssRNA conjugate. C2-PEG2-FMOC-20K-ssRNA conjugate, prepared as described in Example 9, 24 μM in 20 mM Bis-Tris buffer, pH 6.8, NaCl solution (50 μl) was combined with 0.6M HEPES buffer, pH 7.5 (100 μL, containing 5′-aminoC6 ACAA tetramer as standard) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected (reverse phase HPLC at 260 nm with TEAA water/acetonitrile gradient) at various intervals. Observed results demonstrated a decrease in the PEG-ssRNA conjugate peak with an increase in peaks correlating with released NH 2 —C6-ssRNA and PEG2-fulvene (see the corresponding chromatograms of FIG. 23 ). See also the time-concentration plot of FIG. 24 and Table 11.
[0307] NH 2 —C6-ssRNA release from CG-PEG2-FMOC-20K-ssRNA conjugate. CG-PEG2-FMOC-20K-ssRNA conjugate, prepared as described in Example 8, 25 μM in 20 mM Bis-Tris buffer, pH 6.8, NaCl solution (50 ηL) was combined with 0.6M HEPES buffer, pH 7.5 (100 μL, containing 5′-aminoC6 ACAA tetramer as standard) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected (reverse phase HPLC at 260 nm with TEAA water/acetonitrile gradient) at various intervals. Observed results demonstrated a decrease in the PEG-ssRNA conjugate peak with an increase in peaks correlating with released NH 2 —C6-ssRNA and PEG2-fulvene. See Table 11 and the time-concentration plot of FIG. 24 .
[0308] NH 2 —C6-ssRNA release from CAC-PEG2-FMOC-20K-ssRNA conjugate. CAC-PEG2-FMOC-20K-ssRNA conjugate, prepared as described in Example 7, 24 μM in 20 mM Bis-Tris buffer, pH 6.8, NaCl solution (50 μL) was combined with 0.6M HEPES buffer, pH 7.5 (100 μL, containing 5′-aminoC6 ACAA tetramer as standard) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected at various intervals. Observed results demonstrated a decrease in the PEG-ssRNA conjugate peak with an increase in peaks correlating with released NH 2 —C6-ssRNA and PEG2-fulvene. See Table 11 and the time-concentration plot of FIG. 24 .
[0309] Succinate modified NH 2 —C6-ssRNA release from SS-PEG-20K-ssRNA conjugate. SS-PEG-20K-ssRNA conjugate, prepared as described in Example 10, 25.8 μM in 20 mM Bis-Tris buffer, pH 6.8, NaCl solution (504) was combined with 0.6M HEPES buffer, pH 7.5 (100 μL, containing 5′-aminoC6 ACAA tetramer as standard) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected at various intervals. Observed results demonstrated a decrease in the PEG-ssRNA conjugate peak with an increase in peaks correlating with released succinate modified NH 2 —C6-ssRNA (i.e., COOHCH 2 CH 2 CO—NH—C6-ssRNA). See Table 11 and the time-concentration plot of FIG. 24 .
[0310] NH 2 —C6-ssRNA release from SBC-PEG-30K-ssRNA conjugate. SBC-PEG-30K-ssRNA conjugate, prepared as described in Example 11, 17.6 μM in 20 mM Bis-Tris buffer, pH 6.8, NaCl solution (50 μL) was combined with 0.6M HEPES buffer, pH 7.5 (100 μL) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected at various intervals. Observed results demonstrated a decrease in the PEG-ssRNA conjugate peak with an increase in peaks correlating with released NH 2 —C6-ssRNA and PEG-phenol. See Table 11 and the time-concentration plot of FIG. 24 .
[0311] PEG Conjugate Release Results. Release of the PEG-ssRNA conjugates were analyzed by reverse phase HPLC at 260 nm with TEAA water/acetonitrile gradient. Decrease of the conjugate peaks were observed and plotted according to first order rate plot; ln A/A 0 (peak area at 260 nm) vs. time (h). The release half-life (t 1/2 ) for each conjugate was calculated from the slope (m=−k) of the first order rate plot where t 1/2 =ln 2/k. See Table 11 and the time-concentration plot of FIG. 24 .
[0312] Glycine conjugates were prepared by dissolving 10 mg PEG2-FMOC-NHS 20K reagent, as labeled, in 50 μL of 1% glycine buffer pH 9. After 15 minutes of incubation, the glycine conjugate was diluted with water (283 μL) and was combined with 0.6M HEPES buffer, pH 7.5 (667 μl) to provide a conjugate solution of 0.4 M HEPES buffer, pH 7.5. Glycine conjugates incubated at 37° C. in HPLC vials and aliquots were injected at various intervals for analysis by gel-permeation chromatography with refractive index detection. See Table 11.
[0000]
TABLE 11
Release Half-life Observed for Indicated
Conjugates in 0.4M HEPES, 37° C.
C2-
CG-
CAC-
PEG2-
PEG2-
PEG2-
mPEG-
mPEG-
FMOC
FMOC
FMOC
SBC
SS
20K
20K
20K
30K
20K
Gly Conjugate
1.2 h
5.1 h
16.5 h
(pH 7.5)
ssRNA Conjugate
3.3 h
10.7 h
39.8 h
3.7 h
115.5 h
(pH 7.4)
[0313] OPSS-5K-ssRNA Release Kinetics. Release of the PEG from the OPSS-5K-ssRNA conjugate occurs by a displacement mechanism. The substrate prepared in Example 12 above was carried out using a 50 μL, 47 μM sample in FPLC purification buffer (20 mM Bis-Tris, 200 mM NaCl, pH 6.8) using a releasing buffer: KCl: 2.7 mM, NaCl: 137 mM, phosphate: 10 mM, pH 7.4 with reduced glutathione in releasing buffer, 293 mM, was freshly made and used immediately. 50 μL RNA conjugate buffer was exchanged into releasing buffer via gel filtration; dilute RNA was added to a final volume of 0.3 mL with releasing buffer; the reduced glutathione was added into 0.3 mL RNA conjugate solution. In the final solutions; RNA conjugate concentration: 7.7 μM (estimated); reduced glutathione: 4.8 mM. The mixture was incubated at 37° C. The samples were analyzed by HPLC and the data were analyzed with Prism 4 software assuming a pseudo-first order reaction. The half-life release of the conjugate disulfide under the reduced glutathione conditions described above was 6.3 hours.
EXAMPLE 19
[0314] Preparation of Chitosan 10K/FMOC-CAC 20K Conjugate
[0315] The pH of the chitosan 10K (MW=10000, 0.05 g, 0.28 mmol) solution in 5 mL of Phosphate Buffered Saline (PBS) was adjusted to pH 6.3 using 1M hydrochloric acid (HCl) or 1M sodium hydroxide (NaOH). To the solution was added 9-hydroxymethyl-4-(mPEG(10,000)-carboxyamide)-7-(3-(mPEG(10,000))carbamoyl-propyl)-N-hydroxysuccinimide polymeric reagent (FMOC-CAC 20K, 0.1 g, 5.0 μmol). The solution was stirred at room temperature. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M sodium chloride (NaCl) solution as an eluent. The collected eluent was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 membrane and the resulting solution was evaporated at the reduced pressure. Purified yield 42 mg. The GPC chromatogram ( FIG. 25 ) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate running at 0.5 mL/min, temperature 25° C., refractive index detector) shows peaks at 11.0 minutes, 12.3 minutes, 12.8 minutes, and 15.9 minutes as evidence of at least mono- and di-PEGylation of the chitosan.
EXAMPLE 20
[0316] Preparation of Chitosan 10K/mPEG-SS 20K Conjugate
[0317] The pH of the chitosan 10K (MW=10000, 0.1 g, 0.56 mmol) solution in 5 mL of Phosphate Buffered Saline (PBS) was adjusted to pH 6.3 using 1M hydrochloric acid (HCl) or 1M sodium hydroxide (NaOH). To the solution was added mPEG-SS 20 20K polymeric reagent (double ester 20K, 0.2 g, 10.0 μmol). The solution was stirred at room temperature. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M sodium chloride (NaCl) solution as an eluent. The collected eluent was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 and the resulting solution was evaporated at the reduced pressure. The GPC chromatogram ( FIG. 26 ) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate 0.5 mL/min, temperature 25° C.; refractive index detector) shows peaks at 12.1 minutes, 12.7 minutes, and 15.7 minutes.
EXAMPLE 21
Preparation of Chitosan 3-5K/IR Dye 800CW Conjugate
[0318] To a solution of the chitosan 3-5K (MW=3-5000, 0.01 g, 55.6 μmol) in 0.5 mL of DI water, 35 μL of 0.5M sodium hydroxide was added. A solution of the IR Dye 800CW NHS ester from LiCor® (MW=1166.2, 0.0025 g, 2.15 μmol) in 125 μL of DMSO (dimethyl sulfoxide) was added to the dissolved chitosan. The solution is stirred at room temperature. The product was purified by cation exchange chromatography using a 1M HCl eluent on a POROS 50© cation exchange resin. The collected acidic fraction was neutralized using 1M NaOH and was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 membrane. Next, water was evaporated from the resulting solution at the reduced pressure.
EXAMPLE 22
Preparation of Chitosan 10K/IR Dye 800CW Conjugate
[0319] To a solution of the chitosan 10K (MW=10000, 0.01 g, 55.6 μmol) in 0.5 mL of DI water, 25 μL of 0.5M sodium hydroxide was added. The IR Dye 800CW NHS ester from LiCor® (MW=1166.2, 0.005 g, 4.3 μmol) was dissolved in 250 μL of DMSO (dimethyl sulfoxide). Next, f 60 μL of the resulting solution is removed and added to the dissolved chitosan. The solution is stirred at room temperature. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 membrane. Next, water was evaporated from the resulting solution at the reduced pressure.
EXAMPLE 23
[0320] Preparation of Chitosan 3-5K/mPEG-BTC 5K and IR Dye 800CW Conjugate
[0321] A solution of the chitosan 3-5K/mPEG-BTC 5K conjugate (MW=18-20000, 0.01 g) in 0.5 mL of DI water was prepared. The IR Dye 800CW NHS ester from LiCor® (MW=1166.2, 0.005 g, 4.3 μmol) was dissolved in 250 μL of DMSO (dimethyl sulfoxide). Next, 125 μL of the resulting solution was removed and added to the dissolved chitosan. The solution was stirred at room temperature. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 membrane. Next, water was evaporated from the resulting solution at the reduced pressure.
EXAMPLE 24
Preparation of Chitosan 10K/mPEG-BTC 5K and IR Dye 800CW Conjugate
[0322] A solution of the chitosan 10K/mPEG-BTC 5K conjugate (MW=25000, 0.01 g) in 0.5 mL of DI water was prepared. The IR Dye 800CW NHS ester from LiCor® (MW=1166.2, 0.005 g, 4.3 μmol) was dissolved in 250 μL of DMSO (dimethyl sulfoxide). Next, 60 μL of the resulting solution was removed and added to the dissolved chitosan. The solution is stirred at room temperature. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and was dialyzed to remove the excess salt using a SpectraPor MWCO 6-8000 membrane. Next water was evaporated from the resulting solution at the reduced pressure.
EXAMPLE 25
Preparation of Chitosan 3-5K/mPEG-butrALD 5K Conjugate
[0323] Chitosan 3-5K (MW=3-5000, 0.1 g, 0.56 mmol) was dissolved in 5 mL of DI water and the pH of the solution was adjusted to pH 8.4 using 1M sodium hydroxide (NaOH). To the solution was added mPEG-butrALD 5K (MW=5000, 1.39 g, 0.278 mmol). The solution was stirred at room temperature for one hour and then added 0.21 g sodium borohydride (5.56 mmol) was added and the mixture was stirred overnight. The reaction mixture was transferred to SpectraPor MW6-8000 dialysis tubing and dialyzed versus DI water. The dialysate is changed every hour for a total of four washes. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and concentrated under vacuum. The resulting material is redissolved in 10 mL and transferred to SpectraPor MWCO 6-8000 dialysis tubing and dialyzed to remove the excess salt. The conductivity of the dialysate is monitored and replaced every hour until the conductivity is approximately 4 μS/cm. The resulting solution is transferred to a round bottom flask and the solvent was evaporated at the reduced pressure. The GPC chromatogram ( FIG. 27 ) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate 0.5 mL/min, temperature 25° C.; refractive index detector) shows peaks at 13.2 minutes, 13.8 minutes, and 14.8 minutes.
EXAMPLE 26
Preparation of Chitosan 10K/mPEG-butrALD 5K Conjugate
[0324] Chitosan 10K (MW=10000, 0.1 g, 0.56 mmol) was dissolved in 5 mL of DI water and the pH of the solution was adjusted to pH 6.3 using 1M sodium hydroxide (NaOH). To the solution was added mPEG-butrALD 5K (MW=5000, 1.39 g, 0.278 mmol). The solution was stirred at room temperature for one hour and then 0.21 g sodium borohydride (5.56 mmol) was added and the mixture was stirred overnight. The reaction mixture was transferred to SpectraPor MW6-8000 dialysis tubing and dialyzed versus DI water. The dialysate is changed every hour for a total of four washes. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and concentrated under vacuum. The resulting material is redissolved in 10 mL and transferred to SpectraPor MWCO 6-8000 dialysis tubing and dialyzed to remove the excess salt. The conductivity of the dialysate is monitored and replaced every hour until the conductivity is approximately 4 μS/cm. The resulting solution is transferred to a round bottom flask and water was evaporated at the reduced pressure. The GPC chromatogram ( FIG. 28 ) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate 0.5 mL/min, temperature 25° C.; refractive index detector) shows peaks at 11.2 minutes, 12.3 minutes, 13.7 minutes, and 14.7 minutes.
EXAMPLE 27
Preparation of Chitosan 3-5K/mPEG-BTC 5K Conjugate
[0325] Chitosan 3-5K (MW=3-5000, 0.1 g, 0.56 mmol) in 10 mL of 0.1M boric acid and adjusted solution to pH 8.5 using 0.1M sodium hydroxide (NaOH). To the solution was added mPEG-BTC 5K (MW=5000, 0.77 g, 0.14 mmol). The solution was stirred at room temperature overnight. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and concentrated under vacuum. The resulting material is redissolved in 10 mL and transferred to SpectraPor MWCO 6-8000 dialysis tubing and dialyzed to remove the excess salt. The conductivity of the dialysate is monitored and replaced every hour until the conductivity is approximately 4 μS/cm. The resulting solution was transferred to a round bottom flask and water was evaporated at the reduced pressure. The GPC chromatogram (not shown) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate 0.5 mL/min, temperature 25° C.; refractive index detector) shows peaks at 13.2 minutes, 14.4 minutes, and 17.1 minutesindicating mono-, di- and tri-PEGylation.
EXAMPLE 28
Preparation of Chitosan 10K/mPEG-BTC 5K Conjugate
[0326] Chitosan 10K (MW=10000, 0.1 g, 0.56 mmol) was dissolved in 10 mL of 0.1M boric acid solution and the pH of the solution was adjusted solution to pH 6.5 using 0.1 M sodium hydroxide (NaOH). To the solution was added mPEG-BTC 5K polymeric reagent (MW=5000, 0.77 g, 0.14 mmol). The solution was stirred at room temperature overnight. The product was purified by cation exchange chromatography using a POROS 50© cation exchange resin and a 1M HCl as an eluent. The collected acidic fraction was neutralized using 1M NaOH and concentrated under vacuum. The resulting material is redissolved in 10 mL DI water and transferred to SpectraPor MWCO 6-8000 dialysis tubing and dialyzed to remove the excess salt. The conductivity of the dialysate is monitored and replaced every hour until the conductivity is approximately 4 μS/cm. The resulting solution is transferred to a round bottom flask and water was evaporated at reduced pressure. The GPC chromatogram (not shown) (Ultrahydrogel 250 column, mobile phase: 0.2M sodium acetate/0.3M acetic acid, flow rate 0.5 mL/min, temperature 25° C.; refractive index detector) shows peaks at 11.4 minutes, 12.5 minutes, 13.5 minutes and 14.9 minutes indicating mono-, di- and tri-PEGylation.
EXAMPLE 29
Preparation of Chitosan and PEG-Chitosan/siRNA Ionic Complexes
[0327] The chitosan or chitosan/PEG conjugate was dissolved in PBS buffer at pH 5.3, 6.3, or 7.3 with the resulting solution having a final concentration of 5 mg/mL. The siRNA duplex was dissolved in DI water at a final concentration of 2.5 mg/mL. The resulting ionic complexes were prepared by the addition of the specific quantities of the chitosan or chitosan/PEG conjugate solution (listed in the Table 12A to 12D) to the specific quantities of the solution of siRNA.
[0000]
TABLE 12A
Summary of data for Chitosan 3-5K/siRNA Ionic Complexes
Chitosan 3-5K
siRNA
PBS
Ratio
(μL)
(μL)
(μL)
(N:P)
3
3
9
1:1
4.5
3
7.5
1.5:1
6
3
6
2:1
7.5
3
4.5
2.5:1
[0000]
TABLE 12B
Summary of data for Chitosan 10K/siRNA Ionic Complexes
Chitosan 10K
siRNA
PBS
Ratio
(μL)
(μL)
(μL)
(N:P)
1.5
3
10.5
1:1
3
3
9
2:1
4.5
3
7.5
3:1
6
3
6
4:1
7.5
3
4.5
5:1
[0000]
TABLE 12C
Summary of data for PEG-Chitosan 3-5K/siRNA Ionic Complexes
PEG-Chitosan
siRNA
PBS
Ratio
3-5K (μL)
(μL)
(μL)
(N:P)
3
3
9
1:1
4.5
3
7.5
1.5:1
6
3
6
2:1
7.5
3
4.5
2.5:1
[0000]
TABLE 12D
Summary of data for PEG-Chitosan 10K/siRNA Ionic Complexes
PEG-Chitosan
siRNA
PBS
Ratio
10K (μL)
(μL)
(μL)
(N:P)
1.5
3
10.5
1:1
3
3
9
2:1
4.5
3
7.5
3:1
6
3
6
4:1
7.5
3
4.5
5:1
[0328] Evaluation of the prepared chitosan and chitosan-PEG complexes with siRNAs is described in the Example 35.
EXAMPLE 30
PEG-Chitosan Release Kinetics
[0329] CAC-PEG2-FMOC-20K-Chitosan-10K conjugate release. CAC-PEG2-FMOC-20K-Chitosan-10K conjugate, prepared as described in Example 19, 1 mg in 20 mM Bis-Tris, pH 6.8, NaCl solution (167 μL) was combined with 0.6M HEPES, pH 7.5 (333 μL) to provide a conjugate solution of 0.4 M HEPES, pH 7.4. The conjugate solution was incubated in an HPLC vial at 37° C. and aliquots were injected (reverse phase HPLC at 260 nm with TEAA water/acetonitrile gradient) at various intervals. Observed results demonstrated a decrease in the PEG-Chitosan conjugate peaks with an increase in peak correlating with released and PEG2-fulvene.
[0330] Release of the PEG-Chitosan conjugate was analyzed by reverse phase HPLC at 260 nm with TEAA water/acetonitrile gradient. Increase of the PEG-fulvene peak was observed and plotted according to first order rate plot; ln A/A 0 (peak area at 260 nm) vs. time (h). The release half-life (t 1/2 ) for each conjugate was calculated from the slope (m=k) of the first order rate plot where t 1/2 =ln 2/k. Data provided in Table 13.
[0000]
TABLE 13
Release Half-life Observed for Indicated
Conjugates in 0.4M HEPES, 37° C.
C2-
CG-
CAC-
PEG2-
PEG2-
PEG2-
mPEG-
mPEG-
FMOC
FMOC
FMOC
SBC
SS
20K
20K
20K
30K
20K
CAC-Chitosan
NA
NA
2.4 h*
NA
NA
Conjugate, pH 7.4
(*Calculated from limited data, t = 0 and t = 7.2 h. NA = Data not available)
EXAMPLE 31
Synthesis of an Oligomer Having an Ortho Pyridyl Disulfide (OPSS) Active Group and a RGD Peptide Targeting Moiety
[0331] Following the reaction schematic shown below, the synthesis of an oligomer having an ortho pyridyl disulfide (OPSS) active group and a RGD peptide targeting moiety was conducted.
[0000]
4-(2-(2-(3-(pyridin-2-yldisulfanyl)propanamido)ethoxy)ethoxy)butanoic acid (Compound 6)
[0332] 4-(2-(2-aminoethoxy)ethoxy)butanoic acid (Compound 4) (F.W. 312.37, 100 mg, 0.377 mmole) in 20 mL of anhydrous toluene was azetropically distilled under reduced pressure at 60! C on a rotary evaporator. The azeotropic distillation was repeated with 20 mL of anhydrous toluene. Then, the resulting residue was dissolved in anhydrous DCM (20 ml). To the above solution was added N-succinimidyl-3-(2-pyridithio)propionate (Compound 5) (SDPD, F.W. 265.3, 100 mg, 0.32 mmole) and triethylamine (105 μl, 0.75 mmole). The mixture was allowed to stand for overnight under stirring at room temperature. TLC showed the disappearance of SPDP. The reaction solution was washed with diluted phosphoric acid (pH4, 5 ml×2). The organic phase was dried over anhydrous Na 2 SO 4 and concentrated under reduced pressure. The resulting residue was subject to flash chromatography on a Biotage system, giving 140 mg of Compound 6, purity>95% (HPLC). 1 H NMR in CDCl 3 , δ ppm: 8.49 (1H, s), 7.74 (1H, d), 7.69 (1H, m), 7.15 (1H, q), 3.80 (2H, t), 3.64 (12H, m), 3.59 (2H, t), 3.46 (2H, dd), 3.07 (2H, t), 2.64 (4H, m). ESI-MS: [M+H] + 417.
N-(2-(2-(4-(2,5-dioxopyrrolidin-1-yl)-4-oxobutoxy)ethoxy)ethyl)-3-(pyridin-2-yldisulfanyl)propanamide (Compound 7)
[0333] Compound 6 (15 mg, 0.036 mmol) was dissolved in 10 mL of anhydrous DCM. To the above solution were added NHS (4.54 mg, 1.05 equiv.) and EDC hydrochloride (7.25 mg, 1.10 equiv.), respectively. The mixture was stirred for one day at room temperature. Reverse phase HPLC analysis showed that the reaction was complete. The reaction solution was washed with diluted phosphoric acid (pH 4, 10 ml×2). Organic phase was dried over anhydrous Na 2 SO 4 and concentrated under reduced pressure, yielding syrup Compound 7 (15 mg, 74.5%), substitution 85%. 1 H NMR in CDCl 3 , δ ppm: 8.49 (1H, s), 7.66 (2H, m), 7.12 (1H, m), 6.89 (1H, b), 3.86 (1H, t), 3.64 (12H, m), 3.59 (2H, t), 3.46 (2H, dd), 3.08 (2H, t), 2.89 (2H, t), 2.84 (3.4H, s), 2.62 (2H, t). ESI-MS: [M+H] + 560.
[0334] Conjugation of OPSS-TEG-SPA with cRGDfK
[0335] OPSS-TEG-SPA (5.6 mg, 0.010 mmol) [TEG representing a tetra(ethylene oxide)] was mixed with cRGDfK peptide (3.0 mg, 0.005 mmol) in 100 mM carbonate-bicarbonate buffer (pH 10.1). The mixture was allowed to stand for three hours at room temperature. The reaction mixture was analyzed on a Zorbax C18 (4.6×50 mm) with a gradient of 10-60% ACN in 0.1% TFA and flow rate 1.5 ml/min. RGDfK Conjugate with a M.W. 1047 was formed with a retention time of 1.99 min (40.6%, UV 254 nm), compared to 2.17 min for hydrolyzed form (20.1%, UV 254 nm), and 8.13 min for additional component (33%, UV 254 nm). The RDGfK with TEG linker and active OPSS group can be conjugated with siRNA having an active thiol functionality, such as the hexyl thiol modified siRNA described herein. By way of illustration, see Example 32.
EXAMPLE 32
ssRNA-C 6 -SS-TEG-(KfDGR-N Terminus) Conjugate
[0336] ssRNA-C 6 -SS-TEG-(KfDGR-N terminus) conjugate was produced by the reduction of 5′capped-RNA (5′-C6-S-SC6-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′, SEQ ID NO: 186) with Tris (2-Carboxyethyl)phosphine Hydrochloride (TCEP HCl) followed by the coupling with OPSS-TEG-KfDGR-(N terminus).
[0337] To reduce 5′-capped-RNA, a 0.015-ML solution containing 0.003 mL 5′capped-RNA, 0.003-ML,1 M, EPPS, pH 8.5 and 0.007-ML 64 mM TCEP HCl was incubated at 25° C. without stirring for 60 minutes. After 60 minutes incubation, 0.015-ML reaction mixture was loaded on a desalting column (pre-equilibrated with 20 mM HEPES, 50 mM NaCl, pH 7.4) and rinsed with 0.045-ML buffer (20 mM HEPES, 50 mM NaCl, pH 7.4). A total of 0.06-ML solution containing RNA with free thiol group (5′-HSC6-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′) was collected.
[0338] To couple reduced RNA with OPSS-TEG-(KfDGR-N terminus), 0.005-mL of reduced oligo from the above reaction was mixed with 0.005-ML solution containing a mixture of OPSS-TEG-(KfDGR-N terminus) and OPSS-TEG-propionic acid. The reaction mixture was incubated at 25° C. without stirring for three hours. Analysis of the reaction mixture by ion-exchange HPLC revealed a new peak (RT=14.6 min, 26% UV 260 nm) supporting the expected formation of ssRNA-C 6 -SS-TEG-(KfDGR-N terminus) conjugate. An additional peak was observed (RT=15.7 min, 45% UV 260 nm) and correlated with separately prepared impurity marker for ssRNA-C 6 -SS-TEG-propionic acid conjugate. The ssRNA-C 6 -SS-TEG-propionic acid conjugate was prepared as an impurity marker by coupling reduced RNA with OPSS-TEG-propionic acid.
EXAMPLE 33
Additional Syntheses of siRNA, Chitosan, and PEGs Having Targeting Moieties
[0339] Targeting moieties may be attached to either the siRNA, chitosan (or other positively charged polymer described herein), or PEGs including heterobifunctional PEGs that may also be attached at the remote end to either chitosan or siRNA.
[0340] Pemetrexed targeting moiety attached to PEG. Using the following reaction scheme, a pemetrexed moiety (i.e., a moiety having pemetrexed activity) can be attached to a polymer.
[0000]
(S)-4-(4-(2-(2-amino-4-oxo-4,7-dihydro-3H-pyrrolo[2,3-d]pyrimidin-5-yl)ethyl)benzamido)-5-(benzyloxy)-5-oxopentanoic acid (Compound 13)
[0341] To a solution of 4-[2-(2-amino-4,7-dihydro-4-oxo-1H-pyrrolo[2,3-d]-pyrimidin-5-yl)ethyl]benzoic acid (38.4 mg, 0.129 mmol) in 5 mL of DMF was added N-methylmorpholine (40.4 mg, 0.399 mmol), followed by the addition of 2-chloro-4,6-dimethoxy-1,3,5-triazine (22.64 mg, 0.129 mmol). The resulting mixture was stirred for 1.5 hours at 25 !C, at which time HPLC showed that the reaction was complete. L-glutamic acid γ-benzyl ester (30.6 mg, 0.129 mmol) was added, and stirring was continued at 25 !C until complete conversion of precursor was determined by HPLC (around two hours). To the reaction mixture was added 10 mL of methylene chloride and 10 ml of deionized water, and the mixture was stirred for 15 minutes. The layers were separated. The aqueous layer was extracted with DCM (10 ml×2). The organic phases were combined. The solution was concentrated on rotary-evaporator under reduced pressure. The resulting residue was subjected to flash chromatography on a Biotage system. Yield: 55 mg, 82%. 1 HNMR in d 6 -DMSO, δ ppm: 10.61 (1H, s), 10.20 (1H, s), 8.72 (1H, d, J=10 Hz), 7.78 (2H, d, J=5 Hz), 7.35 (5H, m), 7.30 (2H, m), 6.30 (1H, s), 6.07 (2H, s), 5.14 (2H, s), 3.86 (1H, m), 2.97 (2H, t), 2.84 (2H, t), 2.20 (2H, s), 2.02 (1H, m), 1.95 (1H, m). ESI-MS: 518 [M+H] + .
(S)-1-benzyl 5-(2,5-dioxopyrrolidin-1-yl) 2-(4-(2-(2-amino-4-oxo-4,7-dihydro-3H-pyrrolo[2,3-d]pyrimidin-5-yl)ethyl)benzamido)pentanedioate (Compound 15)
[0342] A mixture of Compound 13 (55 mg, 0.11 mmol), NHS (15.4 mg, 0.132 mmol) and EDC hydrochloride (27 mg, 0.140 mmol) in anhydrous DMF was stirred at room temperature for two days. TLC showed the disappearance of starting material. Solvent was stripped off under reduced pressure. The resulting residue was dissolved in DCM (50 mL). The solution was washed with diluted phosphoric acid (pH 4) (50 mL×3). The organic phase was dried over anhydrous Na 2 SO 4 . The solvent was removed, resulting in 48 mg residue, yield 60%, substitution 80%. 1 HNMR in d 6 -DMSO, 6 ppm: 10.65 (1H, s), 10.21 (1H, s), 8.77 (1H, d, J=10 Hz), 7.79 (2H, d, J=5 Hz), 7.34 (5H, m), 7.30 (2H, m), 6.30 (1H, s), 6.08 (2H, s), 5.16 (2H, s), 2.97 (2H, t), 2.89 (2H, t), 2.81 (3.2H, s) 2.36 (2H, m), 2.20 (2H, s). ESI-MS: 615 [M+H] + .
[0343] Conjugation to chitosan amine groups, to PEG amines or to aminohexyl siRNAs is carried out in a similar manner to other reactions of amine substituted polymers described herein, e.g., see Examples 1-3. The following example demonstrates the successful attachment of the above synthesized activated targeting moiety to a heterobifunctional 20 kD.
[0344] Conjugation of NH 2 -PEG-BA 20K and Pemetrexed-NHS Ester
[0345] NH 2 -PEG-butric acid 20K (0.25 g, 12.5 μmol) is added to 1 mL of 0.1M boric acid, the solution is adjusted to pH 9 using 1M NaOH. To the solution is added 0.375 mL of a 40 mg/mL pemetrexed-NHS ester (24.4 μmol) dropwise over 25 minutes while maintaining a constant pH of 9. The reaction mixture is allowed to stir at room temperature for two hours. To the solution is added 0.5 g of sodium chloride and adjusted to pH 3 using 1M HCl. The product is extracted using three aliquots of 5 mL of DCM. The collected DCM fractions are combined and the DCM is removed under vacuum. The precipitated product is analyzed by GPC Ultrahydrogel 250 column running 0.01M HEPES buffer at 0.5 mL/min at 75° C. to assess the remaining unreacted amine. A peak at 12.7 minutes corresponds to the product of pemetrexed-PEG-BA, and unreacted NH 2 -PEG-BA has a retention time of 30.4 minutes. There is no peak at 30.4 minutes confirming that the PEG amine had been fully substituted with the Pemetrexed moiety.
[0346] Activation of Pemetrexed-PEG-BA with NHS.
[0347] The above dried product is redissolved in 2 mL of DCM, to the solution is added 1.6 mg of NHS (N-hydroxysuccinimide, 14 μmol) and 3.3 mg of DCC (N,N′-dicyclohexylcarbodiimide, 16.2 μmol) and stirred overnight. The product is removed by precipitation through the addition of IPA (2-propanol) and collected by filtration. 1 H-NMR (CDCl3, 500 MHz): δ (ppm) 2.82 (s, 4H, CO—CH 2 —CH 2 —CO on NHS); 2.92 (t, CH 2 on β-carbon to NHS ester); 3.64 (s, PEG backbone).
[0348] Phospholipids
[0349] Following the reaction schematic below, 1,2-dipalmitoyl-glycero-3-phosphorimidazolide was prepared.
[0350] 1,2-dipalmitoyl-glycero-3-phosphate monosodium salt (MW=670.87, 50 mg, 74.5 μmol) was dissolved in 5 mL chloroform, to the solution was added 76 mg imidazole (1.1 mmol), 230 mg DCC (1.1 mmol), 151 mg N-hydroxybenzotriazole (HOBt, 1.1 mmol), and 50 μL TEA. The solution was stirred at 60° C. overnight. The product was precipitated by addition of acetone and water giving a fine white precipitate. The precipitate was collected by centrifugation at 13,200 rpm for ten minutes. 1 H-NMR (CDCl3, 500 MHz): δ (ppm) 0.88 (t, 6H, —CH 3 ); 1.25 (bm, —CH 2 —); 7.75 (d, 1H); 7.93 (d, 1H); 8.15 (d, 1H).
[0351] DSPE Targeting Moieties and Their Conjugates
[0352] Following the reaction schematic below, a DSPE targeting moiety and its conjugate can be prepared.
[0000]
Preparation of 1,2-distearoyl-N-succinimidyl-glutaryl-phosphatidylethanolamine (DSPE-NHS)
[0353] To the solution of 5 mL of chloroform was added 100 mg of 1,2-distearoyl-sn-glyvero-3-phosphoethanolamine (DSPE, 0.133 mmol), 36 mg of 4-dimethylamino pyridine (DMAP, 0.294 mmol), 17 mg of glutaric anhydride (0.147 mmol), and 28 μL of triethylamine (TEA). The reaction mixture was stirred at 60° C. for 4 hours. DSPE was precipitated by the addition of 20 mL of acetone and the product was collected by filtration.
[0354] The dried product was redissolved in 1 mL of chloroform and to the solution was added 38 mg of DCC and 18 mg of NHS. The reaction was stirred at room temperature overnight. To the solution was added 10 mL of acetone and then filtered to remove any insoluble material. The acetone/chloroform mixture was removed under vacuum. 1 H-NMR (CDCl3, 500 MHz): δ (ppm) 0.88 (t, 6H, —CH 3 ); 1.25 (s, —CH 2 —); 2.07 (m, 2H, —CH2- γ-carbon on glutaric anhydride); 2.82 (s, 4H, CO—CH 2 —CH 2 —CO on NHS); 2.92 (t, CH 2 on β-carbon to NHS ester).
[0355] Conjugation to chitosan amine groups, to PEG amines or to aminohexyl siRNAs is carried out in a similar manner to other reactions of amine substituted polymers described herein, e.g., see Examples 1-3.
EXAMPLE 34
Biological Evaluation of Conjugates
[0356] Methods. The siRNA sequence is directed against Sjogren syndrome antigen B (SSB) gene.
[0000]
(SEQ ID NO: 191)
Sense: 5′-AmCAmACmAGmACmUUmUAmAUmGUmAA-3′.
(SEQ ID NO: 192)
Antisense: 3′-mUGmUUmGUmCUmGAmAAmUUmACmAUmU-5′.
[0357] (Lower case ‘m’ indicates “2′OMe” modification).
[0358] Annealing conjugates. The antisense strand was re-suspended in siRNA buffer (Thermo Scientific, USA). RNA concentration of the sense-strand-polymer conjugates was determined using RiboGreen (Invitrogen, USA) as per manufacturer's instructions. RNA sense strand-conjugates were mixed with antisense at eqimolar concentrations and heated to 50° C. for five minutes followed by gradual cooling to room temperature. Displayed in FIG. 29 are results of ion exchange chromatography of conjugate CAC-FMOC 20K;5′NH-sense (panel A), antisense (panel B), conjugate annealed with antisense (panel C).
[0359] Cell line and transfection. Human embryonic kidney 293 cells were plated on 12-well plates (1.5×10 5 cells per well) in MEMα supplemented with 10% FBS. The following day, medium was changed to reduced serum OPTI-MEM (Gibco, Carlsbad, Calif., USA). Cells were treated with 100 nM annealed conjugate complexed with Lipofectamine 2000 as per manufacturer's instruction. Four hours after treatment, FBS was added to each well to a final concentration of 2%. Cells were harvested 48 hours after conjugate treatment and RNA isolated using Tri-Reagent (Applied Biosystems, Calif., USA) as per manufacturer's instructions.
[0360] RT-qPCR. RNA yield was determined spectrophotometrically by measuring absorbance at 260 nm and RNA quality was assessed by agarose gel electrophoresis. Equal amounts of RNA (600 μgs) was converted to cDNA using High-Capacity cDNA Reverse transcription Kit (Applied Biosystems, USA) as per manufacturer's instructions. Levels of SSB mRNA in each sample were determined using an ABI7300 Q-PCR instrument and TaqMan assay reagents from Applied Biosystems (SSB assay cat. #4331182, Hs00427601 ml and GAPDH assay cat. #4326317E).
[0361] FIG. 30 shows knockdown of SSB RNA expression by conjugates R1 through R5 when transfected using Lipofectamine2000. SSB gene expression relative to untreated cells (bar1), annealed siRNA (bar2), control SSB siRNA (bar3), conjugates R1 through R5 complexed with Lipofectamine2000 (bars 4 through 8). FIG. 31 shows knockdown of SSB RNA expression in cells treated with conjugates S1 through S3 transfected using Lipofectamine2000. FIG. 32 shows SSB RNA expression knockdown by SSB siRNA with various linkers attached prior to polymer conjugation. All constructs shown were annealed prior to use with the same sense or antisense strand sequence.
EXAMPLE 35
Evaluation of Chitosan-PEG Complexes with siRNAs
[0362] PAGE Gel electrophoresis of siRNA/chitosan ionic complexes. The siRNA and chitosan or chitosan/PEG conjugates are mixed together at a given ratio of N:P with a volume of 15 μL, added to this solution is 3 μL of a loading material containing 50% glycerol. Each sample (10 μl) is loaded into a 15% PAGE gel running a TAE buffer (Tris Acetate EDTA) at pH 7.3. The gel is run at 100 volts for two hours, afterwards the gel is removed from the cassette and stained for 10 minutes using 10 mg/mL ethidium bromide solution and washed for a minimum of one hour in DI water. The ethidium bromide stained gel is visualized by UV light.
[0363] Complexes of various chitosan/siRNA modifications were evaluated using analysis using PAGE gel. PAGE gel analysis was completed using a 1:1 and a 2:1 ratio (N:P) of a chitosan 3-5 kD/mPEG-butrALD 5 kD and chitosan 10 kD/mPEG-butrALD 5 kD using a running buffer of TBE (pH 8.4), TAE (pH 7.3) and TAE (pH 5.3). No neutralization of the siRNA duplex (SEQ ID NO: 183:SEQ ID NO: 192) was seen with the chitosan 3-5K and some slight tailing seen with the chitosan 10K complexes indicating some neutralization of the siRNA duplex.
[0364] The gel showing the analysis of chitosan-PEG complexes with siRNA is provided in FIG. 33 , wherein lane 1 corresponds to the siRNA duplex, lane 2 corresponds to chitosan 3-5K/ALD 5K and siRNA at 1:1, lane 3 correspondes to chitosan 10K/ALD 5K and siRNA at 1:1, lane 4 corresponds to chitosan 10K/ALD 5K and siRNA at 2:1, lane 5 corresponds to IR 800 CW dye labeled chitosan 10K/BTC 5K and siRNA at 1:1, lane 6 corresponds to IR 800CW dye labeled chitosan 10K/BTC 5K and siRNA at 2:1, lane 7 corresponds to siRNA duplex, lane 8 corresponds to chitosan 3-5K/ALD 5K and siRNA at 1:1, lane 9 corresponds to chitosan 10K/ALD 5K and siRNA at 1:1, and lane 10 corresponds to chitosan 10K/ALD 5K and siRNA at 2:1.
[0365] Increasing the nitrogen ratio leads to neutralization of the siRNA duplex. Analysis based on a PAGE gel using TAE buffer at pH 7.3 was performed. The chitosan 10 kD/mPEG-butrALD 5kD neutralizes the siRNA duplex, as revealed by the PAGE gels. The gel showing the analysis of chitosan-PEG complexes with siRNA, wherein the complexes were formed with increased nitrogen ratios is provided in FIG. 34 . In this gel, lane 1 corresponds to siRNA duplex, lane 2 corresponds to chitosan 3-5K/ALD 5K and siRNA at 50:1, lane 3 corresponds to chitosan 3-5K/ALD 5K and siRNA at 20:1, lane 4 corresponds to chitosan 3-5K/ALD 5K and siRNA at 10:1, lane 5 corresponds to chitosan 10K/ALD 5K and siRNA at 50:1, lane 6 corresponds to chitosan 10K/ALD 5K and siRNA at 20:1, lane 7 corresponds to chitosan 10K/ALD 5K and siRNA at 10:1, lane 8 corresponds to siRNA duplex, lane 9 corresponds to IR 800CW dye labeled chitosan 10K/BTC 5K and siRNA at 10:1, and lane 10 corresponds to siRNA duplex.
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Described herein are tricyclic macrolactones. The macrolactones have a high binding affinity for PKC. The compounds described herein can be used in a number of therapeutic applications including cancer and Alzheimer's prevention and treatment. The compounds described herein can also treat memory loss. Also described herein are methods for producing macrolactones. The methods permit the high-yield synthesis of macrolactones in fewer steps and with a higher degree of substitution and specificity.
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[0001] This present application claims benefit of U.S. Provisional Patent Application Ser. No. 60/575,955, filed Jun. 1, 2004, which application is hereby incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates to body cushioning systems for use in vehicles, and in particular side impact protectors for use by people traveling in vehicles. More particularly, the present disclosure relates to a side impact protector that is wearable by a child traveling in a vehicle.
[0003] Juvenile seats are widely used to transport young children in automobiles and other vehicles. Such seats include backless and high back booster seats.
[0000] knowledgeable
SUMMARY
[0004] According to the present disclosure, a side impact protector is configured to be worn by a youth seated in a child-restraint system anchored in place on a vehicle seat. Such a protector may also be worn by a person of any age seated in a vehicle and restrained using a seat belt harness of the type found onboard a vehicle.
[0005] Features of the present disclosure will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The detailed description particularly refers to the accompanying figures in which:
[0007] FIG. 1 is a perspective view of a wearable side impact protector in accordance with a first embodiment of the present disclosure;
[0008] FIG. 2 is a rear elevation view of the protector of FIG. 1 with portions broken away;
[0009] FIG. 3 is a perspective view of a child wearing the side impact protector shown in FIGS. 1 and 2 ;
[0010] FIG. 4 is a perspective view of the child of FIG. 3 seated in a high back booster seat located in a vehicle equipped with a seat-belt restraint system while wearing the side impact protector of FIGS. 1-3 ;
[0011] FIG. 5 is a side elevation view of the high back booster seat of FIG. 4 ;
[0012] FIG. 6 is a perspective view of the child of FIG. 3 seated in a backless booster seat located in a vehicle equipped with a seat-belt restraint system while wearing the side impact protector of FIGS. 1-3 ;
[0013] FIG. 7 is a perspective view of a wearable side impact protector in accordance with a second embodiment of the present disclosure; and
[0014] FIG. 8 is a side elevation view, with portions broken away, of a child seated in a high back booster seat while wearing the side impact protector of FIG. 7 .
DETAILED DESCRIPTION
[0015] Side impact protector 10 includes a head cradle 12 , cradle support 14 coupled to head cradle 12 , a waist strap 16 coupled to a lower portion 18 of cradle support 14 , and a shoulder harness 20 coupled to a middle portion 22 of cradle support 14 as shown, for example, in FIGS. 1 and 2 . Cradle support 14 also includes an upper portion 24 coupled to a rear surface 26 of head cradle 12 as shown best in FIG. 2 . Head cradle 12 and cradle support 14 cooperate to form a brace that is adapted to transmit, direct, resist, or support weight or pressure of the head and/or neck of a person wearing side impact protector 10 .
[0016] Illustratively, shoulder harness 20 is configured as a first strap and a second strap adapted to be coupled to a wearer, and waist strap 16 is configured as a third strap adapted to be coupled to the wearer. First strap 20 is formed to include loops 21 at end portions of first strap 20 . Loops 21 are configured to receive a portion of second strap 20 therethrough.
[0017] Head cradle 12 includes a U-shaped frame 28 formed to include a convex portion providing rear surface 26 and a concave portion 30 facing toward the head of a person wearing side impact protector 10 as shown in FIG. 3 . Head cradle 12 also includes a U-shaped cushion 32 mounted on concave portion 30 to provide padding for the head and neck of the person wearing side impact protector 10 . Head cradle 12 includes side wings 31 to envelope the head of a wearer; however, head cradle 12 is open on the top and front. Illustratively, side wings 31 include a first side wing and a second side wing. A width of head cradle 12 extends from the first side wing 31 to the second side wing 31 and a width of cradle support 14 is less than the width of head cradle 12 .
[0018] Waist strap 16 and shoulder harness 20 are used to retain cradle support 14 in place along the back of a wearer as suggested in FIG. 3 . It is within the scope of this disclosure to use a backpack (not shown) in place of waist strap 16 and shoulder harness 20 to retain cradle support 14 in place on a wearer.
[0019] Cradle support 14 is sized and shaped to cause head cradle 12 to surround a portion of a wearer's head and neck before and after the wearer is seated in a high back juvenile seat 34 or a backless juvenile seat 36 as suggested, for example, in FIGS. 3-6 . Although not shown, a wearer could sit directly on a vehicle seat 38 and be restrained by a vehicle seat-belt harness 40 while wearing side impact protector 10 without necessarily sitting on a juvenile seat 34 or 36 . Seat-belt harness 40 includes a lap belt 41 and a shoulder belt 42 .
[0020] Side impact protector 10 can be used with a car seat having an internal harness system or with a belt-positioning booster seat. Protector 10 can be attached to a wearer via a back pack system or a harness system. Protector 10 can be made of both hard and soft goods such as polyester, nylon, cotton, and polypropylene. As suggested in FIG. 5 , in the case of a high back juvenile seat 34 , a portion of head cradle 12 is located in a space provided between a left side wing 35 and a right side wing 35 of seat 34 when the wearer of side impact protector 10 is seated on seat 34 .
[0021] Side impact protector 110 is shown in FIG. 7 . Protector 110 includes a harness mount plate 111 configured to lie along the back of a wearer and carry, for example, a five-point harness 113 including, for example, a waist strap 116 and a shoulder harness 120 . Protector 110 also includes a brace 115 coupled to harness mount plate 111 and adapted to transmit, direct, resist, or support weight or pressure of the head and/or neck of a person wearing side impact protector 110 .
[0022] In the illustrated embodiment, harness mount plate 111 is formed to include a spaced-apart pair of slots 144 sized to receive a portion of an automobile belt 146 therein. Automobile belt 146 can thus be used to anchor harness mount plate 111 in a desired position relative to a vehicle seat (i.e., seat 38 ) on which a wearer of protector 110 is seated.
[0023] Also in the illustrated embodiment, brace 115 includes a head cradle 112 and a cradle support 114 coupled to head cradle 112 . Head cradle 112 includes a U-shaped frame 128 formed to include a convex portion providing a rear surface 126 and a concave portion 130 facing toward the head of a person wearing side impact protector 110 . Head cradle 112 also includes a U-shaped cushion 132 mounted on concave portion 130 to provide padding for the head and neck of the person wearing side impact protector 110 . Head cradle 112 includes side wings 131 to envelope the head of a wearer; however, head cradle 112 is open on the top and front.
[0024] Cradle support 114 is formed monolithically with U-shaped frame 128 in the illustrated embodiment. Cradle support 114 extends downwardly from U-shaped frame 128 to mate with harness mount plate 111 . In the illustrated embodiment, an adjustable head cradle height-adjustment mechanism 148 provides means for mounting cradle support 114 for movement relative to harness mount plate 111 between among several predetermined positions along the length of cradle support 114 so that a user may vary the height of head cradle 112 relative to harness mount plate 111 worn by the wearer of protector 110 .
[0025] In the illustrated embodiment, height-adjustment mechanism 148 includes a support guide 150 coupled to harness mount plate 111 and formed to include a channel sized to receive cradle support 114 and allow up-and-down movement in directions 119 and 121 of cradle support 114 therein. Height-adjustment mechanism 148 further includes a retainer 152 mounted for movement on support guide 150 in direction 153 to engage and disengage retainer receivers 154 formed in vertically spaced-apart relation one to another along the length of cradle support 114 as suggested, for example, in FIG. 7 .
[0026] With respect to side impact protector 10 , U-shaped frame 28 , concave portion 30 , U-shaped cushion 32 , and first side wing 31 and second side wing 31 associated with the head cradle 12 provide means for enveloping the head of the wearer. First strap 20 , second strap 20 , and third strap 16 also cooperate to form harness means to inhibit movement of the head and a neck of the wearer in response to sudden lateral forces being applied to a torso of the wearer.
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A side impact protector is configured to be worn by a youth seated in a child-restraint system anchored in place on a vehicle seat. Such a protector may also be worn by a person of any age seated in a vehicle and restrained using a seat belt harness of the type found onboard a vehicle.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE01/02980, filed Aug. 3, 2001, which designated the United States and which was not published in English.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for separating fuel from an off-gas, in particular the anode off-gas from a fuel cell, the off-gas substantially containing carbon dioxide and also the fuel. In addition, the invention relates to the associated device that is enabled to carry out the method. In the invention, the fuel is preferably, although not exclusively, methanol. In particular methanol can be liquefied as a mixture of methanol and water according to the concentration of methanol.
[0004] Fuel cells are operated with liquid or gaseous fuels. If the fuel cell operates with hydrogen, a hydrogen infrastructure or a reformer for generating the gaseous hydrogen from the liquid fuel is required. Examples of liquid fuels are gasoline, ethanol or methanol. A DMFC (Direct Methanol Fuel Cell), by contrast, operates directly with methanol (CH 3 OH) as fuel. The function and status of DMFCs are described in detail by the inventor in “VIK-Berichte”, No. 214 (November 1999), pages 55 to 62.
[0005] The off-gas, or exhaust gas, at the anode of a direct methanol fuel cell (DMFC) is the carbon dioxide formed as a result of the anode reaction. At the standard operating temperatures of the DMFC of over 80° C., this gas contains a methanol fraction corresponding to the methanol concentration and water. If this methanol leaves the fuel cell system through the anode off-gas, this would reduce the utilization of fuel. Therefore, on the one hand before the anode off-gas is separated from the anode circuit of the DMFC, this liquid-gas mixture is cooled, liquid and gas are separated or the supersaturated dissolved carbon dioxide is removed from the liquid by a gas separator. In this case too, however, at a reduced temperature the result is a methanol partial pressure in the off-gas which corresponds to the pressure, temperature and methanol concentration in the anode liquid.
[0006] Even at temperatures of 40° C. and ambient pressure, the volumetric proportion of methanol is so high that this methanol proportion significantly exceeds the permitted limits for hydrocarbon emissions from vehicles with internal combustion engines. Therefore, this requires a process which allows as much of the methanol as possible to be recovered from the off-gas.
[0007] The methanol emissions can be at least supposedly reduced if the anode off-gas is admixed with the cathode outgoing air. The significantly increased flow of gas means that the proportion of methanol is reduced relative to the overall volume. However, the absolute quantity of methanol remains constant.
SUMMARY OF THE INVENTION
[0008] It is accordingly an object of the invention to provide a method of separating out fuel from an off-gas (exhaust gas) and an associated device, which overcome the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which allows the absolute quantity of methanol in the off-gas to be reduced.
[0009] With the foregoing and other objects in view there is provided, in accordance with the invention, a method of separating a fuel from an off-gas, preferably from an anode off-gas from a fuel cell, which comprises:
[0010] passing an off-gas primarily containing carbon dioxide and the fuel in a carbon dioxide/fuel mixture through a porous material; and
[0011] pumping water in countercurrent to the off-gas, and substantially completely taking up the fuel from the carbon dioxide/fuel mixture.
[0012] In accordance with an added feature of the invention, the fuel is methanol.
[0013] In accordance with an additional feature of the invention, the method comprises conducting an anode off-gas of a direct methanol fuel cell as the off-gas and cooling a cathode off-gas at a cathode of the fuel cell with a cathode off-gas cooler, using some water formed at the cathode off-gas cooler as the water in the pumping step, and adding the water to an anode circuit.
[0014] In a first embodiment, the counter-current is conducted in vertical flow. Alternatively, the counter-current is a horizontal flow.
[0015] With the above and other objects in view there is also provided, in accordance with the invention, a device for separating a fuel from an off-gas configured to carry out the above-outlined method. The device according to the invention is provided with a gas scrubber for exchanging fluids in a gas phase, on the one hand, and in a liquid phase, on the other hand.
[0016] In accordance with again an added feature of the invention, the gas scrubber ( 20 ) is a vertical configuration comprising a steel pipe ( 21 ) filled with packing elements.
[0017] In accordance with again an additional feature of the invention, the gas scrubber ( 30 ) has vertically arranged lamellae ( 32 ) which are arranged in interrupted or open form and offset with respect to one another.
[0018] In accordance with again another feature of the invention, horizontally arranged lamellae in the gas scrubber ( 30 ) are in each case arranged offset in interrupted or open form.
[0019] In accordance with a concomitant feature of the invention, the gas scrubber ( 30 ) in each case comprises perforated metal sheets and meshes and/or meshes which are in each case arranged offset with respect to one another.
[0020] In the invention, the carbon dioxide/fuel mixture is passed through a porous material and water, which almost completely takes up the fuel from the carbon dioxide/fuel mixture, is fed in countercurrent by means of a pump. The result is that the anode liquid is cooled, with an associated drop in the amount of fuel expelled.
[0021] Although U.S. Pat. No. 5,156,926 (German patent DE 38 12 812 C1) already disclos a fuel cell in which a heat exchanger and a gas-scrubbing installation are present in order to recover the residual fuel components which are present in residual gases and to return them to the process, that prior art document deals with the treatment of a two-substance mixture in the off-gas, with water of reaction being used as carrier liquid. By contrast, the invention is used to treat a three-substance mixture which treats CO 2 and methanol vapor with water in countercurrent, with the result that, in addition to the CO 2 as now pure off-gas, liquid methanol and water are now formed as a liquid mixture. However, this mixture represents the fuel/electrolyte mixture for the DMFC.
[0022] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0023] Although the invention is illustrated and described herein as embodied in a method for separating fuel out of an off-gas and associated device, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0024] 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
[0025] [0025]FIG. 1 is a schematic functional illustration of the system components for operation of a fuel cell;
[0026] [0026]FIG. 2 is a diagrammatic view of a first embodiment of a gas scrubber according to the invention used in the system of FIG. 1; and
[0027] [0027]FIG. 3 is a diagrammatic view of a second embodiment of the gas scrubber according to the invention used in the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a detailed illustration of a system with a DMFC in which the fuel used is methanol. The methanol is stored in a fuel tank 1 with a downstream metering pump 2 and a heating device 3 . The liquid methanol passes as operating medium through the pump 2 and the heater 3 to a fuel cell unit 10 . The fuel cell unit 10 in the exemplary embodiment is a direct methanol fuel cell (DMFC) and it is substantially characterized by an anode 11 , a membrane 12 and a cathode 13 . The anode part is assigned a cooler 4 , a CO 2 separator 5 , a unit 6 for rectification, and a methanol sensor 8 .
[0029] On the cathode side, there is a compressor 14 for air, a cooler or water separator 15 for the cathode liquid and a CO 2 sensor 16 . Furthermore, for operation of the installation, there is a unit 25 for controlling the fuel cell unit 10 and, ideally, an electrical inverter 26 .
[0030] The fuel cell unit 10 is part of a fuel cell system in which in particular individual units form a fuel cell stack. Nothing changes in terms of the peripherals shown in FIG. 1.
[0031] [0031]FIG. 1 gives the operating temperatures from the individual units. The results are temperatures in the range from 40 to 80° C. in the anode circuit, while in the cathode circuit the temperatures are less than 40° C. and downstream of the cooler/water separator 15 the temperatures are approximately 20° C.
[0032] When a DMFC fuel cell is operating, the following must be observed on the anode side: the cooling of the anode liquid after it leaves the stack is used to reduce the expulsion of methanol. However, the lower temperature of the gas separator 5 leads to an increase in the carbon dioxide concentration, since carbon dioxide is more readily soluble in water at lower temperatures. Furthermore, it is therefore necessary to heat the anode liquid by means of a heat exchanger upstream of the stack, so that the temperature gradient in the stack does not become excessive.
[0033] It is significantly more favorable for the carbon dioxide to be separated out immediately downstream of the admission-pressure regulator following the anode outlet of the stack. At higher temperatures, the solubility of carbon dioxide in water is lower, so that the carbon dioxide concentration in the anode liquid is reduced. Therefore, the formation of gas bubbles starts somewhat later in the stack.
[0034] A drawback is the high level of methanol in the carbon dioxide of the off-gas discharged from the gas separator 5 .
[0035] However, if this carbon dioxide/methanol gas mixture is then passed in countercurrent through a pipe through which fluid is flowing and part of the water formed at the cathode off-gas cooler is supplied by means of a pump, this water takes up almost all the methanol. This water can be added to the anode circuit. As a result, although the carbon dioxide concentration in the anode circuit is increased slightly, the methanol is advantageously substantially quantitatively recovered. An upright pipe structure is advantageous for operation of a gas-scrubbing installation of this type.
[0036] [0036]FIG. 2 illustrates a device of this type. A gas scrubber 20 substantially comprises a vertically oriented steel pipe 21 , which is filled with packing elements 22 . Water is flushed through the gas scrubber 20 from the top via a line 23 , while the methanol vapor together with the carbon dioxide is supplied from the bottom via a further line 24 . As a result of the gas scrub, water with methanol is discharged at the lower outlet 27 of the steel pipe 21 , while the CO 2 can escape at the upper outlet 28 of the steel pipe 21 .
[0037] The configuration shown in FIG. 2 corresponds to the standard embodiment of a conventional gas scrubber. However, this design is generally contradictory to the desired compact structure of a fuel cell, in particular the DMFC. A more suitable horizontal structure of a gas scrubber is illustrated in FIG. 3.
[0038] In FIG. 3, a horizontally oriented gas scrubber 31 has feed lines 33 for water and 34 for methanol vapor with carbon dioxide on one side. As a result, water with methanol is discharged via an outlet line 37 and returned to the process, while CO 2 can escape via an outlet line 38 on the other side of the vessel 31 .
[0039] The gas scrubber 30 shown in FIG. 3 comprises the horizontally oriented vessel 31 with lamellae 32 arranged vertically therein. The vertically arranged lamellae 32 are in each case in interrupted or open offset form, so that there can be an intensive exchange between gas phase and liquid. In this way, rectification is achieved even with a horizontal orientation. To achieve an inexpensive design, it is also possible to use offset perforated metal sheets or meshes or a combination of the two.
[0040] [0040]FIGS. 2 and 3 therefore show the advantageous application of the rectification to the separation of liquids/vapors and a gas in countercurrent with water. They therefore make it possible to exploit the system conditions in a fuel cell which is operated with liquid fuel. In this way, operation in particular of a direct methanol fuel cell can be improved.
[0041] The solution to the problem of separating carbon dioxide out of the water/fuel mixture which has been described above on the basis of a DMFC which is operated with methanol as fuel can also be transferred to fuel cells which are operated with other fuels. However, when it is used for the DMFC with a methanol/water mixture as fuel, it is of essential importance that three substances, namely carbon dioxide (CO 2 ), methanol (CH 3 OH) and water (H 2 O), are being treated as separate components. In the process, the methanol in vapor form from the off-gas is advantageously converted into liquid methanol mixed with water. The latter mixture can be added directly to the anode circuit as a fuel/electrolyte mixture.
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Particularly in the case of a fuel cell, the waste gas contains, in essence, carbon dioxide and methanol. According to the invention, the carbon dioxide/methanol gas mixture is directed through a porous material and is scrubbed out in the counter-current flow using water. The device utilizes a gas scrubber to separate out the fuel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The instant application claims full Paris Convention priority to, and incorporates expressly by reference U.S. Provisional Application Ser. No. 60/980,736; published April '08, and assigned to the instant Assignee, Mindframe, Inc. Likewise, incorporated by reference are U.S. Provisional Application Ser. No. 61/044,392; U.S. Provisional Application Ser. No. 61/015,154; U.S. Provisional Application Ser. No. 60/989,422; U.S. Provisional Application Ser. No. 60/987,384, and U.S. Provisional Application Ser. No. 61/019,506, each as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to minimally invasive and catheter delivered revascularization systems for use in the vasculature, especially those suited for usage above the juncture of the Subclavian Artery and Common Coratid Artery. In particular, this disclosure relates to revascularization devices for use in treatment of ischemic stroke, including improved neurological medical devices which are tethered or reconstrainable self-expanding neurological medical devices.
SUMMARY OF THE INVENTION
[0003] According to embodiments of the present invention, there are disclosed acute stroke revascularization/recanalization systems comprising, in combination; catheter systems having guidewires to access and emplace improved neurological medical devices into the cerebral vasculature, the systems including proximal stainless steel pushers with distal nitinol devices.
[0004] According to embodiments, there are disclosed one-piece nitinol devices in combination with the above disclosed and/or claimed catheter systems.
[0005] Briefly stated, according to embodiments a novel enhanced tethered revascularization device is deliverable through highly constricted and tortuous vessels, entering a zone associated with subject thrombi/emboli, where deployment impacts the embolus, compacting the same into luminal walls which enables perfusion and lysis of the embolus, while the revascularization device itself remains continuous with the delivery system acting as a filter, basket or stand alone revascularization mechanism, depending on the status of the embolus and other therapeutic aspects of the treatment being offered for consideration.
[0006] According to embodiments of the system and processes of the present invention, in certain iterations, once deployed the instant system compacts the embolus against the luminal wall, creating a channel for blood flow which may act like a natural lytic agent to lyse or dissolve the embolus.
[0007] According to embodiments, there is provided an improved neurological medical device which comprises, in combination, a catheter system effective for delivering a combination radial filter/revascularization device and basket assembly into a desired location in the cerebral vascular system, a self-expanding radial filter/revascularization device and basket assembly detachably tethered to the catheter system which functions in at least three respective modes, wherein the radial filter/revascularization device and basket assembly is attached to the catheter and wherein radial filter/revascularization device and basket assembly further comprises at least two states per mode, a retracted state and an expanded state; and wherein the radial filter/revascularization device and basket assembly may retracted into the retracted state after deployment in an expanded state, in each mode.
[0008] According to embodiments, there is provided a process comprising in combination providing a revascularization device tethered to a catheter by emplacing the system into a patient for travel to a desired location in a vessel having an obstruction/lesion and deploying the revascularization device by allowing it to move from a first state to a second state across a lesion which compresses the subject embolus into a luminal wall to which it is adjacent whereby creating a channel for blood flow as a lytic agent, and removing the system which the obstruction/lesion is addressed.
[0009] It is noted that if blood flow does not lyse the blood embolus, lytic agents can be administered via the guidewire lumen, as a feature of the present invention.
[0010] According to embodiments, there is provided a process whereby the revascularization device tethered to a catheter functions as a radial filter to prevent downstream migration of emboli.
[0011] The U.S. Food and Drug Administration (FDA) has previously approved a clot retrieval device (The Merci® brand of retriever X4, X5, X6, L4, L5 & L6: Concentric Medical, Mountain View, Calif.). Unfortunately, when used alone, this clot retriever is successful in restoring blood flow in only approximately 50% of the cases, and multiple passes with this device are often required to achieve successful recanalization. IA thrombolytics administered concomitantly enhance the procedural success of this device but may increase the risk of hemorrhagic transformation of the revascularization infarction. There have been several reports of coronary and neuro-stent implantation used for mechanical thrombolysis of recalcitrant occlusions. In summary, stent placement with balloon-mounted or self-expanding coronary and neuro-types of stents has been shown to be an independent predictor for recanalization of both intracranial and extra cranial cerebro-vasculature occlusions. This provides some insight into approaches needed to overcome these longstanding issues.
[0012] By way of example, self-expanding stents designed specifically for the cerebro-vasculature can be delivered to target areas of intracranial stenosis with a success rate of >95% and an increased safety profile of deliverability because these stents are deployed at significantly lower pressures than balloon-mounted coronary stents. However, systems using this data have yet to become commercial, available or accepted by most practitioners.
[0013] The use of self-expanding stents is feasible in the setting of symptomatic medium- and large-vessel intracranial occlusions. With stent placement as a first-line mechanical treatment or as a “last-resort” maneuver, TIMI/TICI 2 or 3 revascularization can be successfully obtained, according to clinical data now available.
[0014] The literature likewise suggests that focal occlusions limited to a single medium or large vessel, particularly solitary occlusions of the MCA or VBA, may be preferentially amenable to stent placement and thus can help clinicians to achieve improved rates of recanalization. In addition, gender may play a role in the success of self-expanding stent implementation. However, systems need to be designed to execute on this.
[0015] Despite increasing utilization of prourokinase rt-PA (recombinant tissue plasminogen activator) or other antithrombotic agents (e.g., Alteplase® and Reteplase®), recanalization rates remain approximately 60%. The major concerns with pharmacologic thrombolysis (alone) has been the rate of hemorrhage, inability to effectively dissolve fibrin\platelet-rich clots, lengthy times to recanalization, and inability to prevent abrupt reocclusions at the initial site of obstruction. In PROACTII, ICH with neurologic deterioration within 24 hours occurred in 10.9% of the prourokinase group and 3.1% of the control group (P=0.06), without differences in mortality. Abrupt reocclusions or recanalized arteries has been found to occur relatively frequently, even with the addition of angioplasty or snare manipulation for mechanical disruption of thrombus, and seems to be associated with poor clinical outcomes.
[0016] The use of other mechanical means has been reported to be effective in recanalization of acute occlusions. It makes sense that a combination of mechanical and pharmacologic approaches would yield greater benefit.
[0017] A known investigation in an animal model has shown, both the Wingspan® brand of self-expanding stent and Liberté® brand of balloon-mounted stent (Boston Scientific, Boston, Mass.) were able to re-establish flow through acutely occluded vessels. The self-expanding stents performed better than the balloon-mounted stents in terms of navigability to the target site. The self-expanding stents incurred lower rates of vasospasm and side-branch occlusions, which suggests superiority of these stents, over balloon-mounted stents, to maintain branch vessel patency during treatment of acute vessel occlusion. In a previous animal studies conducted, intimal proliferation and loss of lumen diameter were seen after the implantation of bare-metal, balloon-expandable stents. The literature further supports this set of issues.
[0018] These phenomena are believed to be attributable to intimal injury created during the high-pressure balloon angioplasty that is required for stent deployment.
[0019] Compared with coronary balloon-mounted stents, self-expanding stents designed for use in the intracranial circulation are superior because they are easier to track to the intracranial circulation and safer to deploy in vessels in which the true diameter and degree of intracranial atherosclerotic disease are unclear.
[0020] Moreover, based on previous experience, currently available self-expanding stents provide enough radial outward force at body temperature to revascularize occluded vessels, with low potential for the negative remodeling and in-stent restenosis that are associated with balloon-mounted stents in nonintracranial vascular beds.
[0021] Because self-expanding stents are not mounted on balloons, they are the most trackable of the stents currently available for the intracranial circulation. Unlike clot retrievers, which lose access to the target (occlusion site) every time they are retrieved (and often to necessitate multiple passes), self-expanding stents allow for wire access to the occlusion at all times, increasing the safety profile of the procedure by not requiring repeat maneuvers to gain access to the target site (as in the case for the Merci® brand of clot retriever).
[0022] Self-expanding stent placement of acute intracranial vessel occlusions may provide a novel means of recanalization after failure of clot retrieval, angioplasty, and/or thrombolytic therapy. The patency rates in this series are encouraging, yet issues remain to be addressed.
[0023] In the setting of acute stroke, restoring flow is of singular importance. In-stent stenosis or delayed stenosis may be treated in a delayed fashion on an elective basis, should the patient achieve a functional recovery from the stroke.
[0024] Recanalization with self-expanding stents may provide flow through the patent artery, and restore flow to the perforators, or, alternatively, they may remain occluded. Restoring flow to the main artery, however, will reduce the stroke burden. What is needed is a solution leveraging positive aspects of stent-based treatment without the negative outcomes which have been associated with traditional stenting.
DRAWINGS OF THE INVENTION
[0025] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
[0026] FIG. 1 is a perspective view of an embodiment of an acute stroke recanalization system according to embodiments of the present disclosure in a first configuration; and
[0027] FIG. 2 is a perspective view of an embodiment of an acute stroke recanalization system according to embodiments of the present disclosure tailored for use with the neurovasculature in a second configuration, further illustrating modular aspects of the system as used with tethered or reconstrainable self-expanding neurological medical devices.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present inventors have realized that by leveraging a conventional self-expanding revascularization device delivery platform, a poly-modic system can be iterated which impacts, addresses and/or crosses an embolus, radially filters, and either removes the offending embolus or is optionally emplaced to address the same. A paucity of extant systems effective for such combination therapies is noted among the art.
[0029] Using endovascular techniques self-expandable tethered or reconstrainable self-expanding neurological medical devices offer instant revascularization/recanalization of MCA's and related vessels, without any of the traditional concerns associated with stenting, according to embodiments of the present invention.
[0030] Expressly incorporated herein by reference are the following U.S. Letters patents and publications, each as if fully set forth herein: 2005/0119684; 2007/0198028; 2007/0208367; U.S. Pat. No. 5,449,372; U.S. Pat. No. 5,485,450; U.S. Pat. No. 5,792,157; U.S. Pat. No. 5,928,260; U.S. Pat. No. 5,972,019; U.S. Pat. No. 6,485,500; U.S. Pat. No. 7,147,655; U.S. Pat. No. 7,160,317; U.S. Pat. No. 7,172,575; U.S. Pat. No. 7,175,607; and U.S. Pat. No. 7,201,770.
[0031] The instant system allows for natural lysis, revascularization of the challenged vessels, and importantly radially filters any particulates generated, to obviate the need to be concerned with distal migration of the same, unlike prior systems or applications which include largely “off-label” usages of devices approved only for aneurysms in the brain.
[0032] The present disclosure relates to revascularization devices used to treat, among other things, ischemic stroke. Naturally, therefore, the revascularization devices of the present disclosure are designed to be used in neuro-type applications, wherein the specifications of the present catheters and revascularization devices may be deployed in the blood vessels of the cerebral vascular system. Similarly contemplated for the revascularization systems and catheters of the present disclosure is deployment in other parts of the body wherein the specifications of the present disclosure may be used in other vessels of the body in a non-invasive manner.
[0033] According to embodiments, disclosed herein is a catheter-based revascularization system. The revascularization devices of the present disclosure are for revascularization of blood vessels. When the catheter-based revascularization system of the present disclosure is deployed into a blood vessel having an embolus, the revascularization device is expanded thereby opening the vessel so that the vessel can resume proper blood flow.
[0034] According to the instant teachings, deployment of the system of the present disclosure establishes immediate 50% of the diameter of the lumen patency of the vessel being addressed. Among the prior art, no system having adequately small profile with flexibility to promote improved access for in-site treatment is known which may be used as a temporary (not implanted) solution. Those skilled in the art readily understand that detachment methods comprising mechanical, electrical, hydraulic, chemical, or thermal, and others are within the scope of the instant teachings.
[0035] Moreover, as the embolus dissolves, either via blood flow or by infusing lytic agents than the guidewire lumen, the deployed revascularization device radially filters larger embolus particles from traveling downstream, thereby reducing the chances of further complications. Once the blood vessel is revascularized, the revascularization device is modified to be in a removable state together with filtered detritus, and the catheter-revascularization system is removed from the blood vessels of the patient.
[0036] Likewise, in the event that no resolution of the embolus is noted in the instant revascularization system the inventors contemplate detachment and employment as a stent of the cage-like membrane. Angiographic recanalization has been associated with improvement in clinical outcome in the setting of acute stroke resulting from acute intracranial thrombotic occlusion. Anatomic limitations (tortuous anatomy, length of the occlusion, or location of occlusion) or supply limitations are among the reasons precluding use of prior art systems until the adverse of the instant teachings.
[0037] Stenting has been used successfully to restore flow after abrupt reocclusion occurring after recanalization with other modalities in previous cases. Stenting has also been reported in cases in which other modalities have failed to recanalize vessels. Even if an underlying stenosis is rarely the cause of stroke, stenting may play a role by morselizing the embolic clot or trapping it against the arterial wall.
[0038] The use of intracranial stents as a method for arterial recanalization during cerebral ischemia caused by focal occlusion of an intracranial vessel has been demonstrated to have benefits in some cases. Despite the use of available pharmacological and mechanical therapies, angiographic recanalization of occluded vessels has not been adequately achieved before stent placement, in most cases.
[0039] When SAH and intracranial hematoma occurred in patients in whom balloon-mounted stents were used, they most likely resulted from distal wire perforation. The distal wire purchase needed to navigate a coronary stent into the intracranial circulation may explain the occurrence of these adverse events. Alternatively, multiple manipulations of the Merci® brand of retriever device or expansion of balloon-mounted stents may have induced microdissections in the vessel. Stents designed for intracranial navigation have better navigability and pliability. The Wingspan® brand of stent (Boston Scientific) was designed to have more radial force than the Neuroform® brand of stent and may further improve this technique. However, the act clearly needs to advance further in this area.
[0040] A therapy for stroke has evolved during the past decade. Approval of the Merci® brand of retriever device represents a significant step toward achieving better outcomes in acute stroke for patients not suitable for IV tPA. However, recanalization is not always achieved using this device. Therefore, additional treatment options are required, as offered for consideration herein.
[0041] Spontaneous dissection of the internal carotid artery (ICA) is one of the main causes of ischemic stroke in young and middle-aged patients, representing 10% to 25% of such cases. Because infarct due to dissection is mainly thromboembolic, anticoagulation has been recommended to prevent new stroke in patients with acute dissection, provided they have no contraindications. In the acute phase, intravenous recombinant tissue-type plasminogen activator (IV rtPA) given within 3 hours after onset of stroke due to dissection is reportedly safe and effective. However, this often needs supplemental therapy to be effective.
[0042] Endovascular treatment with stent deployment for ICA dissection with high-grade stenosis or occlusion may be most appropriate when anticoagulation fails to prevent a new ischemic event. In such cases, the MCA may be patent. However, to compare outcomes of patients with acute stroke consecutive to MCA occlusion due to ICA dissection treated either by stent-assisted endovascular thrombolysis/thrombectomy or by IV rtPA thrombolysis. Stent assisted endovascular thrombolysis/thrombectomy compared favorably with IV rtPA thrombolysis, underscoring the need for the instant device.
[0043] The main limitation of this procedure is the immediate need for an experienced endovascular therapist. The number of cases of MCA occlusion due to carotid artery dissection was quite small and represented <10% of patients admitted for carotid dissection. However, despite these promising preliminary results, potential drawbacks related to the procedure must be considered. Acute complications such as transient ischemic attack, ischemic stroke, femoral or carotid dissection, and death have been reported. Other potential hazards of endovascular treatment of carotid dissection could have been observed. On balance, the risk-benefit favors solutions like the present invention.
[0044] Most patients with acute cerebrovascular syndrome with MCA occlusion consecutive to ICA dissection have poor outcomes when treated with conventional IV rtPA thrombolysis, whereas most patients treated with stent-assisted endovascular thrombolysis/thrombectomy show dramatic improvements. Further large randomized studies are required to confirm these data, which trends likewise are technical bases for the instant systems.
[0045] According to embodiments and as illustrated in FIG. 1 , catheter-based revascularization system 100 provides a platform for lysing emboli in occluded blood vessels. Accordingly, catheter-based revascularization system 100 generally comprises control end 102 and deployment end 104 . According to embodiments, control end 102 is a portion of the device that allows a user, such as a surgeon, to control deployment of the device through the blood vessels of a patient. Included as part of control end 102 is delivery handle 106 and winged apparatus 108 , in some embodiments. Those skilled in the art readily understand module 113 (see FIG. 2 ) is detachable.
[0046] According to some examples of the instant system during shipping of catheter-revascularization system 100 , shipping lock (not shown) is installed between delivery handle 106 and winged apparatus 108 to prevent deployment and premature extension of revascularization device 124 (see FIG. 2 ) while not in use. Furthermore, by preventing delivery handle 106 from being advanced towards winged apparatus 108 , coatings applied to revascularization device 124 are stored in a configuration whereby they will not rub off or be otherwise damaged while catheter-based revascularization system 100 is not in use.
[0047] According to embodiments, agent delivery device 130 provides a conduit in fluid communication with the lumen of the catheter-based revascularization system 100 enabling users of the system to deliver agents through catheter-revascularization system 100 directly to the location of the embolus. The instant revascularization system delivery device may be made from materials known to artisans, including stainless steel hypotube, stainless steel coil, polymer jackets, and/or radiopaque jackets.
[0048] Accordingly, luer connector 132 or a functional equivalent provides sterile access to the lumen of catheter-based revascularization system 100 to effect delivery of a chosen agent. Artisans will understand that revascularization devices of the present invention include embodiments made essentially of nitinol or spring tempered stainless steel. Revascularization devices likewise may be coated or covered with therapeutic substances in pharmacologically effective amounts or lubricious materials. According to embodiments, coatings include namodopene, vasodialators, sirolimus, and paclitaxel. Additionally, at least heparin and other coating materials of pharmaceutical nature may be used.
[0049] Deployment end 104 of catheter-based revascularization system 100 comprises proximal segment 110 and distal segment 120 . Proximal segment 110 , according to embodiments, houses distal segment 120 and comprises outer catheter 112 that is of a suitable length and diameter for deployment into the blood vessel of the neck, head, and cerebral vasculature. For example in some embodiments, proximal segment 110 is from at least about 100 cm to approximately 115 cm long with an outer diameter of at least about 2.5 French to about 4 French.
[0050] Referring also to FIG. 2 , distal segment 120 comprises inner catheter 122 and revascularization device 124 (as shown here in one embodiment having uniform cells, variable cells likewise being within other embodiments of the present invention), which is connected to inner catheter 122 . Inner catheter 122 , according to embodiments, is made from stainless steel coil, stainless steel wire, or ribbon or laser cut hypotube and is of a suitable length and diameter to move through outer catheter 112 during deployment. For example, inner catheter 122 extends from outer catheter 112 38 cm, thereby giving it a total length of between at least about 143 and 175 cm. The diameter of inner catheter 122 according to the exemplary embodiment is 2.7 French, with an inner diameter of at least about 0.012 to 0.029 inches. The inner diameter of inner catheter 122 may be any suitable diameter provided inner catheter 122 maintains the strength and flexibility to both deploy and retract revascularization device 124 .
[0051] Referring to both figures, revascularization device 124 is a self-expanding, reconstrictable retractable device tethered to inner catheter 122 . Revascularization device 124 may be made from nitinol, spring tempered stainless steel, or equivalents as known and understood by artisans, according to embodiments. Revascularization device 124 , according to embodiments and depending on the particular problem being addressed, may be from at least about 3.5 mm to about 50 mm in its expanded state. In an expanded state, revascularization device 124 is designed to expand in diameter to the luminal wall of blood vessel where it is deployed.
[0052] As known to artisans, revascularization device 124 may be coated or covered with substances imparting lubricous characteristics or therapeutic substances, as desired. Naturally, the expandable mesh design of revascularization device 124 must by a pattern whereby when revascularization device 124 is retracted, it is able to fully retract into inner catheter 122 . The nature of the cell type likewise changes with respect to the embodiment used, and is often determined based upon nature of the clot.
[0053] Catheter-revascularization system 100 is deployed through a patient's blood vessels. Once the user of catheter-revascularization system 100 determines that the embolus to be addressed is crossed, as known and understood well by artisans, revascularization device 124 is deployed by first positioning outer catheter 112 in a location immediately distal to the embolus.
[0054] Then, to revascularize/repurfuse the occluded blood vessel, distal catheter 120 is deployed in a location whereby revascularization device 124 expands at the location of the embolus, as illustrated by FIG. 2 . The embolus is thereby compressed against the luminal wall of the blood vessel and blood flow is restored. Modular detachable segment 113 is known also, and may be swapped out, as needed, if an Rx system is used.
[0055] As discussed above and claimed below, creating a channel for flow ideally includes making a vessel at least about halfway-patent, or 50% of diameter of a vessel being open. According to other embodiments, the channel created may be a cerebral equivalent of thrombolysis in myocardial infarction TIMI 1, TIMI 2, or TIMI 3.
[0056] Restoration of blood flow may act as a natural lytic agent and many emboli may begin to dissolve. Revascularization device 124 is designed, according to embodiments, to radially filter larger pieces of the dissolving embolus and prevent them from traveling distal to the device and potentially causing occlusion in another location. Because the revascularization device provides continuous radial pressure at the location of the obstruction, as the embolus dissolves, the blood flow continues to increase.
[0057] After the embolus is lysed, revascularization device 124 is sheathed into outer catheter 112 and removed from the body. According to embodiments, larger pieces of the thrombus may be retracted with revascularization device 124 after being captured in the radial filtering process. According to embodiments, revascularization device 124 may be detachable whereby the revascularization device 124 may detach from catheter-based revascularization system 100 if it is determined that revascularization device 124 should remain in the patient. As discussed above, illustrated in the Figures, and claimed below according to embodiments, catheter-based revascularization system 100 reconstrainable attachment or attachment by tether may be optionally detachable. Revascularization device detachment methods comprise mechanical, electrical hydraulic, chemical, thermal, and those other uses known to artisans.
[0058] While the apparatus and method have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.
[0059] It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the invention both independently and as an overall system and in both method and apparatus modes.
[0060] Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these.
[0061] Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same.
[0062] Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled.
[0063] It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.
[0064] Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.
[0065] Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in at least one of a standard technical dictionary recognized by artisans and the Random House Webster's Unabridged Dictionary, latest edition are hereby incorporated by reference.
[0066] Finally, all referenced listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s), such statements are expressly not to be considered as made by the applicant(s).
[0067] In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.
[0068] Support should be understood to exist to the degree required under new matter laws—including but not limited to United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.
[0069] To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.
[0070] Further, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “compromise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.
[0071] Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible.
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An acute stroke recanalization system and processes include catheter-based improved reconstrainable or tethered neurological devices which are deliverable through highly constricted and tortuous vessels, crossing the zone associated with subject thrombi/emboli, where deployment impacts, addresses or bridges the embolus, compacting the same into luminal walls which enables perfusion and lysis of the embolus, while the improved neurological medical device itself remains contiguous with the delivery system acting as a filter, basket or stand alone stenting mechanism, depending on the status of the embolus and other therapeutic aspects of the treatment being offered for consideration.
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This application is a division of application Ser. No. 07/444,423, filed 12/1/89, now pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a conducting material to form a via of a green sheet.
As a printed wiring substrate widely used for electronic devices, a multilayer ceramic substrate structured by stacking green sheets has been used with improvement in packing density of semiconductor elements.
Such a multilayer ceramic substrate is generally formed by stacking green sheets having through holes filled with conducting material and then firing such green sheets. In this case, patterns formed between stacked sheets are electrically connected through the vias formed in the through holes. As a conducting material forming vias, copper has been used in order to make small an electrical resistance.
2. Description of the Prior Art
The conventional via forming method will be explained with reference to FIGS. 1 to 2. FIG. 1(a) is a schematic sectional view for explaining the via forming method. A green sheet 11 is provided with a plurality of through holes 12 at the predetermined positions. A mask 14 is stacked on this green sheet 11 and the surface of mask 14 is then coated with copper paste 17 by the squeegee 15. In this process, the through holes 12 are filled with copper paste 17.
Meanwhile, the copper paste 17 is fabricated by the process shown in FIG. 1(b). First, the copper powder 1 in the grain size of about 1 μm and a solvent 16 such as MEK (Methyl Ethyl Ketone) are mixed and kneaded in the mixing process F by a mixer.
A method for fabricating a ceramics circuit substrate using such copper paste has been disclosed, for example, in the Japanese laid-open patent application 63-271995 (laid-open date; Sept. 28, 1988) by H. Yokoyama, M. Tsukada and H. Suzuki.
As shown in FIG. 2(a), the copper paste filling the through holes is in such a condition as allowing clearance between particles 1A of copper powder 1. When the green sheet is fired at the temperature of about 800° C., the copper paste is sintered and particles 1A bind with each other as shown in FIG. 2(b). As a result, the copper paste filling the through holes 12 forms vias 13 as shown in FIG. 2(c). FIG. 2(c) schematically shows the section of vias in parallel to the green sheet surface.
In the case of forming the vias 13 by sintering of the copper paste many organic materials are included and therefore such organic materials are vaporized during the sintering process. If such vaporization is generated at the latter process of firing for the green sheet, pores 13A are formed, as shown in FIG. 2(c), at the boundary of internal surface of through hole 12 and via 13 and within the via 13, and binding between the particles becomes non-dense, resulting in a problem that electrical resistance of via 13 becomes high.
Moreover, another problem described hereafter will also be generated.
FIG. 2(d) is a schematic sectional view of a multilayer ceramic substrate 18 fabricated by sintering a plurality of stacked green sheets 11.
When expansion of vapor of organic materials during the firing process occurs, a mound G1 of a pattern 10 formed on the surface of green sheet 11 is generated at the position of via 13 and peeling G2 of a pattern is also generated. As a result, the vias 13 are no longer connected to the pattern 10 accurately.
SUMMARY OF THE INVENTION
It is an object of the present invention to form low resistance vias.
It is another object of the present invention to form vias correctly connected with patterns.
These objects are achieved by using a conducting material which is obtained by kneading a mixed powder including a predetermined amount of copper oxide powder, to copper powder and a solvent including an organic titanium compound cracking (breaking-up) solidified particles coated by a film of the organic titanium compound to respective particles of copper powder and copper oxide powder by after drying up such mixed powder and then executing the spheroidizing process by the collision method by high speed gases flow after classifying such cracked (broken-up) particles in accordance with grain sizes.
Namely, the copper oxide powder added in the predetermined amount to copper powder is reduced in the sintering process and active oxygen is generated at this time. Vaporization of organic materials is accelerated by the effect of such active oxygen and thereby vaporization is carried out at the temperature lower than that in such a case that copper oxide powder in not included. Accordingly, generation of pores at the area between internal surfaces of through holes and vias and within the vias can be suppressed.
Moreover, since respective particles of copper powder and copper oxide powder are coated with an organic titanium compound film, adhesion of respective particles to the internal surface of the through hole can be increased.
In addition, packing density for the through hole of the mixed powder of copper powder and copper oxide powder can also be increased by conducting the spheroidizing to respective particles of copper powder and copper oxide powder.
As a result, the vias have lower electrical resistance and ensure accurate connection with the pattern. The vias can be fabricated by filling the through holes of green sheet with the conducting material and employing the via fabrication method of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a schematic sectional view indicating a method of copper paste coating in the fabrication of vias;
FIG. 1(b) is a block diagram indicating the process of conventional copper paste fabrication;
FIG. 2(a) is a schematic diagram indicating the condition of copper particles of conventional copper paste;
FIG. 2(b) is a schematic diagram indicating the condition of copper particles in the case that the copper paste of FIG. 2(a) is sintered at 800° C.;
FIG. 2(c) is a schematic sectional view, parallel to the conventional green sheet, of vias;
FIG. 2(d) is a schematic sectional view including vias of a conventional multilayer ceramic substrate;
FIG. 3(a) is a schematic sectional view indicating a method of loading the mixed powder into through holes of a green sheet in the present invention;
FIG. 3(b) is a block diagram showing a conducting material fabrication process of the present invention;
FIG. 4(a) is a schematic diagram of copper and copper oxide particles in the mixed powder of copper and copper oxide powder;
FIG. 4(b) is a schematic diagram indicating the condition of copper powder particles and copper oxide powder particles coated with organic titanium compound film;
FIG. 4(c) is a schematic diagram indicating the condition of spherical copper and copper oxide particles coated with organic titanium compound film and having a grain size less than predetermined a value;
FIG. 4(d) is a schematic diagram indicating the condition wherein the through holes of the green sheet are filled with the conducting material fabricated by the process of FIG. 3(b);
FIG. 4(e) is a schematic diagram indicating the condition wherein the via is formed by sintering the conducting material filling the through holes of a multilayer ceramic substrate;
FIG. 5(a) is a photograph by SEM of a part of a column surface of a via in such a case that a conducting material is used that does not have added copper oxide powder;
FIG. 5(b) is a photograph by SEM in such a case that 1% of copper oxide powder is added to copper powder;
FIG. 5(c) is a photograph by SEM in such a case that 5% of copper oxide powder is added to copper powder;
FIG. 5(d) is a photograph by SEM in such a case that 10% of copper oxide powder is added to copper powder;
FIG. 5(e) is a photograph by SEM in such a case that 25% of copper oxide powder is added to copper powder;
FIG. 5(f) is a photograph by SEM in such a case that 50% of copper oxide powder is added to copper powder;
FIG. 6(a) is a schematic sectional view indicating the condition of mixed powder filling the through holes before the firing, wherein the mixed powder has been formed by conducting material fabrication process of the present invention shown in FIG. 3(b), but in which only the spheroidizing process is omitted;
FIG. 6(b) is a schematic sectional view indicating the condition of mixed powder filling the through holes before the firing, wherein the mixed powder has been formed by the conducting material fabrication process of the present invention shown in FIG. 3(b);
FIG. 6(c) is a photograph, by SEM having the section parallel to the green sheet surface, of via fabricated corresponding to FIG. 6(a); and
FIG. 6(d) is a photograph, by SEM having the section parallel to the green sheet surface, of via fabricated corresponding to FIG. 6(b).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be explained with reference to FIGS. 3 to 6.
The like elements are designated by like reference numerals throughout the drawings. FIG. 3(b) is a block diagram indicating a conducting material fabrication process of the present invention and FIG. 4 is a diagram indicating the conditions of powder particles in each process.
First, the copper oxide powder 2 of 1 to 20% is mixed with the copper powder 1 in the grain size of about 1 μm. This condition is indicated in FIG. 4(a) as the copper powder particles 1A and copper oxide powder particles 2A.
Meanwhile, as shown in FIG. 3(b), a solvent 3 is obtained by dissolving an organic titanium compound 3B (for example, isosulfonyltridecylbenzen titanate) of 0.5% in weight with MEK 3A. Solvent 3 is for the mixed powder of copper powder 1 and copper oxide powder 2.
Next, these copper powder 1 and copper oxide powder 2 are mixed with the solvent 3 for about 30 minutes in the mixing process A. After mixing by the mixing process A, MEK 3A included in the solvent 3 is vaporized and dried in the drying process B of FIG. 3(b). Thereby, the surfaces of copper powder particles 1A and copper oxide powder particles 2A are coated with the organic titanium compound film 4 as shown in FIG. 4(b).
Thereafter, the mixed powder solidified by the drying process B is cracked (the solidified mixed powder is broken-up) and is classified through a filter of about 100 mesh in the classifying process C of FIG. 3(b). As a result, the grain size of copper powder particles 1A and copper oxide powder particles 2A is kept at the value less than the predetermined value. As described above, the mixed powder in the grain size less than the predetermined value is spheroidized in the spheroidizing process D of FIG. 3(b) by the collision method of high speed gases flow, for example, using the hybridization system (Nara Machinery Works, Co.). The collision method of high speed gases flow is described in detail, for example, in the "Fine Particle Design" p. 157, by Masazumi Koishi, published by Industrial Survey Inst.
As a result, the conducting material 6 of mixed powder consisting of spheroidized powder particles coated with organic titanium compound film having the grain size less than the predetermined value can be formed, as shown in FIG. 4(c).
The conducting material 6 fabricated by the processes of FIG. 3(b) is used to fill the though holes 12 of green sheet 11 as shown in FIG. 4(d) using a mask 14 of FIG. 3(a) like the prior art. However, in the present invention, since the particles 1A and 2A are spheroidized, the packing density of through hole is sufficiently large.
Further, in order to obtain better filling for all through holes of a green sheet 11, a porous tetrafluoroethylen resin sheet 20 is interposed between the green sheet 11 and a suction table 19, which places the green sheet 11 under a drawing suction as shown in FIG. 3(a). (A suction pump is not depicted.) By interposing the porous tetrafluoroethylen resin sheet 20, sucking force becomes uniform over all through holes of the green sheet 11. As the result, loading the conducting material 6 into the all through holes can be performed uniformly. As described above, a multilayer ceramic substrate 18, in which the vias 13 are formed by sintering the conducting material 6 filling the through holes 12 as shown in FIG. 4(e), may be fabricated by firing the green sheet 11 in which the through holes thereof are filled the conducting material 6.
The firing of the green sheet is generally carried out at the temperature of about 800° C. In this case, organic materials included in the conventional conducting material (copper paste) start to be decomposed at about 400° C. Some of them are vaporized and the others remain. Those remaining as carbon are vaporized at 600° to 800° C. However, when the copper oxide powder 2 is mixed into the conducting material as in the case of the present invention, decomposition of residual carbon is accelerated and is vaporized at 600° C. as oxides. Therefore, carbon, which is vaporized by the firing at 800° C., does not remain.
The organic titanate compound film coating the copper powder particles 1A and copper oxide powder particles 2A changes to titanium oxide (TiO 2 ) in the firing process of the green sheet at 800° C. As a result, the conducting material 6 of the present invention is used for filling the through holes 12 of green sheet 11 and is sintered. In this case, the titanium oxide easily binds with alumina included in the green sheet 11 and thereby the vias 7 are adhered to the internal surface of through hole 12.
As explained above, in the present invention, the packing density of particles 1A and 2A in via 7 is large, pores are not generated at the interface between the interior of via 7 and the internal surface of through hole 12 and thereby electrical resistance of via can be minimized.
In the embodiment explained above, the weight ratio of copper oxide powder 2 in the copper powder 1 is selected to be about 1 to 20% and it has been proved by experiments of the inventor that such range of weight ratio is the best range of weight ratio.
The vias have been fabricated in the mixed powder of five kinds, i.e., in the amount of 1%, 5%, 10%, 25% and 50% copper oxide powder 2 relative to copper powder 1, and the respective metallic structures have also been compared using a scanning electron microscope (SEM).
FIGS. 5(a) to 5(f) show photographs by SEM of a part of cylindrical surface of an exposed via in which the ceramic at the side surface of a multilayer ceramic substrate is selectively etched so that the via is exposed. The magnification factor of these photographs is set to 1000.
FIG. 5(a) is an example of a conventional via in which copper oxide powder is not added.
A white pole shown vertically extended the central area of FIG. 5(a) is the via.
Many pores, as indicated by the arrow marks, can be observed in this pole.
FIG. 5(b) is a photograph by SEM of a via in which copper oxide powder in the amount of 1% is added to copper powder. The white pole shown vertically extending through the central area of FIG. 5(b) is the via. Some black pores exist in the via but the number of such pores is very small.
FIG. 5(c), FIG. 5(d) and FIG. 5(e) respectively show the photographs by SEM taken in the case that the copper oxide powder in the amount of 5%, 10% and 25% is added, respectively. The white pole respectively shown vertically extending through the central area of FIG. 5(c) to 5(e) is also the via as in the case of FIG. 5(a) and FIG. 5(b). Few black pores exist in the vias shown in FIGS. 5(c), 5(d) and 5(e).
FIG. 5(f) shows a photograph in which the copper oxide powder in the amount of 50% is added. In this case, black pores do not exist in the via as in the case of FIG. 5(c), FIG. 5(d) and FIG. 5(e). However, in this case, a mixing rate of copper oxide to copper is large and therefore reduction of copper oxide does not proceed sufficiently and it remains as it is. Accordingly, sintering of the mixed powder of copper powder 2 and copper oxide powder 2 is interfered with and the shape of the sintered copper becomes irregular, resulting in easy disconnection of copper. In FIG. 5(f), a part of a copper grain having an anomalously large grain size is shown. Therefore, it is desirable that amount of copper oxide powder to be added is selected to 50% or less.
Next, the effect of the spheroidizing process on the mixed powder of copper powder 1 and copper oxide powder 2 in the present invention will be explained with reference to FIGS. 6(a) to 6(d).
FIG. 6(a) is a schematic sectional diagram indicating the condition of the mixed powder used to fill the through hole 12 before the firing, wherein the mixed powder is fabricated by the conducting material fabrication process of the present invention shown in FIG. 3(b), but in which only the spheroidizing process is omitted therefrom. It is shown that some pores 13A exist in the mixed powder filling the through holes 12 and the area between the mixed powder and internal walls of through hole 12.
FIG. 6(b) is a schematic sectional diagram indicating the condition of the mixed powder used to fill the through hole 12 before the firing, wherein the mixed powder is fabricated by the conducting material fabrication process of the present invention shown in FIG. 3(b). As shown in FIG. 6(b), in case that the through hole 12 is filled with the conducting material fabricated by the present invention, the mixed powder is almost uniformly packed without generation of pores, unlike FIG. 6(a), because each particle of the mixed powder is spheroidized.
FIG. 6(c) and FIG. 6(d) respectively show photographs, by SEM having the section in parallel to the green sheet surface of the vias respectively formed by firing those shown in FIGS. 6(a) and 6(b). Copper is selectively etched so that the conditions of the via formed in the through hole becomes apparent. The magnification factor of respective photographs is set to 1000.
FIG. 6(c) is a photograph by SEM of a via formed without the spheroidizing process, corresponding FIG. 6(a). The packing density in the circular through hole is bad and pores, as indicated by the arrow mark, are generated between the internal wall surface of the through hole and the via.
FIG. 6(d) is a photograph by SEM of a via, corresponding to FIG. 6(b). In this case, packing density in the circular through hole is good and pores are not generated between the internal wall surface of the through hole and the via and in the via itself.
For fabrication of the shown in FIGS. 6(a) and 6(b), a material having the following compositional amounts is used: Copper powder in the amount of 90 g, copper oxide powder in the amount of 10 g, organic titanium compound in the amount of 0.5 g and MEK is 200 ml.
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Vias each having no pore are formed in a multilayer ceramic substrate by filling through holes of green sheets with conducting material obtained by: kneading mixed powder particles, the powder particles produced by adding copper oxide powder particles in the amount of 50% (in weight) or less to copper powder particles, with a solution including methyl ethyl ketone and 0.5% (in weight) of isosulfonyltridecylbenzene titanate; drying and cracking the kneaded mixed powder particles, producing cracked mixed powder particles; classifying the cracked mixed powder particles with a 100 mesh filter, producing classified mixed powder particles; spheroidizing the classified mixed powder particles with a collision method performed in gases flowing at high speed; and firing the green sheets at a temperature of about 800° C.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from PCT Application Ser. No. PCT/US2011/065746 filed on Dec. 19, 2011, which claims the benefit of U.S. Provisional Application No. 61/425,320 filed on Dec. 21, 2010.
FIELD OF THE INVENTION
The present invention relates to elastomeric resins, fibers made from said resins, fabrics made with said fibers, and applications and uses for the resins, fibers and fabrics. The elastomer resins of the invention provide high strength fibers and fabrics with good physical properties and chemical resistance, making them attractive for use in various applications that use elastic fibers and fabrics.
BACKGROUND OF THE INVENTION
Garments and other articles are prepared using fabrics. Fabrics are prepared from fibers. Fibers are prepared from resins. By controlling the chemical composition of the resin, and the form of the fiber, one can control various properties of the fibers made from the resin, and also the properties of the fabric made from the fibers, and the garment made from the fabric. The invention deals with specific elastomeric resins that may be used to prepare improved fibers, which may be used to prepare improved fabrics, which may be used to prepare improved garments and other articles.
In recent years, the demand for greater functionality in fabrics, including demand for fabric with a combination of performance and comfort, and particularly in garments made from such fabrics, has increased demand for specialized fabrics including compression fabrics. Compression fabrics, which are generally prepared from a combination of two or more different types of fibers, provide compression, however, they often become uncomfortable due to increased heat buildup and often become too tight or too heavy or too bulky. It would be desirable for a garment, and other articles made from such fabrics, to provide an optimal degree of compression specific to the wearer without loss of comfort.
Conventional compression fabrics also have limited balance, that is, conventional fabrics often have good stretch and related physical properties in one direction or axis, but not in the other. Fabrics with good properties in both directions (in both the weft/width and warp/length direction) are referred to as well balanced fabrics, and in some embodiments the fabric has very similar, to essentially equivalent properties, such as modulus, in both directions. Often, fabrics have acceptable weft direction stretch but less than desirable warp direction stretch. It would be desirable for a compression fabric, which may be used to prepare garments and other articles, to have good balance without the loss of its other desirable properties. It would also be desirable for a compression fabric, which may be used to prepare garments and other articles, to have improved warp direction stretch without the loss of its other desirable properties.
Conventional compression fabrics also have limited solvent resistance, making them unsuitable or at least less useful in applications that may include exposure to one or more solvents. It would be desirable for a compression fabric, which may be used to prepare garments and other articles, to have good solvent resistance without the loss of its other desirable properties.
Conventional compression fabrics also have limited alkali and chlorine resistance, making them unsuitable or at least less useful in applications that may include exposure to alkali bases or chlorine, for example, in the production of swimwear and related items, or for use in items that will be commercially laundered. It would be desirable for a compression fabric, which may be used to prepare garments and other articles, to have good alkali and chlorine resistance without the loss of its other desirable properties.
European Patent EP 0592668 B1 relates to thermoplastic polyurethane elastomers and processes for making the same, however the reference does not teach composition with molecular weights as high as those of the invention described herein, particularly those that still possess the elastomeric properties and processability described despite the unusually high molecular weight.
U.S. Pat. No. 7,300,331 teaches brassieres or other breast shaping garments and discusses the benefits of using balanced fabrics in their construction. However, the reference achieves a well balanced fabric by building a multi-layer fabric where the layers are oriented in such a way as to provide an overall piece of fabric, albeit a multi-layer, that has some balance. The reference provides no teaching of single layer fabrics that themselves have good balance.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an elastomer resin which is prepared by reacting: (i) a hydroxyl terminated polyester intermediate derived from a dicarboxylic acid and a blend of at least two alkylene glycols wherein two of the alkylene glycols have a number average molecular weight that differs by at least 20 percent; (ii) a diisocyanate; and (iii) a linear alkylene glycol chain extender. The resulting resin has a weight average molecular weight of at least 600,000, and in some embodiments, a polydispersity index of at least 3.
The invention also provides a melt-spun fiber, film, hose (i.e., tubing), or any other extruded part made from the resins described herein, wherein the resin is further reacted with: (iv) an agent comprising the reaction product of a polyalkylene ether glycol and a diisocyanate. The resulting fiber has a weight average molecular weight of at least 700,000.
The invention also provides for a fabric made from any of the fibers described herein. In some embodiments, the fibers of the invention are used in combination with one or more conventional fibers to produce a fabric.
The invention also provides for articles, such as garments, made from the fabrics described herein.
The invention also provides a method of making an elastomer resin that includes reacting in an internal mixing device: (i) a hydroxyl terminated polyester intermediate derived from a dicarboxylic acid and a blend of at least two alkylene glycols wherein two of the alkylene glycols have a number average molecular weight that differs by at least 20 percent; (ii) a diisocyanate and (iii) a linear alkylene glycol chain extender. The resulting resin has a weight average molecular weight of at least 600,000 and in some embodiments a polydispersity index of at least 3.
The invention also provides a method of making a fiber, film, or hose that includes: (1) preparing any of the elastomer resins described herein in an internal mixing device; (2) further reacting the resin composition with an agent which may be the reaction product of a polyalkylene ether glycol and a diisocyanate; and (3) processing said elastomer resin into a fiber, film, or hose wherein said fiber, film, or hose has a weight average molecular weight of at least 700,000. In some embodiments, the method provides a melt spun fiber that is a monofilament fiber.
The invention also provides a method of making a fabric that includes: (1) preparing any of the elastomer resins described herein in an internal mixing device; (2) further reacting the resin composition with an agent which may be the reaction product of a polyalkylene ether glycol and a diisocyanate; (3) melt-spinning said elastomer resin into a fiber wherein said fiber has a weight average molecular weight of at least 700,000; and (4) processing said fiber, optionally in combination with one or more other fibers, into a fabric.
The invention also provides a method of improving the solvent resistance of an article, wherein said article comprises a fabric and wherein said fabric is comprised of fibers. The method includes the steps of: (1) preparing any of the elastomer resins described herein in an internal mixing device; (2) further reacting the resin composition with an agent which may be the reaction product of a polyalkylene ether glycol and a diisocyanate; (3) melt-spinning said elastomer resin into a fiber wherein said fiber has a weight average molecular weight of at least 700,000; (4) processing said fiber, optionally in combination with one or more other fibers, into a fabric; and (5) processing said fabric into said article with improved solvent resistance.
The invention also provides a method of improving the alkali and chlorine resistance of an article, wherein said article comprises a fabric and wherein said fabric is comprised of fibers. The method includes the steps of: (1) preparing any of the elastomer resins described herein in an internal mixing device; (2) further reacting the resin composition with an agent which may be the reaction product of a polyalkylene ether glycol and a diisocyanate; (3) melt-spinning said elastomer resin into a fiber wherein said fiber has a weight average molecular weight of at least 700,000; (4) processing said fiber, optionally in combination with one or more other fibers, into a fabric; and (5) processing said fabric into said article with improved alkali resistance.
The invention also provides a method of improving the warp direction stretch of a finished knit stretch fabric. The method includes the steps of: (1) preparing any of the elastomer resins described herein in an internal mixing device; (2) further reacting the resin composition with an agent which may be the reaction product of a polyalkylene ether glycol and a diisocyanate; (3) melt-spinning said elastomer resin into a fiber wherein said fiber has a weight average molecular weight of at least 700,000; and (4) processing said fiber, optionally in combination with one or more other fibers, into a knit stretch fabric which has improved warp direction stretch.
In any of these embodiments, the fiber used may be a monofilament fiber or a multifilament fiber. In some embodiments, the fiber is a monofilament fiber.
The compositions of the invention, particularly the resins and the fibers, are easy to extrude. The compositions of the invention are unique when compared to traditional TPU resins and fiber compositions. Generally, the resins of the invention can be melted and maintained at a stable viscosity without the expected crystallized chunks, gels, or flushing problems that occur during periodic line stoppages.
DETAILED DESCRIPTION OF THE INVENTION
Various preferred features and embodiments will be described below by way of non-limiting illustration.
The Resin
The invention provides an elastomer resin, which may be used in the preparation of fibers, fabrics, and various articles. The resin may be prepared by reacting: (i) a hydroxyl terminated polyester intermediate derived from a dicarboxylic acid and a blend of at least two alkylene glycols (or diols) wherein two of the alkylene glycols have a number average molecular weight that differs by at least 20 percent; (ii) a diisocyanate; and (iii) a linear alkylene glycol chain extender.
The hydroxyl terminated polyester intermediate may be derived from a dicarboxylic acid and a mixture of two or more linear glycols. Suitable dicarboxylic acids include aliphatic acids, cycloaliphatic acids, aromatic acids, or combinations thereof. Suitable dicarboxylic acids which may be used alone or in mixtures generally have a total of from 4 to 15 carbon atoms. Examples of suitable acids include: succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, isophthalic acid, terephthalic acid, cyclohexane dicarboxylic acid, and combinations thereof. Anhydrides of any of the above dicarboxylic acids, including phthalic anhydride and tetrahydrophthalic anhydride, may also be used. In some embodiments, the acid is adipic acid.
The hydroxyl terminated polyester intermediate is derived from a mixture of two or more alkylene glycols. In some embodiments, the alkylene glycols used in the invention are linear alkylene glycols and may contain from 2 to 10 carbon atoms. In some embodiments, the glycols have the formula: HO—R—OH where R is an alkylene group containing from 1 or 2 up to 20 or 10 carbon atoms. In other embodiments, R contains from 1 to 6, 2 to 4, or even 3 or 4 carbon atoms. In any of these embodiments, R may be a linear alkylene group.
As noted, the two alkylene glycols used in the blend have a number average molecular weight that differs by at least 20 percent. That is, the difference in the molecular weight of the two alkylene glycols is at least 20 percent of the molecular weight of the alkylene glycol with the higher molecular weight.
In some embodiments, the blend of alkylene glycols includes at least two alkylene glycols where the first alkylene glycol contains at least 1 carbon atom more than the second alkylene glycol. This distinction may be used in combination with, or in some embodiments instead of, the percent difference in molecular weight discussed above. In other embodiments, the first alkylene glycol may contain at least 2 carbon atoms more than the second alkylene glycol. In still other embodiments, the first alkylene glycol contains from 1 to 10, 1 to 6, 2 to 4, or 2 more carbon atoms that the second alkylene glycol. In any of these embodiments, a third, fourth, or even further alkylene glycol may be present. In some embodiments, the first alkylene glycol and second alkylene glycol make up at least 50 percent by weight of the alkylene glycol blend.
Suitable examples of alkylene glycols include: ethylene glycol, propylene glycol, butanediol, pentanediol, hexanediol, heptanediol, octanediol, nonanediol, decane diol, and combinations thereof. Non-linear alkylene glycols may be used, though generally only in small amounts, and may include, for example: 1,2-propanediol, 1,3-butanediol, 2,2-dimethyl-1,3-propanediol, 1,4-cyclohexanedimethanol, and combinations thereof. In some embodiments, the alkylene glycols include linear alkylene glycols. In these embodiments, suitable examples include: methylene glycol, ethylene glycol, 1,3-propanediol; 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-heptanediol, 1,10-decanediol, decamethylene glycol, dodecamethylene glycol, and combinations thereof. In some embodiments, the blend of alkylene glycols used in the invention includes 1,4-butanediol and 1,6-hexanediol.
In some embodiments, the blend of alkylene glycols contains a low level of branched alkylene glycols. For example, the blend of polyols may contain no more than 25, 15, 10, 5 or even 1 or 0.5 percent by weight of branched alkylene glycols. In some embodiments, the blend of alkylene glycols is substantially free of, or even fully free of, branched alkylene glycols.
In some embodiments, the blend of alkylene glycols is substantially free of, or even fully free of, alkylene glycols containing an odd number of carbon atoms greater than 3. In other embodiments, the blend of alkylene glycols is substantially free of, or even fully free of alkylene glycols containing 5, 7, 9, 11, 13, or 15 carbon atoms, where the term “substantially free of” is defined similarly as above.
In some embodiments, the blend of alkylene glycols is substantially free of, or even fully free of, neopentyl glycol.
As used herein, the term “substantially free of” means that the material in question is only present in amounts consistent with contamination and/or by-products present in commercial grades of desired components. That is, in some embodiments, branched alkylene glycols are only present in the blend of alkylene glycols at levels consistent with the presence of branched alkylene glycols found in commercial grades of linear alkylene glycols due to contamination, by-products, or other similar sources.
The first and second alkylene glycols may be present in the blend such that the weight ratio of the first glycol to the second glycol is from 95:5 to 5:95 or from 25:75 to 75:25 or from 60:40 to 40:60 or from 55:45 to 45:55. In some embodiments, the weight ratio of the first glycol to the second glycol is 50:50. These ratios apply only to the first and second alkylene glycols present in the blend and do not preclude the presence of additional alkylene glycols.
While not wishing to be bound by theory, it is believed that the crystallinity and/or the glass transition temperature (Tg) of the hydroxyl terminated polyester intermediate, which may also be referred to as the polyol, is a critical feature for providing the performance improvements described herein. In some embodiments, the hydroxyl terminated polyester intermediate has a Tg of less than −20 degrees C.
The resins of the invention are prepared using a diisocyanate. The diisocyanates useful in the present invention are not overly limited. Useful diisocyanates generally have the formula R(NCO) n where n is generally 2 and R is aromatic, cycloaliphatic, aliphatic, or combinations thereof generally having a total of from 2 to 20 carbon atoms per R(NCO) n molecule.
The diisocyanates of the invention may include some amount of polyisocyanates having the same formula provided above but having an n of 3 or 4, that is a functionality of 3 or 4. These polyisocyanates may also be utilized in very small amounts, for example, less than 5% and desirably less than 2% by weight based upon the total weight of all polyisocyanates, as they generally lead to increased levels of cross-linking, and so at higher amounts will begin to limit the thermoplastic properties of the resulting compositions.
Examples of suitable aromatic diisocyanates include methylene diphenyl diisocyanate also known as diphenyl methane-4,4′-diisocyanate (MDI), H 12 MDI, m-xylylene diisocyanate (XDI), m-tetramethyl xylylene diisocyanate (TMXDI), phenylene-1,4-diisocyanate (PPDI), 1,5-naphthalene diisocyanate (NDI), and diphenylmethane-3,3′-dimethoxy-4,4′-diisocyanate (TODI). Examples of suitable aliphatic diisocyanates include isophorone diisocyanate (IPDI), 1,4-cyclohexyl diisocyanate (CHDI), hexamethylene diisocyanate (HDI), 1,6-diisocyanato-2,2,4,4-tetramethyl hexane (TMDI), 1,10-decane diisocyanate, and trans-dicyclohexylmethane diisocyanate (HMDI). In some embodiments, the diisocyanate includes aromatic and/or aliphatic diisocyanates. In some embodiments, the diisocyanate includes MDI containing less than about 3% by weight of ortho-para (2,4) isomer.
The resins of the invention can be prepared using a chain extender.
Suitable chain extenders include lower aliphatic or short chain glycols having from about 2 to about 10 carbon atoms and include for instance ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, triethylene glycol, cis-trans-isomers of cyclohexyl dimethylol, neopentyl glycol, 1,4-butanediol, 1,6-hexandiol, 1,3-butanediol, and 1,5-pentanediol. Aromatic glycols can also be used as the chain extender and are often the choice for high heat applications. Benzene glycol (HQEE) and xylylene glycols are suitable chain extenders for use in making the TPU of this invention. Xylylene glycol is a mixture of 1,4-di(hydroxymethyl)benzene and 1,2-di(hydroxymethyl)benzene. Benzene glycol is one suitable aromatic chain extender and specifically includes hydroquinone bis(beta-hydroxyethyl)ether also known as 1,4-di(2-hydroxyethoxy)benzene; resorcinol, i.e., bis(beta-hydroxyethyl)ether also known as 1,3-di(2-hydroxyethyl)benzene; catechol, i.e., bis(beta-hydroxyethyl)ether also known as 1,2-di(2-hydroxyethoxy)benzene; and combinations thereof. In some embodiments, the chain extender of the invention is substantially free of, or even fully free of, benzene glycol.
The chain extenders useful for the invention may include any of the linear alkylene glycols described above. In some embodiments, the chain extender includes a glycol having the formula: HO—R—OH where R is a linear alkylene group containing from 1 or 2 up to 20 or 10 carbon atoms. In other embodiments, R contains from 1 to 6, 2 to 4, or even 3 or 4 carbon atoms. Suitable examples include ethylene glycol, 1,3-propanediol; 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-heptanediol, 1,10-decanediol, dodecamethylene glycol, and combinations thereof.
In some embodiments, the chain extender used in the invention includes 1,4-butanediol, ethylene glycol, hydroquinone bis(beta-hydroxyethyl)ether, or combinations thereof. In some embodiments, the chain extender includes 1,4-butanediol, 1,6-hexanediol, or combinations thereof. In still other embodiments, the chain extender includes 1,4-butanediol.
The reaction of these components can result in an elastomer resin having a weight average molecular weight of at least 600,000, a polydispersity index of at least 3, or a combination thereof. Controlling the weight average molecular weight of the resin is achieved by adjusting the ratio of components used, reaction residence time, and/or reaction temperature, all of which is within the ability of one skilled in the art. The components may be reacted in the presence of a catalyst. Generally, any conventional catalyst can be utilized to react the diisocyanate with the hydroxyl terminated intermediate or the chain extender and the same is well known to those skilled in the art. Examples of suitable catalysts include the various alkyl ethers or alkyl thiol ethers of bismuth or tin wherein the alkyl portion has from 1 to about 20 carbon atoms with specific examples including bismuth octoate, bismuth laurate, and the like. Suitable catalysts include the various tin catalysts such as stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, and the like. The amount of such catalyst is generally small such as from about 20 to about 200 parts per million based upon the total weight of the polyurethane forming monomers. In other embodiments, the reaction that results in the resin of the invention is carried out without a catalyst. That is, in some embodiments, the process of making the resin is free of any catalyst.
The elastomer resins of this invention can be made by any of the conventional polymerization methods well known in the art and literature.
Elastomer resins of the present invention may be made via a “one shot” process wherein all the components are added together simultaneously or substantially simultaneously to a heated extruder, or other internal mixing device, and reacted to form the resin. The equivalent ratio of the isocyanate groups present in the diisocyanate to the total equivalents of the hydroxyl groups in the hydroxyl terminated intermediate and the diol chain extender is generally from about 0.95 to about 1.10, or from about 0.97 to about 1.03, or even from about 0.97 to about 1.00. The Shore A hardness of the TPU formed should be from 65A to 95A, or from about 75A to about 85A, to achieve the most desirable properties of the finished article. Reaction temperatures are generally from about 175° C. to about 245° C. or from about 180° C. to about 220° C. The weight average molecular weight (Mw) of the resin may be at least 600,000, at least 800,000 or at least 850,000. In other embodiments, the Mw of the resin is from 600,000, 800,000 or even 850,000 up to 1.5 million or even 1.0 million, as measured by GPC relative to polystyrene standards. These molecular weight values are generally in regards to the resin at the time of its use (i.e., when the resin is processed into fibers or other articles), however in various embodiments the molecule weight values referred herein may be applied to the resin at: (i) the time the resin is manufactured; (ii) 20 to 30 days of the resin having been manufactured; (iii) the time the resin is being processed into fibers or some other article; or (iv) any combination thereof. The molecular weight may change over time, depending on the processing conditions under which it was made and the amount of excess raw materials used in the reaction. Generally, the molecular weight of the resin is expected to slowly increase over time, which is a well known tendency of many resins that those skilled in the art would understand. The polydispersity index of the resin may be at least 3, from 3 to 6, from 3 to 5.5 or even from 3.05 to 5.42 and the same aspect of timing, discussed above, applies here as well.
The elastomer resins can also be prepared utilizing a pre-polymer process. In the pre-polymer route, the hydroxyl terminated intermediate is reacted with generally an equivalent excess of one or more polyisocyanates to form a pre-polymer solution having free or unreacted isocyanate therein. The reaction may be carried out at temperatures of from 80° C. to 220° C. or from 150° C. to 200° C. optionally in the presence of a suitable urethane catalyst. Subsequently, a selective type of chain extender as noted above is added in an equivalent amount generally equal to the isocyanate end groups as well as to any free or unreacted diisocyanate compounds. The overall equivalent ratio of the total diisocyanate to the total equivalents of both the hydroxyl terminated intermediate and the chain extender is thus from about 0.95 to about 1.10, or from about 0.98 to about 1.05 or even from about 0.99 to about 1.03. The equivalent ratio of the hydroxyl terminated intermediate to the chain extender is adjusted to give 65A to 95A, or 75A to 85A Shore hardness. The chain extension reaction temperature is generally from about 180° C. to about 250° C. or from about 200° C. to about 240° C. Typically, the pre-polymer route can be carried out in any conventional device with an extruder being preferred. Thus, the hydroxyl terminated intermediate is reacted with an equivalent excess of a diisocyanate in a first portion of the extruder to form a pre-polymer solution and subsequently the chain extender is added at a downstream portion and reacted with the pre-polymer solution. Any conventional extruder can be utilized, with extruders equipped with barrier screws having a length to diameter ratio of at least 20 or at least 25. Where a prepoly process is used, the compositions of the invention may exhibit a lower polydispersity index.
The resins of the present invention may also contain one or more additional additives. Useful additives can be utilized in suitable amounts and include opacifying pigments, colorants, mineral fillers, stabilizers, lubricants, UV absorbers, processing aids, and other additives as desired. Useful opacifying pigments include titanium dioxide, zinc oxide, and titanate yellow, while useful tinting pigments include carbon black, yellow oxides, brown oxides, raw and burnt sienna or umber, chromium oxide green, cadmium pigments, chromium pigments, and other mixed metal oxide and organic pigments. Useful fillers include diatomaceous earth (superfloss) clay, silica, talc, mica, wallostonite, barium sulfate, and calcium carbonate. If desired, useful stabilizers such as antioxidants can be used and include phenolic antioxidants, while useful photostabilizers include organic phosphates, and organotin thiolates (mercaptides). Useful lubricants include metal stearates, paraffin oils and amide waxes. Useful UV absorbers include 2-(2′-hydroxyphenol) benzotriazoles and 2-hydroxybenzophenones.
Plasticizer additives can also be utilized advantageously to reduce hardness without affecting properties.
Fibers, Fabrics & Articles
The elastic resins of the invention may be processed into fibers, films, hoses or any other extruded article.
In some embodiments, the elastic resins of the invention are melt spun into a fiber where any of the resins described herein are further reacted with: (iv) an agent, such as the reaction product of a polyalkylene ether glycol and a diisocyanate. The resulting fiber has a weight average molecular weight of at least 700,000. Controlling the weight average molecular weight of the fiber is achieved by adjusting the ratio of components used, particularly the amount of cross linker used, and reaction residence time, which is within the ability of one skilled in the art.
The fibers of the invention may be monofilament or multifilament. In some embodiments, the fibers of the invention are monofilament fibers. The weight average molecular weight of the fibers of the invention may be at least 700,000, at least 800,000, or even at least 1 million. In any of these embodiments, the weight average molecular weight of the fibers may also be less than 2 million.
During the melt spinning process, the elastomer resin described above may be lightly cross-linked with an agent, which in some embodiments may be described as a cross-linking agent. The cross-linking agent of the invention is prepared by reacting a polyalkylene ether glycol and a diisocyanate. Suitable polyalkylene ether glycols include polytetramethylene ether glycol (PTMEG). Suitable isocyanates for use in the preparation of the cross-linking agent include any of those described above. In some embodiments, the polyalkylene ether glycol includes PTMEG and the diisocyanate includes MDI.
The cross-linking agent, which may be referred to as a pre-polymer, can have an isocyanate functionality of greater than 1.0, or from 1.0 to 3.0, or even from 1.8 to 2.2, however, it is understood that some portion of the cross-linking agent is made up of molecules with an isocyanate functionality of greater than 2.0. The cross-linking agent may have a number average molecular weight of from 1,000 to 10,000 or from 1,200 to 4,000 or even from 1,500 to 2,800. In some embodiments, the cross-linking agent has a number average molecular weight of at least 1500.
The weight percent of cross-linking agent used with the elastomer resin is from 2.0% to 20%, 8.0% to 15%, or 10% to 13%. The percentage of cross-linking agent used is weight percent based upon the total weight of elastomer resin and cross-linking agent.
The spinning process to make fibers of this invention involves feeding the elastomer resin described above to an extruder to melt the resin. A rheology modifying agent (RMA), for example, the cross-linking agent, is added continuously downstream near the point where the resin melt exits the extruder or after the resin melt exits the extruder. The RMA can be added to the extruder before the melt exits the extruder or after the melt exits the extruder. If added after the melt exits the extruder, the RMA should be mixed with the resin melt using static or dynamic mixers to assure proper mixing. After exiting the extruder, the melt flows into a manifold. The manifold divides the melt stream into one or more smaller streams, where each stream is fed to a plurality of spinnerets. The spinneret will have small holes through which the melt is forced and the melt exits the spinneret in the form of fiber, in some embodiments the fiber remains a monofilament fiber. The size of the holes in the spinneret will depend on the desired size of the fiber.
The polymer melt may be passed through a spin pack assembly and exit the spin pack assembly as a fiber. In some embodiments, the spin pack assembly used is one which gives plug flow of the polymer through the assembly. In some embodiments, the spin pack assembly is the one described in PCT patent application WO 2007/076380, which is incorporated in its entirety herein.
Once the fiber exits the spinneret, it may be cooled before winding onto bobbins. In some embodiments, the fiber is passed over a first godet, finish oil is applied, and the fiber proceeds to a second godet. An important aspect of the process is the relative speed at which the fiber is wound into bobbins. By relative speed, we mean the speed of the melt (melt velocity) exiting the spinneret in relationship to the winding speed of the bobbin. For a typical melt spinning process, the fiber is wound at a speed of 4-6 times the speed of the melt velocity. This draws or stretches the fiber. For the unique fibers of this invention, this extensive drawing is undesirable. The fibers must be wound at a speed at least equal to the melt velocity to operate the process. For the fibers of this invention, the fiber may be wound onto bobbins at a speed no greater than 50% faster than the melt velocity, in other embodiments at a speed no greater than 20%, 10%, or even 5% faster than the melt velocity. It is thought that a winding speed that is the same as the melt velocity would be ideal, but it is necessary to have a slightly higher winding speed to operate the process efficiently. For example, a fiber exiting the spinneret at a speed of 300 meters per minute, would most preferable be wound at a speed of between 300 and 315 meters per minute. Similar examples are readily apparent.
As noted above, the fibers of this invention can be made in a variety of denier. Denier is a term in the art designating the fiber size. Denier is the weight in grams of 9000 meters of fiber length.
When fibers are made by the process of this invention, anti-tack additives such as finish oils, an example of which are silicone oils, may be added to the surface of the fibers after or during cooling and/or just prior to being wound into bobbins.
One important aspect of the melt spinning process is the mixing of the polymer melt with the crosslinking agent. Proper uniform mixing is important to achieve uniform fiber properties and to achieve long run times without experiencing fiber breakage. The mixing of the melt and crosslinking agent should be a method which achieves plug-flow, i.e., first in first out. The proper mixing can be achieved with a dynamic mixer or a static mixer. Static mixers are more difficult to clean; therefore, a dynamic mixer is preferred. A dynamic mixer which has a feed screw and mixing pins is the preferred mixer. U.S. Pat. No. 6,709,147, which is incorporated herein by reference, describes such a mixer and has mixing pins which can rotate. The mixing pins can also be in a fixed position, such as attached to the barrel of the mixer and extending toward the centerline of the feed screw. The mixing feed screw can be attached by threads to the end of the extruder screw and the housing of the mixer can be bolted to the extruder machine. The feed screw of the dynamic mixer should be a design which moves the polymer melt in a progressive manner with very little back mixing to achieve plug-flow of the melt. The L/D of the mixing screw should be from over 3 to less than 30, or from about 7 to about 20, or even from about 10 to about 12.
The temperature in the mixing zone where the TPU polymer melt is mixed with the crosslinking agent may be from about 200° C. to about 240° C., or from about 210° C. to about 225° C. These temperatures are generally necessary to get the reaction while not degrading the polymer.
The spinning temperature (the temperature of the polymer melt in the spinneret) should be higher than the melting point of the polymer. If the spinning temperature is too high, the polymer can degrade. If the spinning temperature is too low, polymer can solidify in the spinneret and cause fiber breakage.
The fibers of the invention may be further processed into fabrics. The fabrics of the invention may be made from any of the fibers described above, which may themselves be made from any of the elastic resins described above. The fabrics may be made by processing any of the fibers described above, optionally in combination with one or more other types of fibers (fibers made from different materials), into a fabric.
The fabrics may be woven fabrics, non-woven fabrics or knitted fabrics. As described above, the fabrics of the invention may be well balanced, in that they have good stretch properties in both axes (in both the weft/width and warp/length direction), which give three dimensional compression in garments. In some embodiments, the stretch of the fabric in both directions, and so its balance, is determined by ASTM D4964. In some embodiments, the fabrics of the invention demonstrate at least 120%, or even 150% stretch performance in both the weft/width and warp/length directions, as measured by ASTM D4964. In some embodiments, the fabric of the invention demonstrate modulus values in the weft/width and warp/length directions that are within 40% of one another, or even within 30%, 25% or even 20% or 10% of each other. The construction of the fabrics made from the resins and fibers described herein is not overly limited, however in some embodiments the fabric is a jersey knit fabric. The invention provides a balanced single layer fabric; however, the fabrics of the invention may still be used in multi-layer constructions, multilayer constructions are just not necessary to achieve good balance in the fabric.
The fabrics, as well as the fibers and even the resins of the invention, may be further processed into articles. In some embodiments, these articles include one or more of the fabrics described above.
Fabrics that utilize the fibers of this invention can be made by knitting or weaving or by non-woven processes such as melt blown or spunbond. In some embodiments, the fabric of this invention is made using one or more different (conventional) fibers in combination with the fibers of the invention. Hard fibers, such as nylon and/or polyester may be used, but others such as rayon, silk, wool, modified acrylic and others can also be utilized to make the fabric of this invention.
The articles of the invention include garments. Various garments can be made with the fabric of this invention. In some embodiments, the fabric is used in making undergarments or tight fitting garments, for which the fabrics of this invention are well-suited due to the comfort provided by the fiber. Undergarments, such as bras and T-shirts as well as sport garments used for activities such as running, skiing, cycling, or other sports, can benefit from the properties of these fibers. It will be understood by those skilled in the art that any garment can be made from the fabric and fibers of this invention. An exemplary embodiment would be a bra shoulder strap made from woven fabric and the wings of the bra made from knitted fabric, with both the woven and the knitted fabric containing the melt spun TPU fibers of this invention.
In other embodiments, the fibers described herein are used to make one or more of any number of garments and articles including but not limited to: sports apparel, such as shorts, including biking, hiking, running, compression, training, golf, baseball, basketball, cheerleading, dance, soccer and/or hockey shorts; shirts, including any of the specific types listed for shorts above; tights including training tights and compression tights; swimwear including competitive and resort swimwear; bodysuits including wrestling, running and swimming body suits; and footwear. Additional embodiments include workwear such as shirts and uniforms. Additional embodiments include intimates including bras, panties, men's underwear, camisoles, body shapers, nightgowns, panty hose, men's undershirts, tights, socks and corsetry. Additional embodiments include medical garments and articles including: hosiery such as compression hosiery, diabetic socks, static socks, and dynamic socks; therapeutic burn treatment bandages and films; wound care dressings; medical garments. Additional applications include military applications that mirror one or more of the specific articles described above. Additional embodiments include bedding articles including sheets, blankets, comforters, mattress pads, mattress tops, and pillow cases.
The fibers of the invention may be bare or covered.
Still another feature of the present invention is that the fibers described herein have greater strength, for example, they produce a fabric with a higher burst strength, compared to more conventional fibers of the same gauge, and/or provide the same or even higher strength compared to conventional fibers of a larger gauge. That is, the fibers of the present invention provide greater strength at the same or even lower gauge compared to conventional elastic fibers.
In some embodiments, the fibers of the present invention are melt-spun monofilament fibers and have an ultimate elongation of at least 400% and also have a relatively flat modulus in the load and unload cycle between 100% and 200% elongation. By relatively flat, it is meant that the modulus does not vary as much as it does for other conventional fibers such as nylon and/or polyester.
In some embodiments, the modulus of the fiber (measured by the method described above), on the 5 th pull cycle, has a modulus that does not increase by more than 400% on the load cycle between 100% and 200% elongation. In some embodiments, the fiber has a denier from 4, 10, 20, 30, 40 70 or even 140 up to 8000, 2000, 1500, 1200, 600, 400, 360, or even 140. Such fibers may on the 1 st pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 50% or 60% up to 150% or 95%. Such fibers may on the 5 th pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 50% or 75% up to 150% or 110%.
In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 70, on the 1 st pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 70%, 80% or even 85% up to 120%, 100% or even 95%. In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 70, on the 5 th pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 80%, 90% or even 95% up to 130%, 110% or even 105%.
In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 140, on the 1 st pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 50%, 55% or even 63% up to 100%, 80% or even 75%. In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 140, on the 5 th pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 50%, 95% or even 100% up to 150%, 120%, 115% or even 109%.
In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 360, on the 1 st pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 40%, 60% or even 65% up to 100%, 80%, 85% or even 70%. In some embodiments, the fibers of the present invention may be described as fibers that, when made to a denier of about 360, on the 5 th pull cycle, have a modulus that increases, on the load cycle between 100% and 200% elongation, from 50%, 60% or even 70% up to 120%, 100%, 80% or even 78%.
It is noted that in the embodiments above, the fiber is not limited to the specific denier size for which the results are specified. Rather, the fibers are described by noting what the modulus would be if the fiber were made to a specific denier and tested. In contrast, the embodiments below deal with fibers of specified denier.
In some embodiments, the fibers of the present invention have denier of from 4, 10, 35, 40 or even 60 up to 130, 100, 80 or even 70. In any of these embodiments, the fibers may have an average denier of about 40 or 70. In such embodiments, the fibers may have a modulus: on the 1 st pull, on the load cycle between 100% and 200% elongation, from 70%, 80% or even 85% up to 120%, 100% or even 95%; and on the 5 th pull, on the load cycle between 100% and 200% elongation, from 80%, 90% or even 95% up to 130%, 110% or even 105%.
In some embodiments, the fibers of the present invention have denier of from 80, 90, 100, 120 or even 140 up to 300, 250, 200, or even 160. In some embodiments, the fibers have an average denier of about 140. In any of these embodiments, the fibers may have a modulus: on the 1 st pull, on the load cycle between 100% and 200% elongation, from 50%, 55% or even 63% up to 100%, 80% or even 75%; and on the 5 th pull, on the load cycle between 100% and 200% elongation, from 50%, 95% or even 100% up to 150%, 120%, 115% or even 109%.
In some embodiments, the fibers of the present invention have denier of from 150, 200, or even 300 up to 1500, 500, 450 or even 200. In some embodiments, the fibers have an average denier of about 360. In any of these embodiments, the fibers may have a modulus: on the 1 st pull, on the load cycle between 100% and 200% elongation, from 40%, 60% or even 65% up to 100%, 80%, 85% or even 75%; and on the 5 th pull, on the load cycle between 100% and 200% elongation, from 50%, 60% or even 70% up to 120%, 100%, 80% or even 78%.
In some embodiments, the present invention may be described by looking to the properties of a Jersey knit fabric made from the fibers described here. In some embodiments, the fiber of the present invention, when knitted into a Jersey fabric, provides a fabric with a burst puncture strength, as measured by ASTM D751, such that the load/thick at failure is at least 710, 800, 900, 1000, 1100, 1200, 1250 lbf/in, or in other embodiments at least 124, 140, 158, 175, 193, 210 or even 219 N/mm. In any of these embodiments, the burst strength may have a maximum value of no more than 1600 or 1500 lbf/in, or in other embodiments of no more than 280 or 263 N/mm.
In some embodiments, the invention is a fiber, according to any of the embodiments described above, where the fiber, if made to 70 denier and then made into a Jersey knit fabric, would provide a Jersey knit fabric with a burst puncture strength (load/thick at failure) of at least 710, 800, 900, 1000, 1200, or even 1250, up to 1400 lbf/in, and in other embodiments at least 124, 140, 158, 175, 210 or even 219, up to 245 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 25, 30, 35, 40, or 40.5 up to 200, 100 or 75 lbf-in, and in other embodiments at least 2.8, 3.4, 4.0, 4.5, or 4.6 up to 22.6, 11.3, or 8.5 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 6, 7, 8, or 9 up to 50, 40 or 20 lb, and in other embodiments at least 2.7, 3.2, 3.6 or even 4.1, up to 22.7, 18.1 or 9.1 kg.
In some embodiments, the invention is a fiber, according to any of the embodiments described above, where the fiber, if made to 140 denier and then made into a Jersey knit fabric, would provide a Jersey knit fabric with a burst puncture strength (load/thick at failure) of at least 1200, 1300, 1500, 1700, or even 1750, up to 1900 lbf/in, and in other embodiments at least 210, 228, 263, 298 or even 306, up to 333 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 60, 70, 75, 80, or even 83.5 up to 800, 200, or 150 lbf-in, and in other embodiments at least 6.8, 7.9, 8.5, 9.0, or 9.4 up to 90.3, 22.6, or 16.9 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 10, 15, 17, or even 17.5 up to 100, 75, 50, or 25 lb, and in other embodiments at least 4.5, 6.8, 7.7 or even 7.9, up to 45.4, 34.0, 22.7 or 11.3 kg.
In some embodiments, the invention is a fiber, according to any of the embodiments described above, where the fiber, if made to 40 denier and then made into a Jersey knit fabric, would provide a Jersey knit fabric with a burst puncture strength (load/thick at failure) of at least 500, 750, 1000, 1400 or even 1450, up to 1600 or 1500 lbf/in, and in other embodiments at least 88, 131, 175, 245 or even 254, up to 280 or 263 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 10, 15, 20 or even 20.5 up to 100, 75, or 50 lbf-in, and in other embodiments at least 1.1, 1.7, or 2.3 up to 11.3, 8.5, or 5.6 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 3, 4, 4.5 or even 5 up to 40, 20, or 10 lb, and in other embodiments at least 1.4, 1.8, 2.0, or even 2.3, up to 18.1, 9.1, or 4.5 kg.
It is noted that in the embodiments above, the fiber is not limited to the specific denier size for which the results are specified. Rather, the fibers are described by noting what the burst strength of the Jersey knit fabric made from the fiber would be if the fiber were made to a specific denier and tested. In contrast, the embodiments below deal with fibers of specified denier.
In some embodiments, the fibers of the present invention have denier of from 4, 10, 35, or even 60 up to 130, 100, or even 80 denier, and in some embodiments an average denier of about 70. In any of these embodiments, the fibers may provide a Jersey knit fabric with a burst puncture strength of at least 710, 800, 1000, 1200, or even 1250, up to 1400 lbf/in, and in other embodiments at least 124, 140, 175, 210 or even 219, up to 245 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 25, 30, 35, 40, or 40.5 up to 200, 100 or 75 lbf-in, and in other embodiments at least 2.8, 3.4, 4.0, 4.5, or 4.6 up to 22.6, 11.3, or 8.5 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 6, 7, 8, or 9 up to 50, 40 or 20 lb, and in other embodiments at least 2.7, 3.2, 3.6 or even 4.1, up to 22.7, 18.1 or 9.1 kg.
In some embodiments, the fibers of the present invention have denier of from 80, 90, 100, 120 or even 140 up to 300, 250, 200, or even 160, or in some embodiments an average denier of about 140. In any of these embodiments, the fibers may provide a Jersey knit fabric with a burst puncture strength (load/thick at failure) of at least 1200, 1300, 1500, 1700, or even 1750, up to 1900 lbf/in, and in other embodiments at least 210, 228, 263, 298 or even 306, up to 333 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 60, 70, 75, 80, or even 83.5 up to 800, 200, or 150 lbf-in, and in other embodiments at least 6.8, 7.9, 8.5, 9.0, or 9.4 up to 90.3, 22.6, or 16.9 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 10, 15, 17, or even 17.5 up to 100, 75, 50, or 25 lb, and in other embodiments at least 4.5, 6.8, 7.7 or even 7.9, up to 45.4, 34.0, 22.7 or 11.3 kg.
In some embodiments, the fibers of the present invention have denier of from 20, 30, 35, or even 40 up to 100, 75, 60, or even 50, or in some embodiments an average denier of about 40. In any of these embodiments, the fibers may provide a Jersey knit fabric with a burst puncture strength (load/thick at failure) of at least 500, 750, 1000, 1400 or even 1450, up to 1600 or 1500 lbf/in, and in other embodiments at least 88, 131, 175, 245 or even 254, up to 280 or 263 N/mm. In any of these embodiments, the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the energy to fail is at least 10, 15, 20 or even 20.5 up to 100, 75, or 50 lbf-in, and in other embodiments at least 1.1, 1.7, or 2.3 up to 11.3, 8.5, or 5.6 N-m. In any of these embodiments, still the fibers may also provide a Jersey knit fabric with a burst puncture strength such that the load at failure is at least 3, 4, 4.5 or even 5 up to 40, 20, or 10 lb, and in other embodiments at least 1.4, 1.8, 2.0, or even 2.3, up to 18.1, 9.1, or 4.5 kg.
The fibers of the present invention may be monofilament fibers. In some embodiments, the fibers have a diameter of 10, 30, 40 or even 45 up to 500, 400, 300 or even 200 microns.
In some embodiments, the fibers of the present invention: when made to a denier of 20 will have a diameter of 20 or 30 to 55 or 50 microns; when made to a denier of 40 will have a diameter of 40 or 60 to 85 or 80 microns; when made to a denier of 70 will have a diameter of 75 or 80 to 130 or 100 microns; when made to a denier of 140 will have a diameter of 80 or 100 to 300 or 150 microns; when made to a denier of 360 will have a diameter of 175 or 190 to 225 or 210 microns; or any combination thereof.
It is noted that in the embodiments above, the fiber is not limited to the specific denier size or diameter provided. Rather, the fibers are described by noting what the diameter the fiber would have if the fiber were made to a specific denier. In contrast, the embodiments below deal with fibers of specified denier.
In some embodiments, the fibers of the present invention have a denier of 10 to 30, or an average of about 20, and in such embodiments the fibers have a diameter of from 10, 20 or even 30 to 65, 60, 55 or even 50 microns, and in some embodiments an average diameter of 48 microns.
In some embodiments, the fibers of the present invention have a denier of 30 to 40, or an average of about 30, and in such embodiments the fibers have a diameter of from 20, 30, 40 or even 60 to 115, 100, 85 or even 80 microns, and in some embodiments an average diameter of 73 microns.
In some embodiments, the fibers of the present invention have denier of from 4, 10, 35 or even 60 up to 130, 100, or 80, or an average of about 70. In such embodiments, the fibers have a diameter of from 50, 60, 70, 75, or even 80 to 220, 200, 150, 130, or even 100 microns, and in some embodiments an average diameter of 89 microns.
In some embodiments, the fibers of the present invention have denier of from 80, 90, 100, 120 or 140 up to 300, 250, 200, or 160. In some embodiments, the fibers have an average denier of about 140. In such embodiments, the fibers have a diameter of from 50, 70, 80, or even 100 to 300, 250, 200, or even 150 microns, and in some embodiments an average diameter of 128 microns.
In some embodiments, the fibers of the present invention have denier of from 150, 200, or even 300 up to 1500, 500, 450 or even 200. In some embodiments, the fibers have an average denier of about 360. In such embodiments, the fibers have a diameter of from 100, 150, 175, or even 190 to 400, 250, 225, or even 210 microns, and in some embodiments an average diameter of 198 microns.
In some embodiments, the diameter of the fiber of the present invention is described by a formula where the diameter of the fiber, in microns, is approximately equal to 11.7 times the denier of the fiber raised to the power of 0.48 (Diameter=11.7×Denier 0.48 ). In some embodiments, the diameter of the fiber is within a 20, 10 or even 5 micron range centered on the result of the described equation.
In some embodiments, the fiber of the present invention has a denier of 40 to 90; a modulus, on the 5 th pull cycle, that increases between 80 and 130% on the load cycle between 100% and 200% elongation; a burst puncture strength, when made into a Jersey knit fabric, as measured by ASTM D751, such that the load/thick at failure for the fabric is between 710 and 1600 lbf/in (124 and 280 N/mm); and is monofilament with a diameter of 80 to 100 microns.
In some embodiments, the fiber of the present invention has a denier of 90 to 160; a modulus, on the 5 th pull cycle, that increases between 50 and 120% on the load cycle between 100% and 200% elongation; and is monofilament with a diameter of 100 to 150 microns.
In some embodiments, the fiber of the present invention has a denier of 300 to 400; a modulus, on the 5 th pull cycle, that increases between 50 and 150% on the load cycle between 100% and 200% elongation; and is monofilament with a diameter of 180 to 220 microns.
The invention will be better understood by reference to the following non-limiting examples.
EXAMPLES
Example Set 1
A set of nine example resins are made by reacting in a continuous reactor: (i) 75.5 parts by weight of a polyester polyol derived from adipic acid with a 50/50 molar mixture of 1,4-butanediol and 1,6-hexanediol where the polyol is prepared in a batch reactor at a reaction temperature of about 125 degrees C. and then vacuum dried where the polyol has a number average molecular weight (Mn) of about 2500; (ii) 20 parts by weight MDI; and (iii) 4.5 parts by weight 1,4-butanediol as a chain extender. During the continuous reaction, 0.08 parts by weight of a lubricant package is added, where the package consists of a 90/10 weight mixture of Acrawax C beads and Glycolube VL. The polymer is allowed to react until the desired weight average molecular weight (Mw) of the elastomer (>600,000) is obtained.
The resulting elastomer resins have weight average molecular weights (Mw) that range from 687,055 to 1,015,685 and polydispersity indexes (PDI) that range from 3.05 to 5.42. The results for each resin example are summarized in the table below, where the molecular weight is measured by GPC:
TABLE I
Resin Example Data
Example No
Mw
Mn
PDI
1-1
1015685
187547
5.42
1-2
1010920
207489
4.87
1-3
865767
240537
3.60
1-4
883539
283921
3.11
1-5
919746
274819
3.35
1-6
758603
205217
3.70
1-7
693608
160449
4.32
1-8
687055
166669
4.12
1-9
723693
237454
3.05
Example Set 2
The elastomer resins described in Example Set 1 are melt spun into 40 denier fibers (Example 2-1), 70 denier fibers (Example 2-2) and 140 D fibers (Example 2-3) by adding 90 parts by weight of the elastomer resin to a reactive extruder along with 10 parts by weight of Hyperlast 5196, an isocyanate terminated polyether with a number average molecular weight of 1500. A conventional melt spinning process is used where the polymer melt is passed through a spinning nozzle selected to give the desired denier fiber. The strands exit the nozzle into air as strands, where the strands are solidified by cooling and then collected by winding the fibers in a winding device. The fibers are allowed to cure until the desired weight average molecular weights (>700,000) are obtained.
Example Set 3
The elastomer resin formulation described for the examples in Example Set 1 is processed in a reactive extruder in order to evaluate its processing characteristics. In this extrusion quality test procedure, a resin is processed into extruded film test parts. An image analysis system interprets video images from a camera that views the film test parts from an overhead projector. The system analyzes the images of the test parts, identifying and counting defects in the test parts. The nominal size of defects detectable by the system is from 80 to 500 microns.
Five specimens of extruded film are taken from a product sample. The specimens are placed on an overhead projector and the image projected onto a screen. A video camera captures and transfers the image to a computer where image analysis software interprets and analyzes the signal. A measurement of the number of defects captured within 4 square inches of each specimen is recorded. The values for the five specimens are averaged and a final Image Analysis (IA) result is reported. An IA value of less than 20 is generally acceptable for cable and other thick profile applications, while an IA value of less than 10 is generally acceptable for blown film and fiber applications. A lower the IA value, the better the extrusion processing properties of the material.
The table below summarizes data collected on parts made from resin processed in an extruder during an extruder processing run. The resin used for all the examples is the same resin formulation described in Example Set 1 above.
TABLE II
Extrusion Quality Data
IA
Ex ID
Value
3-1
4
3-2
4
3-3
4
3-4
4
3-5
3
3-6
4
3-7
4
3-8
3
3-9
3
3-10
3
3-11
3
3-12
3
3-13
3
3-14
3
3-15
3
3-16
3
3-17
4
3-18
4
3-19
4
3-20
4
3-21
4
3-22
4
3-23
4
3-24
3
3-25
3
3-26
3
3-27
3
3-28
4
3-29
3
3-30
3
3-31
4
3-32
3
3-33
3
3-34
3
3-35
3
3-36
3
3-37
3
3-38
3
3-39
4
3-40
4
3-41
4
3-42
4
3-43
4
3-44
4
3-45
4
3-46
4
3-47
4
The results show that the resins of the invention exhibit excellent processing characteristics and are very extrudable.
Example Set 4
The 40 denier fiber of Example set 2 (Example 2-1), and a commercially available fiber of the same denier are tested to evaluate their alkali resistance. The fiber to be tested is wrapped around a Teflon™ card 180 times. Four separate test parts are prepared for each fiber material being tested. After winding, the fiber end is secured on each test part and the resulting test parts are submerged in a solution that is 4% by weight bleach (Chlorox™ bleach) and 0.2% by weight anionic detergent (Tide™ detergent). The solution is held at 70° C. during the testing. Test parts are removed after 30, 60, 120 and 240 minutes of exposure. Once removed from the solution, the parts are washed in de-ionized water and then allowed to air dry for about 12 hours. After the drying period, each part is tested. The parts are tested by removing a 5 cm long sample of the exposed fiber and testing its physical properties using a tensiometer configured with the load cell on top and the crosshead moving down. The crosshead is moving at 100 mm/min. A sample of fiber not exposed to the solution is also tested as a baseline. The difference in the tenacity (measured in grams per denier) is measured, indicating the fiber's alkali resistance. The smaller the impact on the fiber's tenacity, the better its alkali resistance. The table below summarizes the results from the alkali resistance testing:
TABLE III
Alkali Resistance Data
Example 3-1
Example 3-2
Time
40D Fiber (Ex 2-1)
Comparative 40D Fiber 2
(min)
Tenacity
% Loss
Tenacity
% Loss
0 (baseline)
1.365
0
1.565
0
30
0.897
34.29
0.509
67.48
60
0.701
48.64
0.215
86.26
120
0.506
62.83
BROKE 1
NA
240
BROKE 1
NA
BROKE 1
NA
1 A designation of “BROKE” means the fiber physically broke before testing could be completed.
2 The comparative fiber included in this testing is 40D LYCRA ™ 162C, a commercially available 40 denier fiber, marketed by INVISTA ™.
The results show that the fibers made from the resins of the invention have significantly better alkali resistance compared to other commercially available fibers.
Example Set 5
The 140 denier fiber of Example set 2 (Example 2-3), the 70 denier fiber of Example Set 2 (Example 2-2) and a commercially available 70 denier fiber are tested to evaluate their caustic resistance. The fiber to be tested is wrapped around a Teflon™ card 180 times. Four separate test parts are prepared for each fiber material being tested. After winding, the fiber end is secured on each test part and the resulting test parts are submerged in a solution that is 3% by weight caustic (NaOH). The solution is held at 100° C. for a 90 min exposure period. Once removed from the solution, the parts are washed in de-ionized water and then allowed to air dry for about 12 hours. After the drying period, each part is tested. The parts are tested by removing a 5 cm long sample of the exposed fiber and testing its physical properties using a tensiometer configured with the load cell on top and the crosshead moving down. The test is 5 cycles stretching to 300% and a 6 th cycle stretching to break. The crosshead is moving at 100 mm/min. The tensiometer test software measures the gf/den (gram force/denier), on load pull at elongations of 100%, 150%, 200%, and 300%. It also measures the gf/den on the unload pull at 200%, 150%, and 100%. Both the load and unload pulls are measured on the 1 st and 5 th cycle. Other values recorded are maximum load (gf/den), elongation at max load (%), load at break (gf/den), and elongation at break (%). The final value measured is % set on 1 st and 5 th cycles. % set is the length at witch the load reaches 0 on the unload pull minus original length, divided by the original length (i.e., 6-5/5=20%). The table below summarizes the tenacity and 5 th cycle modulus results. A sample of fiber not exposed to the solution is also tested as a baseline. The difference in the tenacity (measured in grams per denier) is measured, indicating the fiber's caustic resistance. The smaller the impact on the fiber's tenacity, the better its caustic resistance.
TABLE IV
Caustic Resistance Data
Example 4-1
Example 4-2
Example 4-3
140D Fiber (Ex 2-3)
70D Fiber (Ex 2-2)
70D Comp Fiber 1
Before
After
Before
After
Before
After
(gm/d)
(gm/d)
% loss
(gm/d)
(gm/d)
% loss
(gm/d)
(gm/d)
% loss
Tenacity
1.272
1.205
5.27
1.344
1.386
+3.1
1.401
1.083
22.7
300% modulus
0.166
0.131
21.08
0.241
0.159
34
0.241
0.157
34.9
(5 th cycle)
1 The comparative fiber included in this testing is 70D LYCRA ™ 162C, a commercially available 70 denier fiber, marketed by INVISTA ™.
The results show that the fibers made from the resins of the invention have significantly better caustic resistance compared to other commercially available fibers.
Example Set 6
Several example fabrics are prepared and tested to determine how balanced the fabric is. The balance of a fabric depends on both the combination and compositions of the fibers used to make it as well as the construction of the fabric itself. A fabric is often described by citing its content, which is related to the mix of fibers present, and its weight, which is related to its construction. The examples here are believed to be of the same general type of construction and, within each sample set, the inventive sample has been prepared to match the weight of the comparative example, thus allowing for a meaningful comparison.
Several fabrics are prepared and tested and compared to two commercially available fabrics. All of the fabrics, including the commercial samples, are of a single layer jersey construction and made with two fibers, an example fiber and a nylon fiber, present as a co fiber. Each of the fabrics, including the commercial samples, have been heat set, dyed and finished before testing.
Example 6-1 is an inventive example of a fabric made from the fibers of Example 2-2 (70 D fibers of the invention) and nylon of a similar denier. Example 6-2 is a comparative example made from LYRCA™, a commercially available spandex type fiber marketed by INVISTAT™, and nylon. The fiber content of the Example 6-1 was chosen so that the weights of 6-1 and 6-2 would match, allowing for a meaningful comparison.
Example 6-3 is an inventive example made from the fibers of Example 2-2 (70 D fibers of the invention) and nylon. Example 6-4 is a comparative example made from LYRCA™ fibers and nylon. The fiber content of the Example 6-3 was chosen so that the weights of 6-3 and 6-4 would match, allowing for a meaningful comparison.
Example 6-5 is an inventive example made from the fibers of Example 2-1 (40 D fibers of the invention) and nylon. The fiber content is 60:40 Example 2-1 fibers:nylon, giving a 36 gauge fabric.
Each of the fabric examples above is tested to determine its balance. The balance of the fabric is tested by stretching a sample of fabric in the length direction at a cycle speed of 20 in/min and a speed conditioning cycle of 1000 mm/min, monitoring the amount of force-stress, measured in lbf, applied to fabric relative to the percent stretch seen in the fabric, up to a maximum force-stress of 15 lbf. The same procedure is then carried out on the fabric but in the width direction. The closer the results for the fabric in length and width directions, the more balanced the fabric is. For the applications of interest for the invention, a fabric should have results in both directions that are within 20% and allow for more than 100% elongation in both directions at 15 lbf. The table below summarizes the results when evaluating the balance of the fabrics.
TABLE V
Fabric Example Data
% Stretch
Force-
Force-
Force-
at Maximum
Stress at
Stress at
Stress at
Force
Example No
40% Stretch
60% Stretch
80% Stretch
(15 lbf)
6-1 LENGTH
2.29 lbf
4.01 lbf
6.14 lbf
120.81%
6-1 WIDTH
1.66 lbf
2.76 lbf
4.23 lbf
124.57%
6-2 LENGTH
3.27 lbf
8.77 lbf
NA
73.68%
6-2 WIDTH
0.68 lbf
1.49 lbf
2.38 lbf
159.33%
6-3 LENGTH
2.22
3.29
4.60
134.85%
6-3 WIDTH
1.84
2.90
4.06
156.42%
6-4 LENGTH
1.17
2.60
6.43
97.20%
6-4 WIDTH
1.39
2.32
3.53
138.76%
6-5 LENGTH
1.12
1.79
2.38
230.83%
6-5 WIDTH
1.01
1.67
2.30
225.95%
The results show that the fabrics of the invention are much more balanced than the comparative examples, which for Example 6-2 did not even reach 80% elongation under 15 lbf of force-stress in the length direction, and which for Example 6-4 did not reach 100%. The inventive examples show comparable force-stress levels at corresponding stretch percentages in both the length and width directions up to the maximum force-stress, indicating very well balanced fabrics.
While in accordance with the patent statutes, the best mode and preferred embodiment has been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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The present invention relates to elastomeric resins, fibers made from said resins, fabrics made with said fibers, and applications and uses for the resins, fibers and fabrics. The elastomer resins of the invention provide high strength fibers and well balanced fabrics with good physical properties and chemical resistance, making them attractive for use in various applications that use elastic fibers and fabrics.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims priority to U.S. application Ser. No. 13/477,335, filed on May 22, 2012, which application is a continuation application of and claims priority to U.S. application Ser. No. 12/721,874, filed on Mar. 11, 2010, now issued U.S. Pat. No. 8,204,589, which application is a continuation application of and claims priority to U.S. application Ser. No. 10/841,367, filed on May 7, 2004, now U.S. Pat. No. 7,706,878. These applications are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to devices for assisting caregivers in delivering therapy to a patient (e.g., automatic external defibrillators).
BACKGROUND
[0003] Resuscitation treatments for patients suffering from cardiac arrest generally include clearing and opening the patient's airway, providing rescue breathing for the patient, and applying chest compressions to provide blood flow to the victim's heart, brain and other vital organs. If the patient has a shockable heart rhythm, resuscitation also may include defibrillation therapy. The term basic life support (BLS) involves all the following elements: initial assessment; airway maintenance; expired air ventilation (rescue breathing); and chest compression. When all these elements are combined, the term cardiopulmonary resuscitation (CPR) is used.
[0004] There are many different kinds of abnormal heart rhythms, some of which can be treated by defibrillation therapy (“shockable rhythms”) and some which cannot (non-shockable rhythms”). For example, most ECG rhythms that produce significant cardiac output are considered non-shockable (examples include normal sinus rhythms, certain bradycardias, and sinus tachycardias). There are also several abnormal ECG rhythms that do not result in significant cardiac output but are still considered non-shockable, since defibrillation treatment is usually ineffective under these conditions. Examples of these non-shockable rhythms include asystole, electromechanical disassociation, and other pulseless electrical activity. Although a patient cannot remain alive with these non-viable, non-shockable rhythms, applying shocks will not help convert the rhythm. The primary examples of shockable rhythms, for which the caregiver should perform defibrillation, include ventricular fibrillation, ventricular tachycardia, and ventricular flutter.
[0005] After using a defibrillator to apply one or more shocks to a patient who has a shockable ECG rhythm, the patient may nevertheless remain unconscious, in a shockable or non-shockable, perfusing or non-perfusing rhythm. If a non-perfusing rhythm is present, the caregiver may then resort to performing CPR for a period of time in order to provide continuing blood flow and oxygen to the patient's heart, brain and other vital organs. If a shockable rhythm continues to exist or develops during the delivery of CPR, further defibrillation attempts may be undertaken following this period of cardiopulmonary resuscitation. As long as the patient remains unconscious and without effective circulation, the caregiver can alternate between use of the defibrillator (for analyzing the electrical rhythm and possibly applying a shock) and performing cardio-pulmonary resuscitation (CPR). CPR generally involves a repeating pattern of five or fifteen chest compressions followed by a pause during which two rescue breaths are given.
[0006] Defibrillation can be performed using an AED. The American Heart Association, European Resuscitation Council, and other similar agencies provide protocols for the treatment of victims of cardiac arrest that include the use of AEDs. These protocols define a sequence of steps to be followed in accessing the victim's condition and determining the appropriate treatments to be delivered during resuscitation. Caregivers who may be required to use an AED are trained to follow these protocols.
[0007] Most automatic external defibrillators are actually semi-automatic external defibrillators (SAEDs), which require the caregiver to press a start or analyze button, after which the defibrillator analyzes the patient's ECG rhythm and advises the caregiver to provide a shock to the patient if the electrical rhythm is shockable. The caregiver is then responsible for pressing a control button to deliver the shock. Following shock delivery, the SAED may reanalyze the patient's ECG rhythm, automatically or manually, and advise additional shocks or instruct the caregiver to check the patient for signs of circulation (indicating that the defibrillation treatment was successful or that the rhythm is non-shockable) and to begin CPR if circulation has not been restored by the defibrillation attempts. Fully automatic external defibrillators, on the other hand, do not wait for user intervention before applying defibrillation shocks. As used below, automatic external defibrillators (AED) include semi-automatic external defibrillators (SAED).
[0008] Both types of defibrillators typically provide an auditory “stand clear” warning before beginning ECG analysis and/or the application of each shock. The caregiver is then expected to stand clear of the patient (i.e., stop any physical contact with the patient) and may be required to press a button to deliver the shock. The controls for automatic external defibrillators are typically located on a resuscitation device housing.
[0009] AEDs are typically used by trained medical or paramedic caregivers, such as physicians, nurses, emergency medical technicians, fire department personnel, and police officers. The ready availability of on-site AEDs and caregivers trained to operate them is important because a patient's chances of survival from cardiac arrest decrease by approximately 10% for each minute of delay between occurrence of the arrest and the delivery of defibrillation therapy.
[0010] Trained lay caregivers are a new group of AED operators. For example, spouses of heart attack victims may become trained as lay caregivers. Lay caregivers rarely have opportunities to defibrillate or deliver CPR, and thus they can be easily intimidated by an AED during a medical emergency. Consequently, such lay providers may be reluctant to purchase or use AEDs when needed, or might tend to wait for an ambulance to arrive rather than use an available AED, out of concern that the lay provider might do something wrong.
[0011] Some trained medical providers, e.g., specialists such as obstetricians, dermatologists, and family care practitioners, also rarely have the opportunity to perform CPR and/or defibrillate, and thus may be uneasy about doing so. Concerns about competence are exacerbated if training is infrequent, leading the caregiver to worry that he or she may not be able to remember all of the recommended resuscitation protocol steps and/or their correct sequence.
[0012] Similarly, both medical and lay caregivers may be hesitant to provide CPR and rescue breathing, or may be unsure when these steps should be performed, particularly if their training is infrequent and they rarely have the opportunity to use it.
[0013] It is well known to those skilled in the art, and has been shown in a number of studies, that CPR is a complex task with both poor initial learning as well as poor skill retention, with trainees often losing 80% of their initial skills within 6-9 months. It has thus been the object of a variety of prior art to attempt to improve on this disadvantageous condition. Aids in the performance of chest compressions are described in U.S. Pat. Nos. 4,019,501, 4,077,400, 4,095,590, 5,496,257, 6,125,299, and 6,306,107, 6,390,996. U.S. Pat. Nos. 4,588,383, 5,662,690 5,913,685, 4,863,385 describe CPR prompting systems. AEDs have always included voice prompts as well as graphical instructions on flip charts or placards since the earliest commercial versions in 1974 to provide both correct timing and sequence for the complex series of actions required of the rescuer (caregiver) as well as placement of the defibrillation electrodes. U.S. patent application Ser. No. 09/952,834 and U.S. Pat. Nos. 6,334,070 and 6,356,785 describe defibrillators with an increased level of prompting including visual prompts either in the form of graphical instructions presented on a CRT or on printed labels with backlighting or emissive indicia such as light emitting diodes. AEDs since the 1970s have used the impedance measured between the defibrillation electrodes to determine the state of the AED as well as appropriate messages to deliver to the rescuer (e.g. “Attach Electrodes” if the initial prompts on the unit have been delivered and the impedance remains greater than some specified threshold) or to determine if there is excessive patient motion (as in U.S. Pat. No. 4,610,254.) U.S. Pat. No. 5,700,281 describes a device which uses the impedance of the electrodes to determine the state of the AED for delivering messages such as “Attach Electrodes”. Enhanced prompting disclosed in these patents provides some benefit to the rescuer in improved adherence to the complex protocol required of them to successfully revive a cardiac arrest patient, but the enhanced prompting is usually not sufficient in real world situations. U.S. Pat. Nos. 5,662,690 and 6,356,785 (and the commercially available OnSite defibrillator) attempts to improve prompting by providing a rescuer-accessible “Help” key that initiates more detailed prompting in cases in which the rescuer or test subject is confused. But testing has shown that with the heightened level of anxiety that accompanies a real cardiac arrest, rescuers rarely remember to press such a Help key. Even notifying the rescuer at the beginning of the protocol to press the Help key does not help a the confused rescuer press the Help key. Furthermore, even if the Help key is pressed, it is necessary to have the rescuer work through a series of user interface interactions via a touchscreen, softkeys or other input means, for the help software to determine at which step the rescuer is in need of additional instructions. Putting the user through these interactions with the help software detracts from the rescuer's ability to provide aid to the patient, and thus delays delivery of therapy.
[0014] AEDs have also been solely focused on defibrillation, which, while it provides the best treatment for ventricular fibrillation and certain tachycardias, is of no therapeutic benefit for the 60% of the cardiac arrest patients presenting in pulseless electrical activity (PEA) or asystole. As AEDs are becoming more prevalent in the home, there are also a host of other health problems that occur such as first aid as well as incidents related to chronic conditions such as asthma, diabetes or cardiac-related conditions for which the AED is of no benefit.
SUMMARY
[0015] In a first aspect, the invention features a device for assisting a caregiver in delivering therapy to a patient, the device comprising a user interface configured to deliver prompts to a caregiver to assist the caregiver in delivering therapy to a patient; at least one sensor configured to detect the caregiver's progress in delivering the therapy, wherein the sensor is other than an electrode in an electrical contact with the body; a memory in which a plurality of different prompts are stored; a processor configured to determine which of the different prompts should be selected for delivery based on the progress detected by the sensor.
[0016] Preferred implementations of this aspect of the invention may incorporate one or more of the following: There may be a plurality of sensors configured to detect the caregiver's progress in delivering the therapy, wherein each of the plurality of sensor is other than an electrode connected to the body. The processor may be configured to vary the time at which prompts are delivered based on the progress detected by the sensor. One or more additional sensors may be configured to detect the caregiver's progress in delivering the therapy, wherein the one or more additional sensors comprise an electrode in electrical contact with the body. The at least one sensor may comprise a photoelectric sensor on the electrode for assisting in detection of whether the electrode has been applied to clothing. The therapy may comprise a series of steps in a protocol, and at least two sensors may be configured to detect whether at least two of the steps in the protocol have been successfully completed. The processor may select a series of more detailed prompts for delivery to a user when progress is slower than a predetermined pace. The processor may be configured to slow down the rate at which prompts are delivered when progress is slower than a predetermined pace. The processor may be configured to choose from among at least three rates at which prompts are delivered, and the choice is based at least in part on the progress detected by the sensor. The progress detected by the sensors may comprise whether a step in the protocol has been initiated and whether the step has been completed. The user interface may deliver at least some of the prompts as oral instructions to be heard by the caregiver. The user interface may deliver at least some of the prompts as visual instructions to be seen by the caregiver. The user interface may comprise an electronic display. The electronic display may provide a series of images. The user interface may comprise a series of printed pages. The device may further comprise one or more detectors configured to detect which page of the series of pages is being viewed by the caregiver. The detectors may comprise magnetic sensors that detect the presence of magnetic members supported by the pages. The processor may be configured to provide prompts with a first level of detail when progress is occurring at or faster than a predetermined rate, and with a second level of detail more specific than the first level of detail when progress is occurring at or slower than the predetermined rate. The sensor may be configured to detect whether the caregiver has made a predetermined error in delivering the therapy, and the processor may be configured to deliver one or more prompts designed to assist the user in correcting the predetermined error. The progress detected by the sensors may comprise whether a step in the protocol has been initiated and whether the step has been completed, and the processor may be configured to pause in delivery of prompts if a step has been initiated but not completed, and no predetermined error associated with the step has been detected. The device may be configured to assist a caregiver in delivering therapy for one or more cardiac malfunctions. The device may be configured to assist a caregiver in delivering therapy for one or more cardiac malfunctions. The device may be configured to assist a caregiver in delivering chest compressions. The device may be configured to assist a caregiver in delivering CPR. The device may be configured to assist a caregiver in delivering an electrical stimulus to the heart. The electrical stimulus may include defibrillation. The electrical stimulus may include pacing.
[0017] The device may comprise a defibrillator; and electrodes constructed to acquire data, indicative of the heart rhythm of the patient and indicative of whether the electrodes are properly placed on the patient and to deliver a defibrillating shock if appropriate. The device may further comprise on a portion of a housing for the device, a series of graphics configured to prompt a caregiver to perform a sequence of steps appropriate for treating a victim of suspected cardiac arrest The graphics may include a picture configured to prompt the caregiver to check the patient for responsiveness. The graphics may include a picture configured to prompt the caregiver to call for emergency assistance. The graphics may include a picture configured to prompt the caregiver to open the patient's airway. The graphics may include a picture configured to prompt the caregiver on how to open the patient's airway. The graphics may include a picture configured to prompt the caregiver to check the patient for signs of circulation. The graphics may include a picture configured to prompt the caregiver to attach the electrodes to the patient. The graphics may include a picture configured to prompt the caregiver on where the electrodes should be attached. The graphics may include a picture configured to prompt the caregiver to stand clear of the patient. The graphics may include a picture configured to prompt the caregiver to press a treatment button to cause the device to administer a defibrillating shock. The graphics may include a picture configured to prompt the caregiver to perform CPR. The graphics may include one or more pictures illustrating procedures for chest compressions and rescue breathing. The pictures may include a heart symbol indicating the location of the treatment button. The device may include a treatment button configured to be pressed by the caregiver to cause the defibrillator to administer a defibrillating shock. The device may further include a light source associated with each of the graphics in the series. The device may comprise electronics configured to sequentially illuminate the light sources. The graphics may include one or more pictures selected from the group consisting of: a picture configured to prompt the caregiver to check the patient for responsiveness; a picture configured to prompt the caregiver to call for emergency assistance; a picture configured to prompt the caregiver to open the patient's airway; a picture configured to prompt the caregiver to check the patient for signs of circulation; a picture configured to prompt the caregiver to attach the electrodes to the patient; a picture configured to prompt the caregiver to stand clear of the patient; and a picture configured to prompt the caregiver to perform CPR. The graphics may include a picture configured to prompt the caregiver to press a treatment button to cause the defibrillator to administer a defibrillating shock. The graphics may include one or more pictures selected from the group consisting of: a picture configured to prompt the caregiver to check the patient for responsiveness; a picture configured to prompt the caregiver to call for emergency assistance; a picture configured to prompt the caregiver to open the patient's airway; a picture configured to prompt the caregiver to check the patient for signs of circulation; a picture configured to prompt the caregiver to attach the electrodes to the patient; a picture configured to prompt the caregiver to stand clear of the patient; and a picture configured to prompt the caregiver to perform CPR. The light sources may comprise LEDs. The audio prompts may be associated with the series of graphics and are given sequentially to guide the caregiver through the sequence of steps. The device may further comprise electronics configured to sequentially illuminate the light sources, wherein the audio prompts are associated with the series of graphics and with the sequential illumination of the light sources, to guide the caregiver through the sequence of steps. The device may further comprise electronics configured to measure the time elapsed from the time at which the caregiver turned the power on to activate the defibrillator, and at least some of the audio prompts are timed to occur based on the elapsed time. At least some of the graphics may be provided on a cover portion of the defibrillator device housing. At least some of the graphics may be provided on the outside of the cover portion of the device. The graphics on the cover portion may include a picture indicating that the cover should be removed from the device. The cover portion may include a space provided for local emergency information. The cover portion may include a window behind which a card bearing local emergency information can be placed. At least some of the graphics may be provided in the form of backlit, translucent images. At least some of the graphics may be provided in the form of a decal. The device may further comprise buttons, associated with at least some of the graphics, which, when pressed, cause more detailed audio prompts related to the associated graphic to be output by the device. The graphics may include one or more pictures indicating that the caregiver should place a passive airway support under the shoulders of the patient. The graphics may include a picture configured to prompt the caregiver to check to see if the patient is breathing. The prompts and graphical interface may illustrate the entire sequence of resuscitation activities that are recommended by the American Heart Association. The prompts may include instructions for performing first aid. The device may comprise a cover to the device whose removal the processor is capable of detecting; and a series of bound pages on the face of the device under the cover with one or more sensors for determining to which page the bound pages have been turned. The device may further comprise a portion of the device used specifically for storage of items commonly used in the course of providing aid such as bandaids, bandages, splints, antiseptic. The storage area may be partitioned into individual wells in which each of the items is stored and a detections means may be provided for determining which, if any, of the items has been removed by the user. Photoelectric sensors may be provided in each of the wells. The prompts and graphical interface may illustrate the Red Cross First Aid treatment protocols.
[0018] The device may include a cover whose removal the processor is capable of detecting; a defibrillator for delivering defibrillation shocks; electrodes configured to be attached to a patient, to acquire data indicative of the patient's heart rhythm and to deliver a defibrillating shock if appropriate; a storage area for said electrodes; and at least one sensor for determining if the electrodes have been removed from the storage area by the user. The storage area may be a compartment that is part of the housing of the device. The storage area may be a package removable from the housing of the device. The cover may be shaped for use as a neck rest for maintaining the patient's airway in the necessary open condition during CPR. A detection means may be provided for determining if the patient's head is correctly located on the cover while it is being used as a neck rest. The detection means may be provided by a pressure sensor. The detection means may be provided by a photoelectric sensor.
[0019] The device may further comprise a decision making system provided by a distributed network may comprise a remotely located human expert, an electronic processor in the device, and an electronic communication link between the human and electronic processor. The information transmitted over the communication link may be both voice and digital data. The data may be bi-directional. The digital data may contain information about the device's location and the status of the device. The device may be capable of being remotely controlled by the human expert. The electronic processor may revert to providing internally generated responsive feedback prompts if the communication link is lost to the remotely located human expert. The device may further comprise a decision-making system comprising circuitry and an electronic processor located in the device. The device may further comprise a decision making system provided by a distributed network comprising a remotely located electronic processing system, a local electronic processing system in the device and an electronic communication link between the remote and local electronic processing system. The device may further comprise a processing system that measures and records the times required for a user to complete a sequence of steps and/or sub-steps in a protocol, and, based on the measured times adjusting the rate of the prompting delivered by the processor and user interface. The adjusting may be based on a comparison of the measured times with a set of stored values. The device may comprise decision-making circuitry for evaluating the difference between the measured times and the set of stored values. The device may further comprise elements for correctly identifying a set of voice commands delivered by the user and performing a set of actions in response to those user voice commands.
[0020] In a second aspect, the invention features an automatic external defibrillator for assisting a caregiver in delivering resuscitation therapy to a patient, the defibrillator comprising a memory in which a plurality of different prompts are stored; a processor configured to determine which of the different prompts should be selected for delivery; a user interface configured to deliver the selected prompts to a caregiver to assist the caregiver in delivering therapy to a patient, wherein the user interface comprises a series of printed pages and one or more detectors configured to detect which page of the series of pages is being viewed by the caregiver.
[0021] Preferred implementations of this aspect of the invention may incorporate one or more of the following. Detectors may comprise magnetic sensors that detect the presence of magnetic members supported by the pages.
[0022] Among the many advantages of the invention (some of which may be achieved only in some of its various aspects and implementations) are that the invention provides a more comprehensive and effective system for prompting users in the delivery of care for first aid, chronic health problems as well as cardiac arrest.
[0023] The invention can provide the further benefit that a device can intelligently vary the amount of detail to provide in prompts to the caregiver. In currently available devices, the prompting has been optimized for the average user, and this is both frustrating and obstructive for the expert user; the more detailed prompting is not needed by the expert user and actually delays delivery of treatment. The invention can eliminate the need for this compromise, by intelligently delivering prompts needed by the particular user.
[0024] Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0025] FIG. 1 is a perspective view of an AED with its cover on.
[0026] FIG. 2 is a perspective view of the AED of FIG. 1 with the cover removed.
[0027] FIG. 3 is a block diagram of the AED.
[0028] FIG. 4 is a plan view of the graphical interface decal used on the cover of the AED of FIG. 1 .
[0029] FIG. 5 is a plan view of the graphical interface decal used on the device housing of the AED of FIG. 1 , as shown in FIG. 2 .
[0030] FIG. 6 a - 6 e are flow charts indicating audio prompts provided during use of the AED of FIG. 1 and steps to be performed by the caregiver in response to the graphical and audio prompts.
[0031] FIGS. 7 a and 7 b list the audio prompts used in the flowcharts shown in FIGS. 6 a - 6 e.
[0032] FIG. 8 is an exploded perspective view of the cover and housing.
[0033] FIG. 9 is a side plan view of the cover indicating angle ‘A’.
[0034] FIGS. 10 a and 10 b are side views of a patient with and without the cover placed beneath the shoulders, to show the effect on the patient's airway of placing the cover beneath the shoulders.
[0035] FIG. 11 is a plan view of a decal providing graphical instructions on the cover for placing the cover under a patient's shoulders.
[0036] FIG. 12 shows an integrated electrode pad.
[0037] FIG. 13 is another view of an electrode pad.
[0038] FIG. 14 is an isometric view of an electrode well along one side of the housing.
[0039] FIG. 15 is a schematic of the electronics contained in the integrated electrode pad of FIG. 12 .
[0040] FIG. 16 is an isometric view of a first-aid kit implementation.
DETAILED DESCRIPTION
[0041] There are a great many possible implementations of the invention, too many to describe herein. Some possible implementations that are presently preferred are described below. It cannot be emphasized too strongly, however, that these are descriptions of implementations of the invention, and not descriptions of the invention, which is not limited to the detailed implementations described in this section but is described in broader terms in the claims.
[0042] The terms “caregiver”, “rescuer” and “user” are used interchangeably and refer to the operator of the device providing care to the patient.
[0043] Referring to FIGS. 1 and 2 , an automated external defibrillator (AED) 10 includes a removable cover 12 and a device housing 14 . The defibrillator 10 is shown with cover 12 removed in FIG. 2 . An electrode assembly 16 (or a pair of separate electrodes) is connected to the device housing 14 by a cable 18 . Electrode assembly 16 is stored under cover 12 when the defibrillator is not in use.
[0044] Referring to FIG. 3 , the AED includes circuitry and software 20 for processing , a user interface 21 including such elements as a graphical 22 or text display 23 or an audio output such as a speaker 24 , and circuitry and/or software 25 for detecting a caregiver's progress in delivering therapy—e.g., detecting whether one or more of a series of steps in a protocol has been completed successfully In some preferred implementations, the detecting also includes the ability to determine both whether a particular step has been initiated by a user and additionally whether that particular step has been successfully completed by a user. Based on usability studies in either simulated or actual use, common user errors are determined and specific detection means are provided for determining if the most prevalent errors have occurred.
[0045] If it is determined that the current step in the protocol has not been completed, then the processor will pause the currently-scheduled sequence of instructions. If, for instance, it has been determined that a particular step has been initiated but not completed, but none of the common errors has occurred subsequent to initiation of the particular step, then the processor may simply provide a pause while waiting for the user to complete the step. If, after waiting for a predetermined period of time based on prior usability tests, there has been no detection of the step completion, the processor may initiate a more detailed set of prompts, typically at a slower sequence rate, describing the individual sub-steps that comprise a particular step. If one of the common errors is detected while waiting for completion of the step, the processor may initiate a sequence of instructions to correct the user's faulty performance.
[0046] Device housing 14 includes a power button 15 and a status indicator 17 . Status indicator 17 indicates to the caregiver whether the defibrillator is ready to use.
[0047] The cover 12 includes a cover decal 30 ( FIG. 1 ) including a logo 31 and a series of graphics 32 , 34 and 36 . Logo 31 may provide information concerning the manufacturer of the device and that the device is a defibrillator (e.g., “ZOLL AED”, as shown in FIG. 1 , indicating that the device is a Semi-Automatic External Defibrillator available from Zoll Medical). Graphics 32 , 34 and 36 lead the caregiver through the initial stages of a cardiac resuscitation sequence as outlined in the AHA's AED treatment algorithm for Emergency Cardiac Care pending arrival of emergency medical personnel . (See “Guidelines 2000 for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care. Supplement to Circulation,” Volume 102, Number 8, Aug. 22, 2000, pp. I-67.) Thus, graphic 32 , showing the caregiver and patient, indicates that the caregiver should first check the patient for responsiveness, e.g., by shaking the patient gently and asking if the patient is okay. Next, graphic 34 , showing a telephone and an emergency vehicle, indicates that the caregiver should call for emergency assistance prior to administering resuscitation. Finally, graphic 36 indicates that after these steps have been performed the caregiver should remove the cover 12 of the defibrillator, remove the electrode assembly 16 stored under the lid, and turn the power on by depressing button 15 . The graphics are arranged in clockwise order, with the first step in the upper left, since this is the order most caregivers would intuitively follow. However, in this case the order in which the caregiver performs the steps is not critical, and thus for simplicity no other indication of the order of steps is provided.
[0048] The device housing includes a device housing decal 40 , shown in FIG. 2 . The graphics are configured to lead the caregiver through the entire resuscitation sequence, as will be explained below with reference to FIGS. 6 a - 6 e . Decal 40 also includes a center graphic 50 , which includes representations of a hand and a heart. Center graphic 50 overlies a treatment button which, when depressed, causes the defibrillator to deliver a defibrillating shock to the electrode assembly 16 .
[0049] Each of the graphics on device housing decal 40 is accompanied by a light source that can be temporarily illuminated to indicate that the illuminated step should be performed at that particular time. These light sources guide the caregiver, step-by-step, through the resuscitation sequence, indicating which graphic should be viewed at each point in time during resuscitation.
[0050] The light source for each of the graphics 42 - 50 is preferably an adjacent LED (LEDs 56 , FIG. 2 ). The heart 54 may be translucent and backlit by a light source in the device housing (not shown). Alternatively, the heart may include an adjacent LED (not shown) and/or the hand 52 may include an LED 57 as shown. Programmable electronics within the device housing 14 are used to determine when each of the light sources should be illuminated.
[0051] In some preferred implementations, a liquid crystal display 51 is used to provide the more detailed graphical prompts when a user is unable to complete the rescue sequence on their own. In these implementations, the purpose of the printed graphics is to provide a more general indication of the current step in the overall sequence, e.g. airway graphics 44 provides an indication that the rescuer should be performing the “Open Airway. Check for Breathing.” sub-sequence, but may not provide a detailed enough description for someone who has forgotten the correct actions to perform. In an alternative embodiment, the graphical instructions may be provided by a larger version of the liquid crystal display (LCD) 51 whereby the LED-lit printed instructions are eliminated or removed and most or all of the graphical instructions are provided by the LCD 30 . In this case, the LCD 51 will automatically show the more detailed instructions when it determines that the user is unable to properly perform the action.
[0052] The programmable electronics may also provide audio prompts, timed to coincide with the illumination of the light sources and display of images on the liquid crystal display 51 , as will also be discussed below with reference to FIGS. 6 a and 6 e .
[0053] The cover 12 is constructed to be positioned under a patient's neck and shoulders, as shown in FIGS. 10 a and 10 b , to support the patient's shoulders and neck in a way that helps to maintain his airway in an open position, i.e., maintaining the patient in the head tuck-chin lift position. The cover is preferably formed of a relatively rigid plastic with sufficient wall thickness to provide firm support during resuscitation. Suitable plastics include, for example, ABS, polypropylene, and ABS/polypropylene blends.
[0054] Prior to administering treatment for cardiac arrest, the caregiver should make sure that the patient's airway is clear and unobstructed, to assure passage of air into the lungs. To prevent obstruction of the airway by the patient's tongue and epiglottis (e.g., as shown in FIG. 10 a ), it is desirable that the patient be put in a position in which the neck is supported in an elevated position with the head tilted back and down. Positioning the patient in this manner is referred to in the American Heart Association Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care as the “head tilt-chin lift maneuver.” The head tilt-chin lift position provides a relatively straight, open airway to the lungs through the mouth and trachea. However, it may be difficult to maintain the patient in this position during emergency treatment.
[0055] The cover 12 has an upper surface 24 that is inclined at an angle A ( FIG. 9 a ) of from about 10 to 25 degrees, e.g., 15 to 20 degrees, so as to lift the patient's shoulders and thereby cause the patient's head to tilt back. The upper surface 24 is smoothly curved to facilitate positioning of the patient. A curved surface, e.g., having a radius of curvature of from about 20 to 30 inches, generally provides better positioning than a flat surface. At its highest point, the cover 12 has a height H ( FIG. 9 ) of from about 7.5 to 10 cm. To accommodate the width of most patients' shoulders, the cover 12 preferably has a width of at least 6 inches, e.g., from about 6 to 10 inches. If the cover 12 is not wide enough, the patient's neck and shoulders may move around during chest compressions, reducing the effectiveness of the device. The edge of the cover may also include a lip 11 ( FIG. 9 ) or gasket (not shown) to prevent water from entering the housing when the cover is in place. The positions shown in FIGS. 10 a and 10 b (a patient in the head lift-chin tilt position and a patient with a closed airway) are also shown in the AHA Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care, Aug. 22, 2000, p. 1-32, FIGS. 7 and 8 .
[0056] The cover 12 is provided with one or more sensors for determining if the patient's shoulders have been properly positioned on the cover 12 . Referring to FIG. 8 , two photoelectric sensors 156 , 157 are used to determine if the cover has been placed underneath the patient's back. The sensors 156 , 157 are located along the acute edge of the cover 12 , with one facing inward and one facing outward with the cable 155 providing both power to the sensors 156 , 157 as well as detection of the sensor output. If the cover 12 is upside down, the inner sensor 156 will measure a higher light level than the outer sensor 157 ; if the cover has been placed with the acute edge facing toward the top of the patient's head, then the outer sensor 157 will measure higher than the inner sensor 156 and will also exceed a pre-specified level. In the case of a properly positioned cover, both inner 156 and outer sensor 157 outputs will be below a pre-specified level. In another embodiment, the detections means is provided by a pressure sensor 158 located underneath the cover decal. Referring to FIG. 6 c , if the processing means 20 detects that the cover is upside down, it will cause an audible prompt to be delivered to the user that is more detailed than the original prompt. The processing means 20 will also slow down the rate of speech of the audio prompts. If the cover is still upside down after a predetermined period of time, the processing means 20 will deliver an even more detailed message on how to properly place the cover. If, after three attempts to get the user to properly position the cover 12 , the processing means 20 will deliver the next audio prompt without further waiting for proper placement of the cover 12 .
[0057] In the preferred embodiment, the defibrillator includes communication capability such as cell phone, global positioning system (GPS) or simpler wireless phone capability. Preferably, both cell phone and GPS are included in the device. The cell phone is preconfigured to automatically dial the Emergency Response Center (ERC) in the community in which it is located such as “911” in much of the United States. The cell phone service is chosen which is able to provide voice, data, as well as GPS capability. Thus in response to a command by the device to “Call 911 by Pressing the Phone button”, the device automatically dials 911 and the built-in speaker 360 and microphone 159 on the device function to provide speakerphone capability. If a connection is successfully made to the emergency response center, the device transmits its exact location based on its GPS capability and also can transmit to the response center the status of the defibrillator. In more advanced modes, the emergency response center can remotely control the operation of the defibrillator via the bi-directional data capability. When a connection is made to the ERC and emergency response personnel (ERP), the automatic voice prompting of the defibrillator can be remotely de-activated by the ERP so as not to distract the rescuer from the instructions given by the ERP. While coaching the rescuer via the speakerphone capability in the defibrillator, the ERP can utilize the responsive feedback prompting functionality of the device to provide more accurate coaching of the rescuer. It is well known, however, that cell phone and other wireless communication methods are not especially reliable even under the best circumstances, and are often completely unavailable in industrial facilities, basements, etc., thus it is important to provide a means of automatically reverting to the mode wherein the device provides all responsive feedback prompts to the user when the processor detects that the communication link has been lost. Additional prompts will also be provided to the user to assuage any concern they might have that the connection to the human expert has been lost (e.g. “Communication has been temporarily lost to 911 personnel. Don't worry. This AED is able to perform all steps and help you through this procedure.”). When a communication link has been lost, the device will preferably automatically begin recording all device and patient status as well as all audio received by the built-in microphone. If the communication link is subsequently reacquired, the device will preferably automatically transmit the complete event, including patient, device and audio data, acquired during the time communication was not available, providing ERP valuable data to help in their medical decision-making The ERP may remotely control the defibrillator via a bi-directional communication link that transmits both voice and data.
[0058] In another embodiment, a remote computer located at the ERC, that is more capable than the processor in the device may provide the remote decision-making capability. The remote computer would run artificial intelligence software utilizing such techniques, e.g., as fuzzy logic, neural nets and intelligent agents to provide prompting to the user.
[0059] FIG. 6 a illustrates, in flow chart form, the default graphical and audio prompts provided by the device for a caregiver performing resuscitation. The prompts shown in the figure do not include responsive feedback prompts by the device that provide more detailed instructions depending on whetherparticular sequences have been successfully completed by the caregiver. The text in boxes indicates steps performed by the caregiver. The text in caption balloons, with ear symbols, indicates audio prompts generated by the defibrillator. FIGS. 6 b - 6 e provide flowcharts of more detailed responsive feedback prompts (the content of which are shown in FIGS. 7 a , 7 b ) that may be provided to supplement the steps of calling for help, open airway/check for breathing, and defibrillation electrode application.
[0060] Thus, when a person collapses and a caregiver suspects that the person is in cardiac arrest 100 ( FIG. 6 a ), the caregiver first gets the defibrillator and turns the power on 102 . If the unit passes its internal self tests, and is ready for use, this will be indicated by indicator 17 , as discussed above. Next, the defibrillator prompts the caregiver with an introductory audio message, e.g., “Stay calm. Listen carefully” (audio prompt 104 ).
[0061] Shortly thereafter, the defibrillator will prompt the caregiver with an audio message indicating that the caregiver should check the patient for responsiveness (audio prompt 106 ). Simultaneously, the LED adjacent graphic 42 will light up, directing the caregiver to look at this graphic. Graphic 42 will indicate to the caregiver that she should shout “are you OK?” and shake the person (step 108 ) in order to determine whether the patient is unconscious or not.
[0062] After a suitable period of time has elapsed (e.g., 2 seconds), if the caregiver has not turned the defibrillator power off (as would occur if the patient were responsive), the defibrillator will give an audio prompt indicating that the caregiver should call for help (audio prompt 110 ). Simultaneously, the LED adjacent graphic 42 will turn off and the LED adjacent graphic 43 will light up, directing the caregiver's attention to graphic 43 . Graphic 43 will remind the caregiver to call emergency personnel (step 112 ), if the caregiver has not already done so.
[0063] After a suitable interval has been allowed for the caregiver to perform step 112 (e.g., 2 seconds since audio prompt 110 ) the defibrillator will give an audio prompt indicating that the caregiver should open the patient's airway and check whether the patient is breathing (audio prompt 114 ). The LED adjacent graphic 43 will turn off, and the LED adjacent graphic 44 will light up, directing the caregiver's attention to graphic 44 , which shows the proper procedure for opening a patient's airway. This will lead the caregiver to lift the patient's chin and tilt the patient's head back (step 116 ). The caregiver may also position an airway support device under the patient's neck and shoulders, if desired, as discussed below with reference to FIGS. 10 a , 10 b . The caregiver will then check to determine whether the patient is breathing.
[0064] After a suitable interval (e.g., 15 seconds since audio prompt 114 ), the defibrillator will give an audio prompt indicating that the caregiver should check for signs of circulation (audio prompt 118 ), the LED adjacent graphic 44 will turn off, and the LED adjacent graphic 45 will light up. Graphic 45 will indicate to the caregiver that the patient should be checked for a pulse or other signs of circulation as recommended by the AHA for lay rescuers (step 120 ).
[0065] After a suitable interval (e.g., 5 to 7 seconds since audio prompt 118 ), the defibrillator will give an audio prompt indicating that the caregiver should attach electrode assembly 16 to the patient (audio prompt 122 ), the LED adjacent graphic 45 will turn off, and the LED adjacent graphic 46 will light up. Graphic 46 will indicate to the caregiver how the electrode assembly 16 should be positioned on the patient's chest (step 124 ).
[0066] At this point, the LED adjacent graphic 47 will light up, and the defibrillator will give an audio prompt indicating that the patient's heart rhythm is being analyzed by the defibrillator and the caregiver should stand clear (audio prompt 126 ). While this LED is lit, the defibrillator will acquire ECG data from the electrode assembly, and analyze the data to determine whether the patient's heart rhythm is shockable. This analysis is conventionally performed by AEDs.
[0067] If the defibrillator determines that the patient's heart rhythm is not shockable, the defibrillator will give an audio prompt such as “No shock advised” (audio prompt 128 ). The LEDs next to graphics 48 and 49 will then light up, and the defibrillator will give an audio prompt indicating that the caregiver should again open the patient's airway, check for breathing and a pulse, and, if no pulse is detected by the caregiver, then commence giving CPR (audio prompt 130 , step 132 ). Graphics 48 and 49 will remind the caregiver of the appropriate steps to perform when giving CPR.
[0068] Alternatively, if the defibrillator determines that the patient's heart rhythm is shockable, the defibrillator will give an audio prompt such as “Shock advised. Stand clear of patient. Press treatment button” (audio prompt 134 ). At the same time, the heart and/or hand will light up, indicating to the caregiver the location of the treatment button. At this point, the caregiver will stand clear (and warn others, if present, to stand clear) and will press the heart, depressing the treatment button and administering a defibrillating shock (or a series of shocks, as determined by the defibrillator electronics) to the patient (step 136 ).
[0069] After step 136 has been performed, the defibrillator will automatically reanalyze the patient's heart rhythm, during which audio prompt 126 will again be given and graphic 47 will again be illuminated. The analyze and shock sequence described above will be repeated up to three times if a shockable rhythm is repeatedly detected or until the defibrillator is turned off or the electrodes are removed. After the third shock has been delivered, the device will illuminate LEDs 48 and 49 and issue the audio prompts 130 / 132 . The device will keep LEDs 48 and 49 illuminated for a period of approximately one minute indicating that if CPR is performed, it should be continued for the entire minute. “Continue CPR” audio prompts may be repeated every 15-20 seconds during this period to instruct the user to continue performing chest compressions and rescue breathing.
[0070] After approximately one minute has elapsed, the device will extinguish LEDs 48 and 49 and illuminate LED 47 . Audio prompt 126 (stand clear, analyzing rhythm) will also be issued and a new sequence of up to three ECG analyses/shocks will begin.
[0071] If the caregiver detects circulation during step 132 , the caregiver may turn off the defibrillator and/or remove the electrodes. Alternatively, the caregiver may not perform further CPR, but nonetheless allow the device to reanalyze the ECG after each one minute CPR period in order to provide repeated periodic monitoring to ensure the patient continues to have a non-shockable rhythm.
[0072] Thus, in the continuing presence of a shockable rhythm, the sequence of three ECG analyses and three shocks, followed by one minute of CPR, will continue indefinitely. If, instead, a non-shockable rhythm is or becomes present, the sequence will be analyze/no shock advised, one minute of CPR, analyze/no shock advised, one minute of CPR, etc. When a shock is effective in converting the patient's heart rhythm to a heart rhythm that does not require further defibrillating treatment, the sequence will be: analyze/shock advised, shock (saves patient), analyze/no shock advised, one minute CPR period (if pulse is detected then caregiver will not do CPR during this period), analyze/no shock advised, one minute CPR period, etc., continuing until the caregiver turns the defibrillator (e.g., if the caregiver detects a pulse) or the electrodes are removed.
[0073] If electrode contact is lost at any time (as determined by the impedance data received from the electrode assembly), this will result in an appropriate audio prompt, such as “check electrodes” and illumination of the LED adjacent graphic 46 . The electrodes 208 may be stored in a well 222 ( FIG. 14 ) that is structurally integrated with the housing 14 or may be a separate pouch 16 .
[0074] It has also been discovered that a not-insignificant portion of caregivers are unable to open the packaging for the electrodes; therefore, a sensor may be provided to determine if the electrode package has been opened. If detection of the electrode package 16 opening has not occurred within a predetermined period of time, the unit will provide more detailed instructions to assist the user in opening the packaging 16 .
[0075] Referring to FIGS. 12 and 13 , in preferred implementations, a means is provided of detecting and differentiating successful completion of multiple steps of electrode application: (1) taking the electrodes 208 out of the storage area 222 or pouch 16 ; (2) peeling the left pad 212 from the liner 216 ; (3) peeling the right pad 214 from the liner 216 ; (4) applying the left pad 212 to the patient 218 ; and (5) applying the right pad 214 to the patient 218 . Referring to FIGS. 12 and 13 , a package photosensor 210 is provided on the outer face of the electrode backing 220 . Detection that the electrode 208 is sealed in the storage area is determined by the photosensor output being below a threshold. A photoemitter/photosensor (PEPS) 223 combination is embedded into each electrode facing towards the liners 216 . The liner 216 is constructed so that a highly reflective aluminized Mylar, self-adhesive disk 224 is applied to the liner 216 in the location directly beneath the PEPS 223 . The reflective disk 224 is coated with a silicone release material on the side in contact with the electrode 208 so that it remains in place when the electrode 208 is removed from the liner. In such a configuration, the processor is fully capable of differentiating substantially the exact step in the protocol related to electrode application. When the package photosensor 210 detects light above a certain threshold, it is known that the electrodes have been removed from the storage area 222 or pouch 16 . The high reflectance area 224 beneath each PEPS 223 provides a signal that is both a high intensity as well as being synchronous with the emitter drive with low background level; thus it is possible to distinguish with a high degree of accuracy which, if either, of the electrodes 212 , 214 is still applied to the liner 216 . When an electrode 212 , 214 is removed from the liner 216 the background level of the signal increases due to ambient light while the synchronous portion decreases because there is little if any of the photoemitter light reflected back into the photosensor; this condition describes when an electrode 212 , 214 is removed from the liner 216 . When it has been determined that an electrode 212 , 214 has been removed from the liner 216 , the processor means 20 proceeds to the next state—looking for application of that electrode to the patient. Application of the electrode 212 , 214 to the patient will result in a decrease in the background level of the signal output and some synchronous output level intermediate to the synchronous level measured when the electrode 212 , 214 was still on the liner 216 . If it has been determined that both electrodes 212 , 214 are applied to the patient 218 but there is an impedance measured between the electrodes that is significantly outside the normal physiological range then it is very possible that the user has applied the electrodes to the patient without removing the patient's shirt. Surprisingly, this is not uncommon in real situations with users; a patient's shirt will have been only partially removed when electrodes are applied resulting in insufficient electrical contact with the patient's skin. FIG. 6 d shows the flowchart for prompting related to retrieval and application of electrodes. As in the case with responding to a user's interactions.
[0076] Many other implementations are within the scope of the following claims.
[0077] For example, the graphics on the center decal can be accompanied by any desired light source. For instance, if desired, all of the graphics can be translucent, and can be backlit. Alternatively, the graphics can be provided in the form of LED images, rather than on a decal.
[0078] While the electrodes have been illustrated in the form of an integral electrode assembly, separate electrodes may be used.
[0079] In some implementations, generally all of the graphically illustrated steps are shown at the same time, e.g., as illustrated by the decal described above. This arrangement allows the caregiver to see the steps that will be performed next and thus anticipate the next step and begin it early if possible. However, alternatively, the graphics can be displayed one at a time, e.g., by using a screen that displays one graphic at a time or backlit graphics that are unreadable when not back lit. This arrangement may in some cases avoid overwhelming novice or lay rescuers, because it does not present the caregiver with too much information all at the same time.
[0080] If desired, each graphic could have an associated button that, when pressed, causes more detailed audio prompts related to that graphic to be output by the defibrillator.
[0081] The cover 12 of the AED may include a decal on its underside, e.g., decal 200 shown in FIG. 11 . Decal 200 illustrates the use of the cover as a passive airway support device, to keep the patient's airway open during resuscitation. Graphic 202 prompts the caregiver to roll the patient over and place cover 12 under the patient's shoulders, and graphic 204 illustrates the proper positioning of the cover 12 under the patient to ensure an open airway.
[0082] While such a graphic is not included in the decal shown in FIG. 5 , the decal 40 may include a graphic that would prompt the user to check to see if the patient is breathing. Such a graphic may include, e.g., a picture of the caregiver with his ear next to the patient's mouth. The graphic may also include lines indicating flow of air from the patient's mouth.
[0083] “Illuminated”, “light up”, and similar terms are used herein to refer to both a steady light and a light of varying intensity (e.g., blinking) A blinking light may be used, if desired, to more clearly draw the user's attention to the associated graphic.
[0084] Referring to FIG. 16 , in other implementations, a home first aid device may be provided for providing instructions and therapy, as needed, for a variety of medical situations. In some implementations, the device would include: (a) a cover to the device whose removal the processor is capable of detecting; (b) a series of bound pages 230 on the face of the device under the cover 12 with a detection means providing for determining to which page the bound pages have been turned; (c) a processor ; (d) a speaker 232 providing audio output. The home first aid device may also include a portion of the device used specifically for storage of items commonly used in the course of providing aid such as bandaids, bandages, splints, antiseptic, etc. The storage area preferably takes the form of a partitioned tray 234 . Alternatively, the storage area may take the form of multiple pockets, pouches, straps, or slots. The storage area is partitioned into individual wells in which each of the items is stored. Photoelectric sensors 236 , 237 may be provided in each of the wells, thereby providing a means of determining which, if any, of the items has been removed by the user. Detecting which page the bound pages are turned to may be provided by embedding small high magnetic intensity samarium cobalt magnets 240 in locations specific to each page. In some implementations, the magnets 240 are located along the bound edge of the pages, outside the printed area of the pages. Magnetic sensors 241 are located in the device housing 14 that correspond to the locations where the magnets 240 located in the specific pages make contact when the specific page is turned. The magnetic sensor 241 may be a semiconductor device employing the Hall effect principle, but may also be a reed switch or other magnetically activated switch. By providing a means of detecting user actions automatically such as the detection of which page the user has turned to or which first aid item has been removed from the storage container, the device is able to interact and respond to the rescuer in an invisible manner, improving both speed as well as compliance to instructions. In such a manner, interactivity is preserved while at the same time providing a printed graphical interface to the user.
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A device for assisting a caregiver in delivering therapy to a patient, the device comprising a user interface configured to deliver prompts to a caregiver to assist the caregiver in delivering therapy to a patient; at least one sensor configured to detect the caregiver's progress in delivering the therapy, wherein the sensor is other than an electrode in an electrical contact with the body; a memory in which a plurality of different prompts are stored; a processor configured to determine which of the different prompts should be selected for delivery based on the progress detected by the sensor.
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FIELD OF THE INVENTION
The present application is directed generally to RFID-based wireless TV remote controls without batteries that use variable IDs to convey commands.
BACKGROUND OF THE INVENTION
TV remote controls (RC) have been provided that use radiofrequency identification (RFID) principles to send commands from a TV RC to a TV. Passive RFID tags in the RC transmit data to the TV receiver through an electric field which is generated by the TV receiver. Typically, such RCs incorporate multiple RFID tags each corresponding to a particular button push, see, e.g., USPP 2008/0094181. As critically recognized herein, it is desirable to minimize the number of RFID tags that must be used in a RC.
SUMMARY OF THE INVENTION
According to present principles, the “ID” field of the RFID tag in a RC changes based upon the particular key pressed of the user. In this way, only a single RFID tag need be incorporated in the RC.
Accordingly, a TV remote control (RC) is powered using RFID principles from an electric field generated by a controlled component. The RC includes a housing containing no batteries and plural command elements on the housing and manipulable by a person. A processor receives signals indicating manipulation of a command element and establishes an ID field for a data packet based on what command element is indicated as having been manipulated. No more than two command elements are associated with the same ID such that at least a first command element is associated with a first ID and at least a second command element is associated with a second ID different from the first command element. One and only one RFID tag is in the RC to send the packet under control of the processor to the controlled component.
In some embodiments each and every command element on the RC is associated with a unique ID different from IDs associated with other command elements. In other embodiments a pair of up/down command elements are associated with a single ID unique to the pair. In this latter embodiment the packet can include a data field indicating “up” or “down”. A computer readable storage medium can be in the RC and can be accessible to the processor for storing correlations between IDs and commands.
In another aspect, a method includes powering, using an electric field generated by a component, a batteryless remote control (RC) having plural keys. At least first and second keys are associated with respective first and second IDs. The method includes receiving a first signal indicating manipulation of the first key and in response to receiving the first signal, configuring a first command packet to have the first ID and a data field. The first command packet is sent to the component to cause the component to execute a command associated with the first command packet. The method further includes receiving a second signal indicating manipulation of the second key and in response to receiving the second signal, configuring a second command packet to have the second ID and a data field. The second command packet is sent to the component to cause the component to execute a command associated with the second command packet.
In another aspect, a system includes a component to be controlled and an RFID reader assembly in the component to be controlled and generating an electric field. The system further includes a portable remote control (RC) powered by the electric field. Plural command elements are on the RC. In response to manipulation of a command element, a data packet is generated in the RC with an ID field correlated to the command element such that an ID in the ID field depends on what command element is manipulated, such that, at least a first command element is associated with a first ID and at least a second command element is associated with a second ID different from the first command element. An RFID tag is in the RC for sending the packet to the controlled component.
The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an example system in accordance with present principles;
FIG. 2 is a schematic diagram of an example RC RFID data packet;
FIG. 3 is a flow chart of example set up logic; and
FIG. 4 is a flow chart of example operating logic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , a component to be controlled by a remote control (RC) may be instantiated in one implementation by a TV 10 with TV chassis 12 bearing a TV display 14 presenting demanded images under control of a TV processor 16 . The TV processor 16 accesses a tangible computer readable medium 18 such as solid state or disk-based storage to obtain data and to execute code stored on the medium 18 . A TV tuner 20 may also be supported on the chassis 12 .
As shown in FIG. 1 , an RFID reader assembly 22 is supported in the chassis 12 or dangles therefrom, but in any case communicates with the TV processor 16 . The RFID reader assembly 22 includes, among other components, an RFID reader and an RFID electric field generator. An RFID antenna 24 may communicate with the RFID reader assembly 22 .
The electric field generated by the RFID reader assembly 22 powers a remote control (RC) 26 that is sufficiently near the TV 10 such that the RC 26 need contain no battery to function. The RC 26 includes a portable hand-held housing 28 typically holding an RC processor 30 accessing a tangible computer readable storage medium 32 containing data and/or code executable by the RC processor 30 . Also, the RC 26 includes an RFID tag 34 and preferably includes one and only one RFID tag 34 for receiving power from the electric field generated by the RFID reader assembly 22 and for sending RF signals to the RFID reader assembly 22 in accordance with further description below.
Typically, multiple command elements such as buttons or keys are disposed on the RC housing 28 and can be manipulated by a person to generate commands for execution thereof by the TV processor 16 . In the example non-limiting embodiment shown, volume control up/down keys 36 are provided on the RC as are channel up/down keys 38 . An enter key 40 may also be provided. Other keys may be provided as desired.
FIG. 2 shows a data packet 42 that is generated by the RC 26 when a key is manipulated. The data packet 42 is sent using RFID principles by the RFID tag 34 to the RFID reader assembly 22 in the TV 10 .
As shown, the data packet 42 may include a preamble 44 to alert the RFD reader assembly 22 that a command is incoming. The data packet 42 includes an ID field 46 which is the field that conventionally uniquely identifies the RFID tag 34 , but that is used differently in accordance with principles below. A data field 48 may follow the ID field 46 . As set forth further below, the data field 48 may simply include a single bit meaning that the packet 42 represents a command, or it may include a binary one or zero indicating one of two binary states in some implementations, as explained further below.
Now referring to FIG. 3 , at block 50 ID-key pairs are established, typically by the manufacturer of the TV 10 /RC 26 . Specifically, in one embodiment, each key 36 - 40 shown on the RC 26 in FIG. 1 is associated with a respective ID. Thus, in this first embodiment each ID indicates a specific command, e.g., channel up, channel down, volume up, volume down, enter. In another embodiment each key pair 36 , 38 is associated with a respective ID. Thus, in this second embodiment first and second IDs indicate a channel change or a volume change respectively, and a third ID may indicate “enter”. In this second embodiment the data field 48 binary value is established to indicate the direction of the change. The TV 10 and RC 26 are programmed with the ID-to-key correlations at block 52 .
FIG. 4 illustrates example operating logic. Commencing at block 54 , a key manipulation is received by the RC processor 30 . Moving to block 56 , the RC processor 30 accesses the RC medium 32 to determine the ID corresponding to the manipulated key. A command packet such as the packet 42 in FIG. 2 is configured accordingly at block 58 .
In the first embodiment described above in which every key is correlated to a unique ID, the ID field 46 contains that ID. The data field 48 may be empty or may simply include a dummy signal indicating that the command is active or otherwise in existence, but in any case the data field may be identical for every command regardless of ID.
On the other hand, in the second embodiment described above in which up/down key pairs are associated with a single ID between them, if the keystroke is one of a pair of keys the ID field 46 contains the ID associated with that pair. The data field 48 then contains a signal, potentially binary only, indicating which key in the pair was manipulated and, thus, which of the two commands associated with ID is to be executed. A binary “zero” for instance can indicate “down” while a binary “one” can indicate “up”.
In any case, the packet is sent by the RC 26 at block 60 and read by the TV 10 at block 62 . At block 64 in the first embodiment the ID is extracted from the ID field 46 and correlated to the corresponding command at block 66 . For instance, a particular ID might be correlated to “change volume up one setting”. In contrast, at block 64 in the second embodiment the ID is extracted from the ID field and, if it represents a pair of keys, the binary information is extracted from the data field 48 . Then, at block 66 the ID is correlated to a command, e.g., “change volume”, and the binary data from the data field is correlated to a command direction, e.g., “up”. The command is executed at block 68 .
While the particular RFID-BASED WIRELESS REMOTE CONTROL USING VARIABLE ID FIELD is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims.
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A TV remote control is powered using RFID principles from an electric field generated by the TV and so the RC requires no batteries. The RC changes the ID field of the data packet it transmits based on what button was pushed so that a first button is associated with a first ID, a second button is associated with a second ID, and so on. In this way, only a single RFID tag need be provided in the RC.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/030,265, filed on Feb. 21, 2008, which is hereby incorporated in its entirety herein by reference.
FIELD
The invention relates generally to a multiple speed transmission having a plurality of planetary gear sets and a plurality of torque transmitting devices and more particularly to a transmission configured for a front wheel drive vehicle having eight or more speeds, four planetary gear sets and a plurality of torque transmitting devices.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
A typical multiple speed transmission uses a combination of a plurality of torque transmitting mechanisms, planetary gear arrangements and fixed interconnections to achieve a plurality of gear ratios. The number and physical arrangement of the planetary gear sets, generally, are dictated by packaging, cost and desired speed ratios.
While current transmissions achieve their intended purpose, the need for new and improved transmission configurations which exhibit improved performance, especially from the standpoints of efficiency, responsiveness and smoothness and improved packaging, primarily reduced size and weight, is essentially constant. Accordingly, there is a need for an improved, cost-effective, compact multiple speed transmission.
SUMMARY
A transaxle is provided having an input member, an output member, a plurality of planetary gear sets, and a plurality of torque-transmitting mechanisms. The plurality of planetary gear sets each have a sun gear member, a planetary carrier member, and a ring gear member.
In one aspect of the present invention, the housing of the transaxle has a first wall, a second wall, and a third wall extending between the first and second walls. The first, second, third and fourth planetary gear sets are disposed within the housing. The fourth planetary gear set is adjacent the first wall, the first planetary gear set is adjacent second wall, the third planetary gear set is adjacent the fourth planetary gear set and the second planetary gear set is between the first and third planetary gear sets.
Moreover, the ring gear member of the first planetary gear set is permanently coupled to the sun gear member of the second planetary gear set. The ring gear member of the second planetary gear set is permanently coupled to the planet carrier member of the third planetary gear set. The ring gear member of the third planetary gear set is permanently coupled to the planet carrier member of the fourth planetary gear set. The sun gear member of the third planetary gear set is permanently coupled to the sun gear member of the fourth planetary gear set. The output member is permanently coupled to the carrier member of the fourth planetary gear set. The input member is permanently coupled to the carrier member of the first planetary gear set. The sun gear member of the first planetary gear set is permanently coupled to the housing.
Further, the housing has a first area defined radially inward from an outer periphery of the planetary gear sets and axially bounded by the first wall and the fourth planetary gear set, a second area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the third and fourth planetary gear sets, a third area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the second and third planetary gear sets, a fourth area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the first and second planetary gear set, a fifth area defined radially inward from the outer periphery of the planetary gear sets and axially bounded by the first planetary gear set and the second wall, and a sixth area defined radially inward from the third wall and radially outward from the outer periphery of the planetary gear sets and axially bounded by the first wall and the second wall.
In another aspect of the present invention, a first clutch is disposed in at least one of the first, third, fourth and sixth areas. A second clutch is disposed in at least one of the first, third and fourth areas. A third clutch is disposed in at least one of the second, fifth and sixth areas. A fourth clutch is disposed in at least one of the second, fourth, fifth and sixth areas. A brake is disposed in at least one of the first, second and sixth areas. The clutches and the brake are selectively engageable to establish at least eight forward speed ratios and at least one reverse speed ratio between the input member and the output member.
In yet another aspect of the present invention, a transfer gear train is provided having a first and second transfer gear. The first transfer gear is rotatably fixed to the output member and the second transfer gear is rotatably fixed to an intermediate shaft. A differential gear set is provided for driving a pair of road wheels. A pinion gear is rotatably fixed to the intermediate shaft, and an input differential gear in mesh with the pinion gear and configured to rotatably drive the differential gear set is also provided.
In still another aspect of the present invention, a power transfer assembly having a first and second transfer gear, a power transfer member, a final drive planetary gear set and a differential gear set. The first transfer gear is rotatably fixed to the output member and the second transfer gear is rotatably fixed to a drive shaft. The power transfer member is rotatably coupled to the first and second transfer gear for transferring rotational energy from the first transfer gear to the second transfer gear. The final drive planetary gear set is coupled to the drive shaft for receiving a driving torque from the second transfer gear. The differential gear set is coupled to the final drive planetary gear set and to a pair of road wheels for receiving a final drive rotational torque and transferring the final drive torque to the pair of road wheels.
Further, areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1A is a schematic diagram of a gear arrangement for a front wheel drive transmission, according to the principles of the present invention;
FIG. 1B is a chart showing the locations of the torque transmitting devices for the arrangement of planetary gear sets of the transmission shown in FIG. 1A , in accordance with the embodiments of the present invention;
FIG. 2 is a schematic diagram of a front wheel drive transaxle arrangement incorporating the gear arrangement of the transmission of FIG. 1A and FIG. 1B , according to the principles of the present invention; and
FIG. 3 is a schematic diagram of another embodiment of a front wheel drive transaxle arrangement incorporating the gear arrangement of the transmission of FIG. 1A and FIG. 1B , according to the principles of the present invention.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring now to FIG. 1A , an embodiment of a front wheel drive multi-speed or eight speed transmission is generally indicated by reference number 10 . The transmission 10 is illustrated as a front wheel drive or transverse transmission, though various other types of transmission configurations may be employed. The transmission 10 includes a transmission housing 11 , an input shaft or member 12 , an output shaft or member 13 and a gear arrangement 15 . The input member 12 is continuously connected to an engine (not shown) or to a turbine of a torque converter (not shown). The output member 13 is continuously connected with a final drive unit (not shown) or transfer case (not shown).
The gear arrangement 15 of transmission 10 includes a first planetary gear set 14 , a second planetary gear set 16 , a third planetary gear set 18 , and a fourth planetary gear set 20 . The planetary gear sets 14 , 16 , 18 and 20 are connected between the input member 12 and the output member 13 .
In a preferred embodiment of the present invention, the planetary gear set 14 includes a sun gear member 14 C, a ring gear member 14 A, and a planet carrier member 14 B that rotatably supports a set of planet or pinion gears 14 D (only one of which is shown). The sun gear member 14 C is connected to transmission housing 11 with a first shaft or intermediate member 42 . The ring gear member 14 A is connected for common rotation with a second shaft or intermediate member 44 and a third shaft or intermediate member 46 . The planet carrier member 14 B is connected for common rotation with input shaft or member 12 and a fourth shaft or intermediate member 48 . The pinion gears 14 D are configured to intermesh with the sun gear member 14 C and the ring gear member 14 A.
The planetary gear set 16 includes a ring gear member 16 A, a planet carrier member 16 B that rotatably supports a set of planet or pinion gears 16 D and a sun gear member 16 C. The ring gear member 16 A is connected for common rotation with a fifth shaft or intermediate member 50 . The sun gear member 16 C is connected for common rotation with the second shaft or intermediate member 44 . The planet carrier member 16 B is connected for common rotation with the sixth shaft or intermediate member 52 . The pinion gears 16 D are configured to intermesh with the sun gear member 16 C and the ring gear member 16 A.
The planetary gear set 18 includes a ring gear member 18 A, a planet carrier member 18 B that rotatably supports a set of planet or pinion gears 18 D and a sun gear member 18 C. The ring gear member 18 A is connected for common rotation with a seventh shaft or intermediate member 54 . The sun gear member 18 C is connected for common rotation with the eighth shaft or intermediate member 56 . The planet carrier member 18 B is connected for common rotation with the fifth shaft or intermediate member 50 . The pinion gears 18 D are configured to intermesh with the sun gear member 18 C and the ring gear member 18 A.
The planetary gear set 20 includes a sun gear member 20 C, a ring gear member 20 A, and a carrier member 20 B that rotatably supports a set of planet or pinion gears 20 D. The sun gear member 20 C is connected for common rotation with the eighth shaft or intermediate member 56 . The ring gear member 20 A is connected for common rotation with a ninth shaft or intermediate member 58 . The planet carrier member 20 B is connected for common rotation with the output shaft or member 13 and the seventh shaft or intermediate member 54 . The pinion gears 20 D are configured to intermesh with the sun gear member 20 C and the ring gear member 20 A.
The transmission 10 also includes a plurality of torque-transmitting mechanisms or devices including a first clutch 26 , a second clutch 28 , a third clutch 30 , a fourth clutch 32 and a brake 34 . The first clutch 26 is selectively engagable to connect the sixth shaft or intermediate member 52 to the ninth shaft or intermediate member 58 . The second clutch 28 is selectively engagable to connect the input shaft or member 12 to the sixth intermediate member 52 . The third clutch 30 is selectively engagable to connect the fourth intermediate member 48 to the eighth intermediate shaft or member 56 . The fourth clutch 32 is selectively engagable to connect the third shaft or intermediate member 46 to the eighth shaft or intermediate member 56 . Finally, the brake 34 is selectively engagable to connect the ninth intermediate member 58 to the transmission housing 11 to restrict rotation of the member 58 relative to the transmission housing 11 .
The transmission 10 is capable of transmitting torque from the input shaft or member 12 to the output shaft or member 13 in at least eight forward torque ratios and one reverse torque ratio. Each of the forward torque ratios and the reverse torque ratio are attained by engagement of one or more of the torque-transmitting mechanisms (i.e. first clutch 26 , second clutch 28 , third clutch 30 , fourth clutch 32 and brake 34 ). Those skilled in the art will readily understand that a different speed ratio is associated with each torque ratio. Thus, eight forward speed ratios may be attained by the transmission 10 .
The transmission housing 11 includes a first wall or structural member 102 , a second wall or structural member 104 and a third wall or structural member 106 . The third wall 106 interconnects the first and second walls 102 and 104 to define a space or cavity 110 . The input shaft or member 12 and output shaft or member 13 are supported by the second wall 104 by bearings 112 . The planetary gear sets 14 , 16 , 18 and 20 and the torque-transmitting mechanisms 26 , 28 , 30 , 32 and 34 are disposed within cavity 110 . Further, the cavity 110 has a plurality of areas or zones A, B, C, D, E, and F in which the plurality of torque transmitting mechanisms 26 , 28 , 30 , 32 and 34 will be specifically positioned or mounted, in accordance with the preferred embodiments of the present invention.
As shown in FIG. 1A , zone A is defined by the area or space bounded by: the first wall 102 , planetary gear set 20 , radially inward by a reference line “L” which is a longitudinal line that is axially aligned with the input shaft 12 , and radially outward by a reference line “M” which is a longitudinal line that extends adjacent an outer diameter or outer periphery of the planetary gear sets 14 , 16 , 18 and 20 . While reference line “M” is illustrated as a straight line throughout the several views, it should be appreciated that reference line “M” follows the outer periphery of the planetary gear sets 14 , 16 , 18 and 20 , and accordingly may be stepped or non-linear depending on the location of the outer periphery of each of the planetary gear sets 14 , 16 , 18 and 20 . Zone B is defined by the area bounded by: planetary gear set 20 , the planetary gear set 18 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone C is defined by the area bounded by: the planetary gear set 18 , the planetary gear set 16 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone D is defined by the area bounded by: the planetary gear set 16 , the planetary gear set 14 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone E is defined by the area bounded by: the planetary gear set 14 , the second end wall 104 , radially outward by reference line “M”, and radially inward by reference line “L”. Zone F is defined by the area bounded by: the first wall 102 , the second wall 104 , radially inward by reference line “M” and radially outward by the third wall 106 .
In the gear arrangement 15 of transmission 10 shown in FIG. 1A , the planetary gear set 20 is disposed closest to the first wall 102 , the planetary gear set 14 is disposed closest to the second wall 104 , the planetary gear set 18 is adjacent the planetary gear set 20 , and the planetary gear set 16 is disposed between the planetary gear sets 18 and 14 . The torque-transmitting mechanisms are intentionally located within specific Zones in order to provide advantages in overall transmission size, packaging efficiency, and reduced manufacturing complexity. In the particular example shown in FIG. 1A , the first clutch 26 and brake 34 are disposed within Zone A, the second clutch 28 is disposed within Zone D, the third and fourth clutches 30 and 32 are disposed within Zone E.
However, the present invention contemplates other embodiments where the torque-transmitting mechanisms 26 , 28 , 30 , 32 and 34 are disposed in the other Zones. The feasible locations of the torque-transmitting mechanisms 26 , 28 , 30 , 32 and 34 within the Zones are illustrated in the chart shown in FIG. 1B . The chart of FIG. 1B lists clutches and the brake in the left most column and the available zones to locate the clutch/brake in the top row. An “X” in the chart indicates that the present invention contemplates locating the clutch or brake in the zone listed in the top row. For example, brake 34 may be located in zones A, B or F and fourth clutch 32 may be located in zones B, D, E or F.
Referring now to FIG. 2 , a front wheel drive powertrain 150 incorporating a transaxle 153 is illustrated, in accordance with the embodiments of the present invention. Transaxle 153 includes the transmission 10 having the gear arrangement 15 of FIGS. 1A and 1B . Transmission 10 is mounted to an engine 152 . Engine 152 provides a driving torque through input shaft 12 to transmission 10 . Engine 152 is generally an internal combustion engine, however, the present invention contemplates other types of engines such as electric and hybrid engines. Further, transaxle 153 includes a transfer gear train 154 , a differential 156 , and a pair of drive axles 158 and 160 that drive a pair of road wheels 162 and 164 , respectively.
Transfer gear train 154 includes a first transfer gear 166 and a second transfer gear 168 . Output shaft or member 13 is coupled to the first transfer or spur gear 166 . First transfer gear 166 may be a straight spur gear having straight gear teeth or a helical gear having helical gear teeth. First transfer gear 166 meshes with the second transfer gear 168 . Second transfer gear 168 is rotatably fixed to an intermediate shaft or rotatable member 170 . Further, a pinion 172 is mounted to shaft 170 and intermeshes with an input differential gear 174 . Input differential gear 174 transfers driving torque to the differential 156 . Differential 156 , as conventionally known, transfers the driving torque generated by engine 152 to the two drive axles 158 and 160 . Drive axles 158 and 160 are independently driven by differential 156 to supply the driving torque to the vehicle road wheels 162 and 164 .
Referring now to FIG. 3 , another embodiment of a front wheel drive powertrain 200 incorporating a transaxle 202 is illustrated, in accordance with the embodiments of the present invention. Transaxle 202 includes the gear arrangement 15 of transmission 10 of FIGS. 1A and 1B and is mounted to the engine 152 . Engine 152 provides a driving torque through input shaft 12 to transmission gear arrangement 10 . Further, transaxle 202 includes a transfer chain 204 , a driven sprocket or gear 206 , a differential 208 , a final drive planetary gear set 210 and a pair of drive axles 158 and 160 that drive a pair of road wheels 162 and 164 , respectively.
Transfer chain 204 engages at a first end 212 a drive sprocket or gear 214 and at a second end 216 the driven sprocket or gear 206 . The drive sprocket 214 is coupled to output shaft or member 13 . Driven sprocket 206 is rotatably fixed to a drive shaft or rotatable member 220 . Further, drive shaft 220 is coupled to the sun gear of the final drive planetary gear set 210 to achieve the desired gear ratio. The final drive planetary gear set 210 transfers driving torque to the differential 208 though the carrier member of the final drive planetary gear set 210 to the housing of the differential 208 . Differential 208 , as conventionally known, transfers the driving torque generated by engine 152 to the two drive axles 158 and 160 through bevel gears of differential 208 . Drive axles 158 and 160 are independently driven by differential 208 to supply the driving torque to the vehicle road wheels 162 and 164 .
The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A front wheel drive transmission is provided having an input member, an output member, four planetary gear sets, a plurality of coupling members and a plurality of torque transmitting devices. Each of the planetary gear sets includes a sun gear member, a planet carrier member, and a ring gear member. The torque transmitting devices include clutches and a brake arranged within a housing.
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TECHNICAL FIELD
[0001] This disclosure relates generally to textile fabrics, more specifically to textile fabrics that may be used for cleaning, e.g., mop heads, that include a frictional surface with a series of ribs on at least one side of the fabric and that may be smooth on the other side of the fabric or have ridges on both sides of the fabric.
BACKGROUND
[0002] There are three major classes of fabric—woven, non-woven and knitted fabrics. A woven fabric is formed by weaving. In contrast, nonwoven fabrics are fabrics made from fibers, bonded together by chemical, mechanical, heat or solvent treatment. The term nonwoven is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. Nonwoven fabrics may lack strength unless densified or reinforced by a backing. When used for cleaning products such as wipes, clothes or mop heads, such nonwoven cleaning products are normally disposable. Compared to the woven and nonwoven fabrics, knitted fabrics are much more elastic, have much greater durability and can range widely in weight and thickness. Knitted fabrics are typically thicker and can be more absorbent than their woven and non-woven counterparts, which accounts for their uses as towels and cleaning cloths.
[0003] For cleaning articles, such as disposable cleaning wipes, nonwoven fabrics have been used frequently. Many nonwoven wipes are made from a composite fabric containing a mixture or stabilized matrix of thermoplastic filaments and at least one additional fabric, often called the “second fabric” or “secondary fabric”. Nonwoven webs with frictional ridges or tufts are also known in the art. For example, nonwoven webs with hollow ridges which extend outward from the surface of the nonwoven web are known. The ridges can be made by a number of processes, but are preferably formed by directly forming the nonwoven web on a surface with corresponding ridges, or by forming the nonwoven on an apertured surface with a pressure differential sufficient to draw the fibers through the apertures, thereby forming the ridges. Nonwoven webs with ridges have also been prepared by bonding a portion of the nonwoven web and leaving a portion of the nonwoven web unbonded using a compaction roll. In some cases, the ridges or tufts of a nonwoven fabric may include a mixture of a thermoplastic polymer and a secondary fabric.
[0004] Such nonwoven webs with frictional tufts, ridges or ribs are used in a variety of applications such as disposable absorbent articles, dry wipes, wet wipes, wet mops and dry mops. However, knitted fabrics with such frictional ridges are not available. Further, knitted fabrics with frictional ridges on one side and a smooth surface on the other side are also not available.
[0005] As concerns about the environment and specifically the overuse of landfills, there is a need for improved cleaning cloths and mops that are not disposable, but that are durable and reusable. Hence, improved cleaning fabrics that are knitted or woven, as opposed to nonwoven fabrics, are needed.
SUMMARY OF THE DISCLOSURE
[0006] A knitted fabric with frictional ridges for cleaning devices is disclosed. The knitted structure of the fabric imparts durability and strength as well as softness. The frictional ridges enhance the cleaning/scrubbing ability of the knitted fabric.
[0007] In an embodiment, a stable knitted fabric is disclosed which comprises a face side comprising a plurality of parallel and elongated ridges and a back side comprising a smooth surface without elongated ridges. As an alternative, both sides may include the elongated ridges.
[0008] In another embodiment, a stable, finely knitted fabric is disclosed which comprises a plurality of yarns comprising filaments having thicknesses of about 1.5 denier or less with the yarns having thicknesses ranging from about 50 to about 250 denier. The fibers may be made by any process for making micro-denier fibers including “Island in the Sea”, bicomponent, electrospinning (nanofiber), etc. The yarns are knitted into the fabric using a right-leaning top triangle (RTT) stitch illustrated below. The fabric comprises a face side comprising a plurality of elongated ridges and a back side comprising a smooth surface without elongated ridges.
[0009] A covered sponge is also disclosed which comprises a sponge enclosed within a knitted cover. The knitted cover is at least partly fabricated from a stable knitted fabric comprising a face side comprising a plurality of parallel and elongated ridges and a back side comprising a smooth surface without elongated ridges. The smooth back side may enhance wicking between the sponge and the ridged front side.
[0010] In any one or more of the embodiments described above, the fabric comprises a right-leaning top triangle (RTT) stitch illustrated below.
[0011] In any one or more of the embodiments described above, the fabric may comprise fibers made from polymers consisting of, for example, polyesters, polyamides, polyethylene terephthalate and combinations thereof.
[0012] A method of making a knit fabric is also disclosed which comprises forming a plurality of yarns of dissimilar weights, wherein each yarn is formed by spinning fibers comprising approximately 1.50 denier or less. The method also includes forming the fabric by knitting the plurality of yarns of dissimilar weights to have ridges extending in the direction of the knitting.
[0013] In a refinement, the forming of the fabric further comprises knitting the plurality of yarns of dissimilar weight to provide the knitted ridges.
[0014] In another refinement, the forming of the plurality of yarns of dissimilar weights further comprises forming at least some yarns of dissimilar weights from bi-component splittable filaments.
[0015] In another refinement, the forming of the plurality of yarns of dissimilar weights comprising forming a plurality of yarns of dissimilar weights from micro-denier fibers.
[0016] In another refinement, the knitting of the plurality of yarns of dissimilar weights to have knitted ridges further comprises knitting the yarns at imaginary intersection points of a grid such that a first yarn skips the grid and is knitted every other grid, a second yarn is knitted every grid, and a third yarn is knitted in rows along the grid to form the ridges on the front side of the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic line diagram illustrating a prior art knitted stitch or pattern.
[0018] FIG. 2 is a schematic line diagram illustrating a disclosed RTT knitted stitch or pattern.
[0019] FIG. 3 is a plan view of a disclosed fabric made with the RTT pattern of FIG. 2 .
[0020] FIG. 4 is another plan view of the disclosed fabric of FIG. 3 .
[0021] FIG. 5 is a flow diagram illustrating the knitting of disclosed cleaning articles using the RTT pattern of FIGS. 2-4 .
[0022] FIG. 6 is a more detailed flow diagram illustrating the knitting of disclosed cleaning articles using the RTT pattern of FIGS. 2-4 .
[0023] FIG. 7 illustrates the face side of the disclosed knitted fabric.
[0024] FIG. 8 illustrates both the face and back sides of the disclosed knitted fabric.
DETAILED DESCRIPTION
[0025] FIGS. 1 and 2 provide a convenient comparison of a prior art weft pattern 10 ( FIG. 1 ) and the disclosed, more complex RTT pattern fabric 20 ( FIG. 2 ). The fabric 20 of FIG. 2 is a warp structure. The warp structure of FIG. 2 can be fabricated using the methods of FIGS. 5-6 and the detailed description of FIGS. 2-4 provided below.
[0026] A fine microfiber fabric 20 with low drag is accomplished using ridges 26 (FIGS. 4 and 7 - 9 ) on one side 28 of the microfiber fabric. The ridges 26 allow a wipe cloth or mop head to avoid dragging or sticking to a surface when wiped on a surface. The poor absorbency of polyesters and other polymer fibers has also been addressed. The ridges 26 in the micro-denier fiber fabric 20 enhance the absorbency of the fabric 20 .
[0027] Specifically, it has been discovered by applicant that a capillary action results from spaces between the knit filaments. Specifically, a smaller tube has more capillary action. And smaller tubes allow more tubes on a fabric of a given size. The ridges 26 reduce the drag caused by suction or capillary suction or the possible drag caused by the micro-denier fibers binding or snagging on irregularities in the surface. Without being bound by any particular theory, it is believed these ridges 26 reduce the surface tension of any liquid being wiped on a surface by the fabric 20 . It is also believed that the ridges 26 might break the surface tension of any liquid. Channels 27 for air are provided between the ridges 26 ( FIG. 4 ) so that any suction does not cause as much drag since the fabric 20 and liquid is riding on some of the air in the channels 27 . Previously there was little or no air. This is particularly true when wiping in the direction of the ridges 26 , rather than wiping against the ridges 26 (perpendicular to the ridges 26 ).
[0028] The disclosed fabric 20 is an improved liquid applicator. Specifically, the ridges 26 on the fabric 20 , when placed against a dry surface, may create channels 27 of air that urge an increased flow of liquid from the fabric 20 to the surface being cleaned. As an alternative embodiment, an absorptive layer, such as a sponge 36 ( FIGS. 7-9 ) may be added on the back side 35 opposite the ridges 26 to act as a fluid reservoir. By placing the ridges 26 in a microfiber fabric 20 , both high absorption and low drag when wiping are achieved.
[0029] A microfiber is defined as approximately 1.0 denier or below but greater than 0.3 denier. Example applications are towels, upholstery, flat mops, isolator covers and wipers or cleaning cloths. An additional problem addressed by the disclosed fabric 20 is that, by reducing friction, the pad is not twisted or pulled off of a mop frame as prior art mop pads are prone to do. Further, while the fabric 20 made of micro-denier blended yarn has significantly greater effective surface area, the ridges 26 reduce the amount of micro-denier fiber in contact with the surface being cleaned or prepared. The fabric 20 also has less effective surface area as a pad or surface in contact with a sterile instrument.
[0030] FIG. 2 illustrates a line diagram of an example of the disclosed fabric of three types of yarns 21 , 22 and 33 according to an embodiment. In FIG. 2 , each yarn 21 - 23 is illustrated by a single line. A matrix of horizontal gridlines 24 and vertical gridlines 25 are also illustrated for reference purposes and form no part of the fabric 20 . The illustrated exemplary fabric 20 exhibits high performance characteristics. The three yarns 21 - 23 are intertwined in a knit configuration. The yarn 21 is thicker than yarns 22 and 23 . The yarns 21 - 23 each have a micro-denier fiber content. The yarns 21 - 23 are knitted at the intersection points of the horizontal gridlines 24 and vertical gridlines 25 . The yarn 22 skips the grid and is knitted every other grid. The yarn 23 is knitted every grid. The thickest yarn 21 is knitted in rows along the grid to form the ridges 26 on the front side 28 . This places more of the micro-denier fibers in yarn 23 on the back side 35 ( FIG. 9 ) than the front side 28 , thereby improving fluid transfer.
[0031] The fabric 20 can be knitted using a wide variety of knitting machine technologies including, but not limited to, warp knit, circular knit, superpol, and/or Jacquard or even woven on a loom. The thickest yarn 21 may be a 200 denier 384 filaments yarn of all polyester filament thickness of (0.52 denier). The medium thickness warp yarn 22 may be a bi-component, splittable filament yarn 150 with the split filaments having a thickness of about 0.13-1.00 denier or less. The yarn 23 may be a 75 denier 36 filaments (filament thickness of about 0.5 denier).
[0032] After splitting, each filament of yarn 22 results in about eight to sixteen micro-denier fibers each of about 0.13 to about 0.2 denier. The two fabrics of the bi-component yarn 22 are polyester and polyamide which is the generic name for Nylon®. The bi-component filament made of two dissimilar materials allows it to be split into micro-denier fibers.
[0033] The yarn 21 is knitted to form a ridge while the yarn 22 is knitted to form a smooth top side surface between the ridges. The yarn 22 is knitted within the fabric in a zigzag pattern and forms a smooth backside surface. The yarn 23 is knitted to form a base fabric that holds all yarns including yarns 21 and 22 . This means that the ridges 26 consist of one line each of yarn 21 and yarn 23 . The yarn 22 runs zigzag (to left and right) for 3 needle spaces. The yarn 23 runs zigzag for one (1) needle space knotting three (3) microfibers at a time. The yarn 21 runs straight circling each microfiber. Ridges are formed by placing the yarn 21 on every 5th needle and at the back side of the fabric. The yarn 23 also runs the ridged parts and knots microfiber and ridged fibers together. Microfiber loops are longer on the surface than at the back. This is one reason there are ribs or ridges 26 only on the top surface. However, as will be appreciated by those skilled in the art, ridges 26 can also be placed on both the top surface 28 and the bottom surface 36 .
[0034] FIG. 3 is a hatched diagram and plan view of the fabric 20 . FIG. 3 illustrates the same yarns 21 - 23 of FIG. 2 except the drawing is a hatched diagram rather than a line diagram. In FIG. 2 , each yarn 21 - 23 is illustrated by a single line. In FIG. 3 , the yarns 21 - 23 are each illustrated by a series of hatches.
[0035] FIG. 4 illustrates a plan view of the surface of the ridged fabric 20 . In FIG. 4 , the ridges 26 generally contain the yarn 21 and the areas between the ridges 27 generally contain the yarns 22 and 23 . The ridged, microdenier surface 28 of the disclosed knitted fabric 20 is effective at removing viruses, vegetative bacteria, bacterial spores, mold spores and other organic matter. Not only can bacteria be removed, but also high levels of endotoxins can be removed from a wiped surface as well. Endotoxins are the waste from bacteria. This is useful for example in a critically controlled environment in a sterile clean room manufacturing facility, such as a pharmaceutical manufacturing plant, a baby formula facility, a research laboratory or food preparation or compounding plant.
[0036] FIG. 5 is a flow diagram of an exemplary method of making the knitted fabric 20 . In step 31 a plurality of yarns is formed of different, dissimilar or varying weights. Each yarn is formed in step 32 by spinning a fiber of approximately 1.50 denier or below. In step 33 the fabric 20 is formed by knitting the plurality of yarns of dissimilar (different or varying) weights to have knitted ridges 26 as shown in FIG. 4 . Optionally, a refinement of steps 31 - 34 can be made as shown in FIG. 6 . The steps 132 - 133 usually are performed at the same time as steps 31 - 33 but can be done separately. Also steps 31 and 32 or 31 and 132 can be performed at the same time. In step 132 the plurality of yarns of different weights is formed by spinning only fibers of the same fabric. In step 133 the fabric is formed by knitting only the yarns of the same material produced above in step 132 . The yarns are knitted at imaginary intersection points of a grid, such as the horizontal gridlines 24 and vertical gridlines 25 illustrated in FIG. 2 .
[0037] A first yarn 22 ( FIG. 2 ) skips the grid and is knitted every other grid. A second yarn 23 ( FIG. 2 ) is knitted every grid. A third yarn 21 , the thickest yarn of the three ( FIG. 2 ) is knitted in rows along the grid to form the ridges 26 on a front side 28 ( FIG. 4 ). To achieve the desired properties, the fabric 20 is knitted and not woven. Knitting involves tying knots and weaving uses a warp and a weft. A ridge 26 can be formed in the fabric 20 by yarn that has been knitted around itself.
INDUSTRIAL APPLICABILITY
[0038] Exemplary applications for the knit fabric 20 with ridges 26 are mop heads, sponges, applicators for disinfectants, and wipes. The improved fabric 20 transports fluid from one side 28 to an opposite side 35 of the fabric 20 , wherein the direction of flow is away from the smooth side 28 . The wetter side 35 may include a sponge 36 ( FIG. 9 ), terry cloth or denser microfiber fabric.
[0039] Although certain embodiments have been described and illustrated in the above description and drawings, it is understood that this description is by example only, and that numerous changes and modifications can be made by those skilled in the art without departing from the true spirit and scope of this disclosure. Although the examples in the drawings depict only example constructions and embodiments, alternate embodiments are available given the teachings of this disclosure.
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A stable finely knitted fabric is disclosed which includes a plurality of yarns including filaments of about 1.5 denier or less. The yarns are knitted into a fabric using a right-leaning top triangle (RTT) pattern. The fabric includes a face side having a plurality of parallel and elongated ridges and a back side having a smooth surface without elongated ridges. The fabric exhibits a wicking action from the smooth side to the ridged side of the fabric and excellent absorption. Further, the fabric may be used as a liquid applicator, when an absorbant liquid reservoir layer is added to the back side, as channels of air between the ridges increase liquid flow from the back side to the face side.
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[0001] This application claims priority to U.S. provisional application Ser. No. 61/840,483, filed Jun. 28, 2013, the entire disclosure of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to cancer receptor-specific bioprobes for single photon emission computed tomography (SPECT) and computed tomography (CT) or magnetic resonance imaging (MRI) for dual modality molecular imaging. The base of the bioprobes is the self-assembled polyelectrolytes, which transport gold nanoparticles as CT contrast agents, or SPION or Gd(III) ions as MR active ligands, and are labeled using complexing agent with technetium-99m as SPECT radiopharmacon. Furthermore these dual modality SPECT/CT and SPECT/MR contrast agents are labeled with targeting moieties to realize the tumorspecificity.
BACKGROUND OF THE INVENTION
[0003] Combining two or more different imaging modalities using multimodal probes can be considerable value in molecular imaging, especially for cancers that are difficult to diagnose and treat. This synergistic combination of imaging modalities, commonly referred to as image fusion, ensures enhanced visualization of biological targets, thereby providing information on all aspects of structure and function, which is difficult to obtain by a single imaging modality alone.
[0004] Single photon emission computed tomography, SPECT, allows noninvasive determination of in vivo biodistribution of radiotracers at picomolar concentrations. Using specific radiolabeled probes, obtaining functional information with high sensitivity about molecular processes is possible. SPECT images, however, have limited spatial resolution and lack anatomical details for reference, making the precise localization of lesions difficult. Co-registration of SPECT with anatomical images, from CT or from MR has been commonly used in the clinic to address this problem. The nanomedicine approach uses targeted nanoparticles as platforms to design imaging probes for cancer and other human disorders. In the computed tomography (CT) particular, nanoparticles of gold are suitable for diagnosis of various different types of cancers. On the molecular imaging front, gold with a K-edge at 80.7 keV has higher absorption than iodine (K-edge at 33 keV), thus minimizing bone and tissue interference, which results anatomical references in better contrast with a lower x-ray dose.
THE STATE OF THE ART
[0005] U.S. Pat. No. 7,976,825 relates to macromolecular contrast agents for magnetic resonance imaging.
[0006] Biomolecules and their modified derivatives form stable complexes with paramagnetic ions thus increasing the molecular relaxivity of carriers. The synthesis of biomolecular based nanodevices for targeted delivery of MRI contrast agents is described. Nanoparticles have been constructed by self-assembling of chitosan as polycation and poly-gamma glutamic acids (PGA) as polyanion. The nanoparticles are capable of Gd-ion uptake forming a particle with suitable molecular relaxivity. Folic acid is linked to the nanoparticles to produce bioconjugates that can be used for targeted in vitro delivery to a human cancer cell line.
[0007] WO06042146 relates to conjugates comprising a nanocarrier, a therapeutic agent or imaging agent and a targeting agent. Disclosed are conjugates comprising a nanocarrier, a therapeutic agent or imaging agent, and a targeting agent, wherein the nanocarrier comprises a nanoparticle, an organic polymer, or both. Compositions comprising such conjugates and methods for using the conjugates to deliver therapeutic and/or imaging agents to cells are also disclosed. The conjugate is a compound having the following formula: A-X-Y wherein A represents the chemotherapeutic agent or imaging agent; X represents the nanoparticle, organic polymer or both, wherein the organic polymer has an average molecular weight of at least about 1,000 daltons; and Y represents the targeting agent.
[0008] WO0016811 relates to an MRI contrast agent wherein imaging capability is expressed only within the target abnormal cells, such as tumor, and imaging is not conducted at the site where imaging is not necessary, thereby the detection sensitivity of the abnormal cells such as tumor is improved. Disclosed is an MRI contrast agent, which comprises a complex of a polyanionic gadolinium (Gd) type contrast agent and a cationic polymer, or a complex of a polycationic Gd type contrast agent and an anionic polymer, both complexes being capable of forming a polyion complex, and which expresses an MRI capability at a neutral pH in the presence of a polymer electrolyte.
[0009] The state of the art so far failed to provide for the improved compositions according to the present invention.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to novel, targeting dual-modality SPECT/CT and SPECT/MR tumorspecific contrast agents.
[0011] For SPECT/CT modality, the fusion nanoparticulate composition comprises (i) at least two polyelectrolyte biopolymers, (ii) targeting molecules conjugated to a polyelectrolyte biopolymer, (iii) gold nanoparticles coated by the polyelectrolyte biopolymer, (iv) optionally a complexing agent conjugated to the polyelectrolyte biopolymer, and (v) a radionuclide, preferably technetium-99m complexed to the nanoparticles.
[0012] For SPECT/MR modality, the fusion nanoparticulate composition comprises (i) at least two polyelectrolyte biopolymers, (ii) targeting molecules conjugated to a polyelectrolyte biopolymer, (iii) a complexing agent conjugated to the polyelectrolyte biopolymer, (iv) superparamagnetic iron oxid nanoparticles coated by the polyelectrolyte biopolymer or Gd ions complexed to the polyelectrolyte biopolymer via complexing agents and (v) a radionuclide, preferably technetium-99m complexed to the nanoparticles.
[0013] In a preferred embodiment, one of the polyelectrolyte biopolymers is polycation, which is preferably chitosan; and the other of the polyelectrolyte biopolymers is polyanion, which is preferably poly-gamma-glutamic acid.
[0014] In a further embodiment, the molecular weight of chitosan in the nanoparticles ranges from about 20 kDa to 600 kDa, and the molecular weight of the poly-gamma-glutamic acid in the nanoparticles ranges from about 50 kDa to 1500 kDa. In a preferred embodiment, the degree of deacetylation of chitosan ranges between 40% and 99%.
[0015] For SPECT/CT imaging, the self-assembled nanoparticles comprise gold nanoparticles, which are coated by a polyelectrolyte biopolymer and this system self-assembles with the other biopolymer to produce stable nanosystem for computed tomography.
[0016] In a preferred embodiment, the gold nanoparticles are synthesized in situ, in the presence of a polyelectrolyte biopolymer or targeting polyelectrolyte biopolymer. In a preferred embodiment the gold nanoparticles are synthesized in presence of poly-gamma-glutamic acid, or folated poly-gamma-glutamic acid.
[0017] For SPECT/MR imaging, nanoparticulate contrast agent contains superparamagnetic iron oxid nanoparticles (SPION) as T2 MR active ligand, or Gd(III) ions as Ti MR active ligands.
[0018] In a preferred embodiment, the superparamagnetic iron oxide particles are coated by a polyelectrolyte biopolymer and this system self-assembles with the other biopolymer to produce stable nanosystem for magnetic resonance imaging.
[0019] In a further embodiment, the nanoparticles as SPECT/MR fusion contrast agent contain Gd(III) ions as paramagnetic ligands, which are complexed to one of the polyelectrolytes, via the carboxyl groups of polyanion or complexone ligands conjugated to the polycation biopolymer.
[0020] In some embodiments, these self-assembled particles internalize into the targeted tumor cells as a consequence of the presence of targeting ligands. The internalized superparamagnetic contrast agents enhance relaxivity, improve the signal-to-noise and therefore conduce to early tumor diagnosis. In a further embodiment, the self-assembled nanosystems contain complexing agents, which can facilitate the radioactively labeling due to the complexing process between the complexing agent and the radiopharmacon. Preferred complexing agents include, but are not limited to: diethylenetriaminepentaaceticacid (DTPA), 1,4,7,10-tetracyclododecane-N,-N′,N″,N′″-tetraaceticacid (DOTA), ethylene-diaminetetraaceticacid (EDTA), 1,4,7,10-tetraazacyclododecane-N,N′,N″-triaceticacid (DO3A), 1,2-diaminocyclohexane-N,N,N′,N′-tetraaceticacid (CHTA), ethyleneglycol-bis(beta-aminoethylether)N,N,N′,N′,-tetraaceticacid (EGTA), 1,4,8,11-tetraazacyclotradecane-N,N′,N″,N′″-tetraaceticacid (TETA), 1,4,7-triazacyclononane-N,N′,N″-triaceticacid (NOTA).
[0021] These nanoparticles, as CT or MR contrast agents are radioactively labeled with technetium-99m to produce radiopharmaceutical fusion SPECT/CT or SPECT/MR imaging agent for tumor detection. Targeting moieties are conjugated to one of the self-assembled biopolymers to realize a targeted delivery of imaging agents.
[0022] In a preferred embodiment, the targeting agent is preferably folic acid, LHRH, RGD.
[0023] In a further embodiment, the nanoparticles have a mean particle size between about 30 and 500 nm, preferably between about 50 and 400 nm, and most preferably between 70 and 250 nm.
[0024] The present invention provides fusion imaging agents that are compositions comprising radioactively labeled active nanoparticles. The compositions of the invention target tumor cells, selectively internalize and accumulate in them as a consequence of the presence of targeting ligands, therefore are suitable for early tumor diagnosis.
[0025] In its second aspect, the invention relates to a process for the preparation of a targeting contrast composition according to the invention, comprising the steps of
[0026] a) contacting of a solution comprising the polyanion, the targeting agent and the MR or CT active ligand, preferably gold nanoparticle with the conjugate of the polycation and the complexing agent; and
[0027] b) labeling of the self-assembled nanoparticles.
[0028] Furthermore, the invention concerns the use of the targeting contrast composition according to the invention as SPECT/MR or SPECT/CT imaging agents in diagniosis, preferably in cancer diagnosis.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0029] FIG. 1 shows the TEM micrograph of poly-γ-glutamic acid coated gold nanoparticles
[0030] FIG. 2 shows the size and size distribution of CT active self-assembled nanoparticles.
[0031] FIG. 3 represents CT image of CT active self-assembled nanoparticles, Hounsfield unit=70.8 of nanosystem (a) compared with Hounsfield unit=−6.1 of distilled water (b).
[0032] FIG. 4 shows the size and size distribution of 99m Tc labeled MRI (T1) active self-assembled nanoparticles.
[0033] FIGS. 5A and 5B show the chromatogram of free 99m Tc pertechnetate ( FIG. 5A ) and 99m Tc labeled nanoparticles ( FIG. 5B ). Free, unbound 99m Tc was migrated with the solvent to the front line (Rf=1), while the labeled nanoparticle compound was located at the origin (Rf=0). Integrating measured peaks showed the proper ratios of labeled and non-labeled components.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present invention provides novel, targeting, self-assembled nanoparticles as dual-modality SPECT/MRI or SPECT/CT tumorspecific contrast agent, method for forming them and methods of using these compositions for targeted delivery. The self-assembled particles are provided as nanocarriers, labeled with targeting moieties, containing complexone ligands conjugated to a polycation biopolymer, MR or CT active ligand complexed to the nanoparticles, and a radionuclide complexed to the nanoparticles. These radiolabeled, dual-modality nanoparticles can specifically internalize and accumulate in the targeted tumor cells to realize the receptor mediated uptake. Radiolabeled, targeted nanoparticulate compositions, methods for making these targeting dual-modality contrast agents, radiolabeling and using such compositions in the field of diagnosis and therapy are also provided.
Nanoparticles, as Contrast Agent Compositions
[0035] The present invention is directed to biopolymer-based self-assembled nanocarriers as dual-modality tumorspecific contrast agent for SPECT/MR or SPECT/CT. Biocompatible, biodegradable, polymeric nanoparticles are produced by self-assembly via ion-ion interaction of oppositely charged functional groups of polyelectrolyte biopolymers to form nanocarriers for SPECT and MRI or CT active ligands. In a preferred embodiment, the biopolymers are water-soluble, biocompatible, biodegradable polyelectrolyte biopolymers. One of the polyelectrolyte biopolymers is a polycation, a positively charged polymer, which is preferably chitosan or any of its derivatives. The other of the polyelectrolyte biopolymers is a polyanion, a negatively charged biopolymer. The polyanion is preferably selected from a group consisting of polyacrylic acid (PAA), poly-gamma-glutamic acid (PGA), hyaluronic acid (HA), and alginic acid (ALG).
[0036] In a preferred embodiment, the polycation of the nanoparticles ranges in molecular weight from about 20 kDa to 600 kDa, and the polyanion of the nanoparticles ranges in molecular weight from about 50 kDa to 2500 kDa.
[0037] In a preferred embodiment, the degree of deacetylation of chitosan ranges between 40% and 99%. The nanoparticles contain targeting moieties necessary for targeted delivery of nanosystems.
[0038] The targeting agent is coupled covalently to one of the biopolymers using carbodiimide technique in aqueous media. The water soluble carbodiimide, as coupling agent forms amide bonds between the carboxyl and amino functional groups, therefore the targeting ligand could be covalently bound to one of the polyelectrolyte biopolymers.
[0039] In the present invention, the preferred targeting agent is selected from folic acid, lutenizing hormone-releasing hormone (LHRH), and an Arg—Gly—Asp (RGD)-containing homodetic cyclic pentapeptide such as cyclo(-RGDf(NMe)V) and the like.
[0040] In a preferred embodiment, the most preferred targeting agent is folic acid, which facilitates the folate mediated uptake of nanoparticles, as tumor specific contrast agents. The nanoparticles of the present invention are preferably targeted to tumor and cancer cells, which overexpress folate receptors on their surface. Due to the binding activity of folic acid ligands, the nanoparticles selectively link to the folate receptors held on the surface of targeted tumor cells, internalize and accumulate in the tumor cells. The folic acid is coupled covalently to the polyanion biopolymer using a carbodiimide technique. The folic acid due to its carboxyl and amino groups can be coupled to the polyanion biopolymer directly or via a PEG-amine spacer.
[0041] In a preferred embodiment, the self-assembled nanoparticles are comprised of a polyanion biopolymer, a polycation biopolymer, a targeting agent covalently attached to one of the biopolymers and at least one complexing agent covalently coupled to the polycation.
[0042] The complexing agent is coupled covalently to the polycation biopolymer. Water-soluble carbodiimide, as coupling agent is used to make stable amide bonds between the carboxyl and amino functional groups in aqueous media. Using reactive derivatives of complexing agents (e.g. succinimide, thiocyanete), the polycation-complexone conjugate can be directly formed in one-step process without any coupling agents. The nanoparticles can make stable complex with the radionuclide metal ions and for SPECT/MRI T1 modality, paramagnetic ions through these complexone ligans.
[0043] In a preferred embodiment, the complexing agents are preferably diethylenetriaminepentaacetic acid (DTPA), 1,4,7,10-tetracyclododecane-N,-N′,N″,N′″-tetraacetic acid (DOTA), ethylene-diaminetetraacetic acid (EDTA), 1,4,7,10-tetraazacyclododecane-N,N′,N″-triacetic acid (DO3A), 1,2-diaminocyclohexane-N,N,N′,N′-tetraacetic acid (CHTA), ethylene glycol-bis(beta-aminoethyl ether)N,N,N′,N′,-tetraacetic acid (EGTA), 1,4,8,11-tetraazacyclotradecane-N,N′,N″,N′″-tetraacetic acid (TETA), 1,4,7-triazacyclononane-N,N′,N″-triacetic acid (NOTA) or their reactive derivatives. More preferably, the complexing agents are DOTA, DTPA, EDTA and NOTA, most preferably DTPA for paramagnetic ligand and NOTA for radionuclide metal ions. The targeted, dual-modality self-assembled nanoparticles described herein are radiolabeled with a radionuclide metal ion, which is preferably Tc-99m as SPECT active ligand.
[0044] In a preferred embodiment, the radionuclide metal ions are homogeneously distributed throughout the self-assembled nanoparticle. The radionuclide metal ions can make stable complex with the free complexing agents attached to the polycation biopolymer, therefore they could be performed homogeneously dispersed.
[0045] For the formation of the dual-modality SPECT/MR tumorspecific contrast agents, T1 or T2 ligands are conjugated to the nanocarriers, and thereafter radiolabelling with radionuclide technetium ( 99 Tc) is carried out.
[0046] For T1 MRI modality, paramagnetic ions are complexed to the nanocarriers. The paramagnetic ions are preferably lanthanide or transition metal ions, more preferably gadolinium-, manganese-, chromium-ions, most preferably gadolinium ions, useful as MRI contrast agent.
[0047] The paramagnetic ions are homogeneously distributed throughout the self-assembled nanoparticle. The paramagnetic ions can make stable complex with the complexone ligands attached to the polycation biopolymer, therefore they could be performed homogeneously dispersed.
[0048] For T2 modality, superparamagnetic ligand, preferably superparamagnetic iron oxide nanoparticles are conjugated to a polyelectrolyte biopolymer, and they are preferably homogenously dispersed. The superparamagnetic iron oxide nanoparticles (SPION) are synthesized in situ in the presence of the polyanion, and then the self-assembling with the polycation is performed.
[0049] Size of dried SPIONs ranges between 1 and 15 nm, preferably 3 and 5 nm.
[0050] To achieve the dual-modality SPECT/CT tumorspecific contrast agents, gold nanoparticles are conjugated to the nanocarriers, and thereafter radiolabelling with radionuclide technetium is carried out.
[0051] The gold nanoparticles are synthesized in situ in the presence of the polyanion, and then the self-assembling with the polycation is performed.
[0052] In a preferred embodiment, the nanoparticles described herein have a hydrodynamic diameter between about 30 and 500 nm, preferably between about 50 and 400 nm, and the most preferred range of the hydrodynamic size of nanoparticles is between 70 and 250 nm.
Methods of Making Nanoparticles, as Dual-Modality Contrast Agent Compositions
[0053] The present invention is directed to novel, radiolabeled, biocompatible, biodegradable, targeting nanoparticles as dual-modality SPECT/MRI or SPECT/CT contrast agents. The nanoparticle compositions described herein are prepared by self-assembly of oppositely charged polyelectrolytes via ion-ion interaction between their functional groups. The targeting ligands are conjugated covalently to one of the polyelectrolyte biopolymers and the complexing agents covalently coupled to the polycation biopolymer. These nanoparticles can contain paramagnetic ligand as MRI T1, suparparamagnetic ligands as MRI T2 agents or gold nanoparticles as CT active ligands. These targeted nanoparticles are radioactively labeled with Tc-99m radionuclide to produce dual-modality fusion contrast agents.
[0054] In a preferred embodiment, the targeting ligand is attached to one of the biopolymers covalently. The targeting agent is preferably folic acid, LHRH, RGD, the most preferably folic acid.
[0055] Folic acid is coupled covalently to the polyanion biopolymer using the carbodiimide technique. Folic acid due to its carboxyl and amino groups can be coupled to the polyanion biopolymer directly or via a PEG-amine spacer.
[0056] The polyanion via its reactive carboxyl functional groups can form stable amide bond with the amino functional groups of folic acid or the folic acid-PEG amino spacer using the carbodiimide technique. A folated biopolymer meaning a folated polyanion can be used for the formation of nanoparticles, as targeted dual-modality contrast agent.
[0057] In a preferred embodiment, the polycation derivatives namely polycation-complexone polyelectrolyte derivatives are used for the formation of self-assembled nanoparticles. These derivatives of polycation are produced by coupling complexing agent to it covalently. Water soluble carbodiimide is used as coupling agent to form stable amide linkage between the amino groups of polycation and carboxyl groups of complexing agent. Using reactive derivatives of complexing agents (e.g. succinimide, thiocyanete), the polycation-complexone conjugate can be directly formed in one-step process without any coupling agents. In the present invention several complexing agent having reactive carboxyl groups are used to make stable complex with metal ions and therefore afford the possibility to use these systems as imaging agent.
[0058] For the formation of a conjugate, the concentration of the biopolymer ranges between about 0.05 mg/ml and 5 mg/ml, preferably 0.1 mg/ml and 2 mg/ml, and the most preferably 0.3 mg/ml and 1 mg/ml.
[0059] The overall degree of substitution of complexing agent in the polycation-complexone conjugate is generally in the range of about 1-50%, preferably in the range of about 5-30%, and most preferably in the range of about 10-20%.
[0060] Two types of polycation-complexone conjugate can be used for the formation of nanoparticles: (i) a polycation-complexone conjugate, where the complexing agent specific to the radionuclide is covalently attached to the polycation; and (ii) a polycation-complexone conjugate, when two different complexing agents are covalently coupled to the polycation biopolymer, one of them is specific to the paramagnetic ligand and the other is to the radionuclide.
[0061] In a preferred embodiment, nanoparticulate compositions, as targeted, dual-modality SPECT/MRI T1 contrast agents are provided. The T1 MR active agent is a paramagnetic ligand, which is preferably a lanthanide or transition metal ion, more preferably a gadolinium-, a manganese-, a chromium-ion, most preferably a gadolinium ion, useful for MRI. The preferred paramagnetic ions can make stable complex with the targeting, self-assembled nanoparticles due to the complexing agents covalently conjugated to polycation.
[0062] The gadolinium-chloride solution was used as simple aqueous solution without any pH adjusting. In a preferred embodiment, concentration of gadolinium ion ranges between about 0.2 mg/ml and 1 mg/ml, most preferably between 0.4 mg/ml and 0.5 mg/ml. The molar ratio of said gadolinium ions and complexone conjugated to the polycation ranges preferably between 1:10 and 1:1, more preferably 1:5 and 1:1, and most preferably 1:1.
[0063] In a preferred embodiment, nanoparticulate compositions, as targeted, dual-modality SPECT/MRI T2 contrast agents are provided. The T2 MR active agent is a superparamagnetic ligand, preferably iron-oxide ligand, which is preferably nanoparticulate iron-oxide (SPION), which is complexed to a polyelectrolyte biopolymer, and preferably homogenously dispersed.
[0064] The superparamagnetic iron oxide nanoparticles are produced in situ in presence of polyanion or targeted polyanion biopolymers, therefore superparamagnetic iron oxide particles are coated by a polyelectrolyte biopolymer.
[0065] The SPION synthesis can be performed using several types of Fe(III) and Fe(II) ions, such as pl. FeCl 3 xnH 2 O (hydrate), Fe 2 (SO 4 ) 3 , Fe(NO 3 ) 3 , Fe(III)-phosphate, FeCl 2 xnH 2 O, FeSO 4 xnH 2 O (hydrate), Fe(II)-fumarate, or Fe(II)-oxalate.
[0066] Preferably, the concentration of polyanion is between 0.01-2.0 mg/ml, the ratio of the Fe(III) and Fe(II) ions ranges between 5:1 and 1:5. The reaction takes place at elevated temperature ranging between 45 and 90° C. under N 2 atmosphere.
[0067] In a preferred embodiment, nanoparticulate compositions, as targeted, dual-modality SPECT/CT contrast agents are provided. The CT active ligands are gold nanoparticles with size range of 2-15 nm, preferably 5-12 nm. The gold nanoparticles are produced in situ in presence of polyanion or targeted polyanion biopolymer, therefore gold nanoparticles are homogenously dispersed and coated by the polyelectrolyte biopolymer.
[0068] Preferably, the concentration of the polyanion is between 0.01-3.0 mg/ml, the molar ratio of AuCl 3 and polyanion monomers ranges between 2:1 and 5:1. Synthesis of gold nanoparticles in situ in presence of polyanion may be performed using sodium borohydride as reducing agent and optionally sodium citrate dehydrate as stabilizing agent. The molar ratio of gold chloride, sodium borohydride and optionally sodium citrate dehydrate is 1:1:1.
[0069] For the production of dual modality contrast agents, the T1 MR, T2 MR or CT active ligand bearing nanoparticles are radioactively labeled with SPECT active radionuclide ligand, which is preferably Tc-99m ion. The preferred radioactive metal ions can make stable complex with the targeting, self-assembled nanoparticles due to the complexing agents, which are covalently conjugated to polycation. In the last step, targeted, self-assembled nanoparticles are radiolabeled with Tc-99m to produce dual modality radiodiagnostic imaging agents. The radiolabeling takes place in physiological salt solution.
[0070] For labeling, SnCl 2 (x2H 2 O) as reducing agent is added to nanoparticles, then generator-eluted sodium pertechnetate ( 99m TcO 4 − ) is added to the solvent. The incubation temperature for radiolabeling is room temperature, the incubation time for radiolabeling ranges preferably between 2 min and 120 min, more preferably 5 min and 90 min, and the most preferably 30 min and 60 min.
[0071] The nanocarrier formation of the present invention can be obtained in several steps. For the production of a SCECT/MR T1 dual-modality contrast agent, a solution of the targeted polyanion and the polycation-complexone are mixed to form stable, self-assembled nanoparticles, and then an aqueous solution of paramagnetic ions is added to these nanoparticles to make stable paramagnetic nanoparticulate contrast agent. Thereafter these paramagnetic nanoparticles are radioactively labeled with Tc-99m SPECT active radionuclide metal ions to produce the fusion contrast agent.
[0072] For production of SPECT/MR T2 dual-modality contrast agent, solution of targeted, SPION-loaded polyanion and polycation-complexone are mixed to form stable, superparamagnetic self-assembled nanoparticles. After that these superparamagnetic nanoparticles are radioactively labeled with Tc-99m SPECT active radionuclide metal ions to produce the fusion contrast agent.
[0073] For the production of a SPECT/CT dual-modality contrast agent, a solution of the targeted, gold nanoparticles-loaded polyanion and the polycation-complexone are mixed to form stable, superparamagnetic self-assembled nanoparticles. Then these CT active nanoparticles are radioactively labeled with Tc-99m SPECT active radionuclide metal ions to produce the fusion contrast agent.
[0074] The nanoparticle compositions of present invention are prepared by mixing an aqueous solution of the biopolymers at given ratios and order of addition. The polyelectrolytes have statistical distribution inside the nanoparticles to produce globular shape of the nanosystems.
[0075] The size of nanoparticles can be controlled by several reaction conditions, such as the concentration of biopolymers, the ratio of biopolymers, and the order of addition. The pH of the biopolymer solution is one of the main factors, which influence the nanoparticle formation due to the surface charge of biopolymers. The charge ratio of biopolymers depends on the pH of the environment. In preferred embodiment, for the nanoparticle formation, the pH of the polycation or its derivatives varies between 3.5 and 6.0, and the pH of the aqueous solution of the polyanion or its derivatives ranges between 7.5 and 9.5.
[0076] Biopolymers with high charge density form stable nanoparticles due to these given pH values. The surface charge of nanoparticles could be influenced by several reaction parameters, such as ratio of biopolymers, ratio of residual functional groups of biopolymers, pH of the biopolymers and the environment, etc. The electrophoretic mobility values of nanoparticles, showing their surface charge, could be positive or negative, preferably negative, depending on the reaction conditions described above.
[0077] In a preferred embodiment, the concentration of biopolymers ranges between about 0.005 mg/ml and 2 mg/ml, preferably between 0.2 mg/ml and 1 mg/ml, most preferably 0.3 mg/ml and 0.5 mg/ml. The concentration ratio of biopolymers mixed is about 2:1 to 1:2, most preferably about 1:1. The biopolymers are mixed in a weight ratio of 6:1 to 1:6, most preferably 3:1 to 1:3.
Methods of Using Nanocarrier Compositions
[0078] The radiolabeled, targeting dual-modality nanoparticle compositions are useful for targeted delivery of radionuclide metal ions MR or CT active ligands coupled or complexed to the nanoparticles. The present invention is directed to methods of using the above-described nanoparticles, as targeted, dual-modality SPECT/MR or SPECT/CT contrast agents.
[0079] The nanoparticles as nanocarriers deliver the imaging agents to the targeted tumor cells in vitro, therefore can be used as targeted, dual-modality SPECT/MR or SPECT/CT contrast agents. The radiolabeled nanoparticles internalize and accumulate in the targeted tumor cells, which overexpress folate receptors, to facilitate the early tumor diagnosis. The side effect of these contrast agents is minimal, because of the receptor mediated uptake of nanoparticles.
[0080] In a preferred embodiment, the radioactively labeled, targeted dual-modality imaging agents are stable at pH 7.4, they may be injected intravenously. Based on the blood circulation, the nanoparticles could be transported to the area of interest.
[0081] The osmolarity of nanosystems was adjusted using formulating agents. The formulating agent was selected from the group of glucose, physiological salt solution, phosphate buffered saline (PBS), sodium hydrogen carbonate and other infusion base solutions.
[0082] The ability of the radiopharmaceutical, dual-modaity nanoparticles to be internalized was studied in cultured cancer cells, which overexpresses folate receptors using confocal microscopy and flow cytometry.
[0083] Specific localization, accumulation and biodistribution of these radioactively labeled targeted nanoparticles were investigated in vivo using tumor induced animal. Targeted, radiolabeled nanoparticles specifically internalize into the tumor cells overexpressing folate receptors on their surface. The specific localization was examined by SPECT/MR and SPECT/CT methods, and the biodistribution was estimated by quantitative ROI analysis.
EXAMPLES
Example 1
Preparation of Folated Poly-Gamma-Glutamic Acid (γ-PGA)
[0084] Folic acid was conjugated via the amino groups to γ-PGA using carbodiimide technique. γ-PGA (m=60 mg) was dissolved in water (V=100 ml) to produce aqueous solution. The pH of the polymer solution was adjusted to 6.0. After the dropwise addition of cold water-soluble 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide methiodide (CDI) (m=13 mg in 2 ml distilled water) to the γ-PGA aqueous solution, the reaction mixture was stirred at 4° C. for 1 h, then at room temperature for 1 h. After that, folic acid (m=22 mg in dimethyl sulfoxide, V=10 ml) was added droppwise to the reaction mixture and stirred 4° C. for 1 h, then at room temperature for 24 h. The folated poly-γ-glutamic acid (γ-PGA-FA) was purified by dialysis.
Example 2
Preparation of Folated Poly-Gamma-Glutamic Acid
[0085] Synthesis of folated PGA was performed in a two steps process. First PEG amine was coupled to FA based on a well-known reaction describe elsewhere. JACS, 130 (2008) 114671 After that FA-PEG amine was conjugated via the amino groups to PGA using carbodiimide technique: γ-PGA (m=300 mg) was dissolved in water (V=300 ml) to produce aqueous solution at a concentration of 1 mg/ml. The pH of the polymer solution was adjusted to 6.0. After addition of 1-hydroxybenzotriazole hydrate (m=94 mg), the reaction mixture was sonicated for 5 min The reaction mixture was cooled to 4 ° C. and cold water-soluble 1 [ 3 -(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (EDC) (m=445 mg in V=15 ml water) was added dropwise to the γ-PGA aqueous solution. The reaction mixture was stirred at 4° C. for 10 min, then folic acid-PEG-amine solution (m=100 mg in V=15 ml water) and triethylamine (V=324 μl) were added dropwise to the reaction mixture. The reaction mixture was stirred for 24 h. The folated poly-γ-glutamic acid (γ-PGA-PEG-FA) was purified using mPES MicroKros Filter Module (10 kD).
Example 3
Preparation of Folated Poly-Gamma-Glutamic Acid Coated Gold Nanoparticles
[0086] Folated PGA was dissolved in distilled water (V=10 ml) to produce a solution with a concentration of c=0.5 mg/ml. After the dropwise addition of solution of gold (III) chloride hydrate (V= 500 μl, c=1.7 mg/ml), solution of sodium citrate tribasic dihydrate (V=75 μl, c=10 mg/ml) was added dropwise to the reaction mixture. Then solution of sodium borohydride (V=40 μl, c=1 mg/ml) was added to the reaction. The reaction mixture was stirred at room temperature for 4 h, after that it was purified by dialysis. ( FIG. 1 )
Example 4
Preparation of Folated Poly-Gamma-Glutamic Acid Coated Iron Oxide (PFS)
[0087] The pH of the folated PGA solution (c=0.3 mg/ml, V=30 ml) was adjusted to 2.8. After the dropwise addition of FeCl 3 x6H 2 O solution (c=0.5 mg/ml, V=13.9 ml), the pH of the reaction mixture was raised to 8.5 and after that it was reduced to 6.0. The reaction mixture was stirred for 30 min under N2 atmosphere, and FeCl 2 x4H 2 O (m=8.9 mg) was added to the reaction mixture. Reaction temperature was raised to 80° C. and the pH was raised by addition of ammonium solution (V=3 ml, c=12.5 m/m %). Reaction time is 15 min.
Example 5
Preparation of Chitosan-DTPA Conjugate
[0088] Chitosan (m=15 mg) was solubilized in water (V=15 ml); its dissolution was facilitated by dropwise addition of 0.1 M HCl solution. After the dissolution, the pH of chitosan solution was adjusted to 5.0. After the dropwise addition of DTPA aqueous solution (m=11 mg, V=2 ml, pH=3.2), the reaction mixture was stirred at room temperature for 30 min, and at 4° C. for 15 min after that, CDI (m=8 mg, V=2 ml distilled water) was added dropwise to the reaction mixture and stirred at 4° C. for 4 h, then at room temperature for 20 h. The chitosan-DTPA conjugate (CH-DTPA) was purified by dialysis.
Example 6
Preparation of Self-Assembled MRI (T1) Active Nanoparticulate Contrast Agent
[0089] CH-DTPA solution (c=0.3 mg/ml, V=1 ml, pH=4.0) was added into γ-PGA-FA solution (c=0.3 mg/ml, V=2 ml, pH=9.5) under continuous stirring. An opaque aqueous colloidal system was gained, which remained stable at room temperature for several weeks at physiological pH. To make complex with Gd 3+ , a solution of Gd(III)-chloride (c=0.4 mg/ml, V=400 μl) was added dropwise to the aqueous colloid system containing targeted self-assembled nanoparticles (γ-PGA-FA/CH-DTPA-Gd) and stirred at room temperature for 30 min.
Example 7
Preparation of Self-Assembled MRI (T2) Active Nanoparticles
[0090] CH-DTPA solution (c=0.3 mg/ml, V=1 ml, pH=4.0) was added into folated poly-gamma-glutamic acid coated iron oxide (PFS) solution (c=0.3 mg/ml, V=3 ml, pH=9.5) under continuous stirring.
Example 8
Preparation of Self-Assembled CT Active Nanoparticles
[0091] Stable self-assembled nanoparticles were developed via an ionotropic gelation process between the folated poly-γ-glutamic acid coated gold nanoparticles (γ-PGA-FA-gold-NPs), and chitosan-DTPA conjugate (CH-DTPA). Briefly, CH-DTPA solution (c=0.2 mg/ml, V=1 ml, pH=4.0) was added into γ-PGA-FA-gold-NPs solution (c=0.2 mg/ml, V=3 ml, pH=9.5) under continuous stirring. An aqueous colloidal system was gained, which remained stable at room temperature for several weeks at physiological pH. ( FIG. 2 , 3 )
Example 9
Labeling Method of Self-Assembled Nanoparticles
[0092] For labelling, 40 μg SnCl 2 (x2H 2 O) (in 10 μl 0.1 M HCl) as reducing agent was added to 2.6 ml of nanoparticle suspension, then 1 ml (900 MBq activity) of sterile generator-eluted pertechnetate ( 99m TcO 4 —) solution was added to the solvent. Labelling was performed during 60-minute incubation at room temperature. ( FIG. 4 )
Example 10
Characterisation of 99m Tc labeled self-assembled nanoparticles
[0093] Radiochemical purity was examined by means of thin-layer chromatography, using silica gel as the coating substance on a glass-fibre sheet (ITLC-SG). Plates were developed in methyl ethyl ketone. Free, unbound 99m Tc-pertechnetate migrated with the solvent to the front line, while the labelled nanoparticle compound was located at the origin (bottom). The Raytest MiniGita device (Mini Gamma Isotope Thin Layer Analyzer) was applied to determine the distribution of radioactivity in the developed ITLC-SG plates. The labelling efficiency was examined 1 h, 6 h and 24 h after labeling. Radiochemical samples were stored at room temperature in a dark place. The radiolabeled products showed high degree and durable labelling efficiency above 99% ( FIG. 5 ).
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The invention relates to cancer receptor-specific bioprobes for single photon emission computed tomography (SPECT) and computed tomography (CT) or magnetic resonance imaging (MRI) for dual modality molecular imaging. The base of the bioprobes is the self-assembled polyelectrolytes, which transport gold nanoparticles as CT contrast agents, or SPION or Gd(III) ions as MR active ligands, and are labeled using complexing agent with technetium-99m as SPECT radiopharmacon. Furthermore these dual modality SPECT/CT and SPECT/MR contrast agents are labeled with targeting moieties to realize the tumorspecificity.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
This application is a continuation-in-part of applicants' copending patent application U.S. Ser. No. 09/231,269, filed on Jan. 15, 1999.
FIELD OF THE INVENTION
A snowboard assembly comprised of a snowboard connected to a locking device.
BACKGROUND OF THE INVENTION
Retractable locking assemblies for securing equipment such as ski poles, skis, and the like are well known. Thus, by way of illustration, U.S. Pat. No. 5,063,762 of Catherine M. Vanderweghe discloses a locking assembly external to, and mounted on, a portable or riding device.
The locking assembly described in the Vanderweghe patent is less than ideal. In the first place, it is rather cumbersome to use, requiring locking structure on each of two separate ski poles. Furthermore, because it involves the digital manipulation of several small parts, such as a rewind button 14 and a retractable cover 16 , it is often difficult to manipulate by one whose fingers are numbed.
To the best of applicants' knowledge, no one in the prior art has provided a snowboard assembly comprised of a locking device which easy to use, relatively durable and reliable, and attractive.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a snowboard assembly comprised of a snowboard attached to a locking assembly, wherein the locking assembly is comprised of a case attached to said snowboard, and a locking assembly disposed within said case.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by reference to the specification and to the enclosed drawings, in which like reference numerals refer to like elements, and in which:
FIG. 1 is a perspective view of one preferred locking device of this invention securing two ski poles and two skis to a stand;
FIG. 2 is a perspective view of the locking device of FIG. 1;
FIG. 3 is top view of the locking device of FIG. 1;
FIG. 4 is a side view of the locking device of FIG. 1;
FIG. 5 is bottom view of the locking device of FIG. 1;
FIG. 6 is a front view of the locking device of FIG. 1;
FIG. 7 is a back view of the locking device of FIG. 1;
FIG. 8 is a schematic view of the interior of the locking device of FIG. 1;
FIG. 9 a front view of a shim disposed within the brackets of the locking device of FIG. 1;
FIG. 10 is side view of the shim of FIG. 9;
FIG. 11 is a sectional view of a ski pole disposed within the brackets of the locking device of FIG. 1 without a shim;
FIG. 12 is a sectional view of the a ski pole disposed within the shim of FIG. 9 which, in turn, is disposed within the brackets of the locking device of FIG. 1;
FIG. 13 is a perspective view of another locking device of this invention securing a snowboard to a stand;
FIG. 14 is a side view of the locking device of FIG. 13 connected to such snowboard;
FIG. 14 a is a perspective view of the locking assembly 100 depicted in FIG. 14;
FIG. 15 is a top view of the locking device of FIG. 14;
FIG. 16 is a right side view of the locking device of FIG. 14;
FIG. 17 is a front view of the locking device of FIG. 14;
FIG. 18 is an enlarged sectional view of a portion of the device depicted in FIG. 17;
FIG. 19 is a perspective view of another preferred locking device of the invention;
FIG. 20 is a side sectional view of the device of FIG. 19;
FIG. 21 is a front sectional view of the device of FIG. 19;
FIG. 22 is a partial sectional view of the device of FIG. 19, illustrating a ski pole disposed within such device without the use of a shim; and
FIG. 23 is a partial sectional view of the device of FIG. 19, illustrating a ski pole disposed within such device with the use of a shim.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first portion of this specification, reference will be made to a locking assembly 10 which can be used with one or more ski poles 16 and 18 . In the second portion of this specification, reference will be made to a locking assembly 100 which is attached to a snowboard 102 .
FIG. 1 is a perspective view of a locking assembly 10 which, in the preferred embodiment depicted, is being used to secure skis 12 and 14 and ski poles 16 and 18 to stand 20 . In the preferred embodiment depicted, locking assembly 10 is attached to ski pole 18 , and a retractable cable 22 from locking assembly 10 extends from locking assembly 10 , around ski pole 18 , ski 12 , ski pole 16 , stand 20 , and ski 14 , and then back to the locking assembly 10 , wherein it is secured.
FIG. 2 is a perspective view of locking assembly 10 . It will be seen that retractable cable 22 may be extended in the direction of arrows 24 , 26 , and 28 and secured within keyhole orifice 30 . The skis 12 and 14 , the ski poles 16 and 18 , and the stand 20 which the cable 22 is wrapped around have been omitted from FIG. 2 for the sake of simplicity of representation. It will be understood, however, that cable 22 preferably, when fully extended, is from about 1 to about 3 feet long and, more preferably, from about 20 to about 28 inches.
One may use any cable in the locking assembly 10 that will serve the desired function. Thus, as used in this specification, the term cable includes cables made from metal materials, elastomeric materials, and any other materials commonly used in industry exhibiting the traits of strength of flexibility. The preferred cable material is a braided metallic structure.
Referring again to FIG. 2, once the cable 22 has been secured within keyhole 30 , it is lockably secured therein and only can be removed upon the alignment of the proper combination numbers in tumblers 32 , 34 , and 36 .
One may use any conventional cable lock with a retractable cable for the assembly depicted in FIG. 2 . Thus, by way of illustration and not limitation, one may use one or more of the assemblies disclosed in U.S. Pat. Nos. 5,063,762, 4,543,806 (retractable cable lock), U.S. Pat. No. 3,950,972 (lock with retractable cable), U.S. Pat. No. 3,906,815 (retractable cable assembly and lock), U.S. Pat. No. D272,986 (combination lock with retractable cable), and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
Combination locks with retractable cables are readily commercially available and may be purchased, e.g., as a “RECOILER” lock, manufactured by the Ski Tote U.S.A. of 161 Plaza LaVista, Camarillo, Calif. 93010. Similar ski locks may be purchased under the name of “KRYPTONITE.”
In one embodiment, the combination lock with retractable cable is manufactured by the Sinox Company of Taiwan and sold as part number PL966.
Referring again to FIG. 2, and in the preferred embodiment therein, it will be seen that locking assembly 10 is comprised of a first bracket 38 and a second bracket 40 , each of which is removably attached to body 42 . In the embodiment depicted, the brackets 38 and 40 are removably attached by means of screws 44 and 46 , and also by means of other screws (not shown in FIG. 1 ).
Referring again to FIG. 2, and in the preferred embodiment depicted, it will be seen that first bracket 38 defines an orifice 48 , and the second bracket 40 defines an orifice 50 . The orifices 48 and 50 define an angled path for a ski pole. Thus, referring to FIG. 4, when a line 52 is drawn through the center of orifices 48 and 50 , it will preferably form an angle 54 with the base 56 of the locking device 10 of from about 8 to about 15 degrees and, more preferably, from about 9 to about 12 degrees. Thus, the ski pole (not shown in FIG. 2) disposed within orifices 48 and 50 diverges away from tumblers 32 , 34 , and 36 and thus gives one more ready access thereto. Additionally, it is preferred that the distance 58 between the top 60 of tumblers 32 , 34 , and 36 and the bottom 62 of notch 64 be at least about 0.25 inches and, more preferably, is from about 0.3 to 0.65 inches.
In another embodiment, not shown, the first bracket 38 and the second bracket 40 are combined into one bracket(not shown).
It is preferred that the body 42 of the locking assembly 10 , and the brackets 38 and 40 , consist essentially of plastic material. In one preferred embodiment, the plastic material used is a polyester, and most preferably a elastomeric material which consists essentially of polyester. By way of illustration and not limitation, one suitable polyester elastomer is sold by the E.I. duPont deNemours Company of Wilmington, Del. as ST801.
FIG. 3 is a top view of locking assembly 10 , illustrating how screws 44 , 45 , 46 , and 47 secure the brackets 38 and 40 . In one preferred embodiment, screws 44 , 45 , 46 , and 47 are substantially rust-proof screws such as those which are coated with “black oxide 632 ”. Alternatively, or additionally, one may use stainless steel screws.
FIG. 4 is a side view of the locking device 10 . In the preferred embodiment depicted in FIG. 4 ,it will be seen that cable 22 is disposed within a notch 66 which preferably has a length 68 of at least about 0.7 inches and a height of at least about 0.3″ to allow ready access to the cable 22 . In one embodiment, the notch 66 may be as large as, e.g., 1.0″ by about 0.5″.
Referring again to FIG. 4, it will be seen that device 10 is comprised of a button 70 which, when depressed, will release the locking mechanism (not shown in FIG. 4) and, additionally, will release the tension on the cable 22 .
FIG. 8 is a schematic view of one preferred locking mechanism. Referring to FIG. 8, it will be seen that cable 22 is wound around spring-loaded reel assembly. Cable locks with spring-loaded reel assemblies are well known to those skilled in the art and are described, e.g., in U.S. Pat. No. 5,653,467 (spring loaded reel with gear lock), U.S. Pat. Nos. 4,566,198, 4,404,822 (cable lock with spring loaded reel), U.S. Pat. No. 4,086,795 (cable lock with spring loaded reel), and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
Referring again to FIG. 8, it will be seen that cable 22 is equipped with a locking tab 74 which may be withdrawn in the direction of arrows 76 , 78 , and 80 and removably locked within keyhole orifice 30 . Once so locked, it may be disengaged when release button 70 is depressed.
In the mechanism depicted in FIG. 8, when button 70 is depressed, it will cause locking cylinder 82 to travel in the direction of arrow 84 , thereby aligning orifice 30 with locking tab 74 and allowing their engagement. This type of locking cylinder arrangement, and similar arrangements, are well known to those skilled in the art and are described, e.g., in U.S. Pat. Nos. 5,855,129, 5,472,313, 5,288,210, 5,275,534, 5,236,302, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
FIG. 9 is an end view of a shim 86 which may be disposed within orifices 48 and 50 (see FIG. 2 ); and FIG. 10 is a side view of shim 86 . As will be apparent to those skilled in the art, ski poles, such as ski pole 18 , come in a variety of diameters, generally varying from about 0.515″ to about 0.750 in diameter. The locking device 10 is preferably equipped with a multiplicity of shims 86 of varying internal diameters. In one embodiment, the internal diameter 88 is from about 0.515″ to about 0.560″, and the external diameter 90 of shim 86 is preferably about 0.750 inches. The length 92 of shim(s) 86 is generally from about 2.4 to about 2.5 inches.
FIG. 11 illustrates an embodiment wherein shim 86 is not disposed within orifices 48 and 50 , whereas FIG. 12 illustrates an embodiment wherein shim 86 is so disposed within orifices 48 and 50 .
FIG. 13 is a perspective view of another locking device 100 being used to secure a snowboard 102 to stand 20 . As is known to those skilled in the art, a snowboard is a generally long structure in the shape of a plate, generally flat, whose thickness is approximately constant. Reference may be had, e.g., to U.S. Pat. Nos. 5,998,668, 5,988,470, 5,984,757, 5,984,346, 5,984,343, 5,984,325, 5,983,529, 5,980,602, 5,979,726, 5,979,080, 5,975,557, 5,975,556, 5,975,554, 5,975,546, 5,975,229, 5,971,423, 5,967,542, 5,966,844, and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.
Referring again to FIG. 13, and in the preferred embodiment depicted therein, it will be seen that snowboard 102 is comprised of a first retention element 103 , and a second retention element 105 , both of which are adapted to a snowboarder's (“surfer's) boots in support on the base structure 107 of the snowboard 102 .
Referring again to FIG. 13, it will be seen that locking device 100 is mounted on base structure 107 in the front half of the snowboard. However, as will be apparent to those skilled in the art, the locking device 100 can be mounted substantially in any position on snowboard 102 and its base structure 107 . It is preferred that the locking device 100 be suitably mounted so that the cable 22 can be wrapped around a post 20 .
FIG. 14 is a side sectional view of the locking device 100 attached to snowboard 102 . Any conventional attachment means may be used to secure the locking device 100 to the snowboard 102 . By way of illustration and not limitation, one may use adhesive attachment means such as, e.g., “VHB ACRYLIC FOAM TAPE” sold by the Minnesota Mining and Manufacturing Corporation of Minneapolis, Minn. as product number VHB4941.
In one embodiment, any of the commonly available double-stick tapes may be used to secure the locking assembly 100 to the snowboard. Thus, e.g., one may use product number 4956 of the Minnesota Mining and Manufacturing Corporation which is identified as “Double Linered Loose Pieces.”
Referring again to FIG. 14, and in the preferred embodiment depicted therein, it will be seen that a ramped shelf 104 is attached to the snowboard 102 by means of base 110 . and, mounted therein is a cable lock assembly 106 which is substantially identical to the lock assembly 10 but differs therefrom in not containing the body 42 and the brackets 38 and 40 . The lock assembly 106 is substantially identical to the “KRYTPONITE” combination lock with retractable cable which is referred to elsewhere in this specification.
The ramped shelf is configured that cable lock assembly 106 is disposed at an angle 109 with regard to base 110 of from about 5 to about 20 degrees and, more preferably, from about 8 to about 15 degrees. This geometric relationship insures ready visual and tactile access to the tumblers 32 , 34 , and 36 and allows for cover 108 to have an aerodynamic profile with minimal wind resistance.
In one embodiment, illustrated in FIG. 14, each of base 110 , ramped shelf 104 , and cable lock assembly 106 are integrally connected to each other.
In one embodiment, not shown, adhesive means are used to secure lock assembly 106 to ramped shelf 104 . In another embodiment, not shown, a screw is used to secure lock assembly 106 to ramped shelf 104 .
In the preferred embodiment depicted in FIG. 14, ramped shelf 104 is integrally and hingeably attached to cover 108 and base 110 . As will be apparent to those skilled in the art, this arrangement prevents the entry of snow and other contaminants into the locking device but facilitates easy entry thereto whenever necessary.
One may use any conventional means for hingeably attaching cover 108 to base 110 . In one embodiment, illustrated in FIG. 14 a , a live hinge 111 is used to providing such attachment means. As is known to those skilled in the art, a live hinge is a device which is usually integrally molded with a body as a unitary physical structure. Reference may be had, e.g., to U.S. Pat. Nos. 5,988,429, 5,855,272, 5,842,806, 5,785,399, 5,676,306, and the like. The entire disclosure of each of these United States patents is hereby incorporated by reference into this specification.
Referring again to FIG. 14 a , it will be seen that, in the preferred embodiment depicted therein, means are provided for removably locking cover 108 to base 110 . In the preferred embodiment illustrated, these means comprise a male lip 113 adapted to engage with a female lip 115 and to removably secure cover 108 to base 110 . When so secured, the cover 108 and the base 110 provide a weatherproof seal protecting against the elements. When a user desires to disengage cover 108 from base 110 , he may apply pressure with a finger on ridges 117 in the direction of arrow 119 .
FIG. 15 is a top view of the assembly of FIG. 14, showing it in its closed position. It will be seen that, in the preferred embodiment depicted, the combination of cover 108 and base 110 , in its closed position, forms a enclosure 119 which is substantially pear shaped. Although other aerodynamic shapes also may be used, what is important is that such shape not have any sharp, wind-resistant edges or surfaces. The absence of sharp edges also minimizes the risk of injury to the snowboarder.
Referring again to FIG. 15, and in the preferred embodiment depicted therein, it will be seen that the distance 121 between the front of tumblers 32 , 34 , and 36 and the edge 123 formed by the intersection of cover 108 and base 110 is preferably at least about 0.4 inches. In one embodiment, distance 121 is preferably from about 0.4 to about 0.8 inches.
FIG. 16 is a side view of the assembly of FIG. 15, from which detail of the locking device 106 has been omitted for the sake of simplicity of representation. Referring to FIG. 16, it will be seen that orifice 131 is formed between cover 108 and base 110 and is adapted to receive a cable (not shown in FIG. 16, but see FIG. 8 and cable 22 ).
FIG. 17 is a front schematic view of the device of FIG. 14 . An orifice 133 is formed between cover 108 and base 110 and is adapted to receive a cable (not shown in FIG. 16, but see FIG. 8 and cable 22 ).
FIG. 18 is partial sectional view of the device of FIG. 14, illustrating how lips 113 and 115 interlockably engage each other when cover 108 is closed.
FIG. 19 is a perspective view of another locking device 130 which functions in a manner similar to that of the device depicted in FIGS. 1 and 21 and has many of the same components such as, e.g., a barrel tumbler locking mechanism with a retactrable cable. As will be apparent to those skilled in the art, the device 130 differs from the device 10 in that the former device is comprised of a handle body 132 with an orifice (not shown) adapted to receive pole 18 . By comparison, the body 42 of the device of FIG. 2 is attached to brackets 38 and 40 , which brackets receive the ski pole 18 . Otherwise, these devices are similar in structure and operation.
Referring to FIG. 19, it will be seen that, in the preferred embodiment depicted, body 132 is attached to a clip 134 .
FIG. 20 is a sectional view of the device of FIG. 19 . As will be apparent, the reel device 72 of FIGS. 20 and 21 operates in substantially the same manner as the reel device 72 of FIG. 8 .
Referring to FIG. 20, and in the preferred embodiment depicted therein, it will be seen that a shim is being used to securely attach ski pole 18 within the body 132 .
FIGS. 22 and 23 are partial sectional views which illustrate how the device of FIG. 20 can be used without a shim (FIG. 22) and with a shim (FIG. 23 ).
It is to be understood that the aforementioned description is illustrative only and that changes can be made in the apparatus, in the ingredients and their proportions, and in the sequence of combinations and process steps, as well as in other aspects of the invention discussed herein, without departing from the scope of the invention as defined in the following claims.
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A snowboard assembly containing a snowboard attached to a locking device. The locking device is contained within an enclosure, which is attached to the snowboard. The enclosure contains a base hingeably attached to a cover; the cover and base may be readily connected to and disconnected from each other. The locking device is inclined with respect to the base to afford ready visibility and easy access. A cable is connected to the locking device and is adapted to be connected to a post or other secure structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a circuit for discriminating dual tone multiple frequency signals (referred as DTMF signals) and, more particularly to a circuit for discriminating the DTMF signals for a remote-controlled telephone apparatus.
2. Description of the Prior Art
Recently, there have been developed many varieties of remote-control systems using the telephone line. In some such systems, for example, an automatic telephone answering apparatus may perform many useful functions, such as sending prerecorded answering messages or outgoing messages signals (referred as OGM signals hereafter) to callers on remote telephone sets, and for recording an incoming message signal (referred as ICM signal hereafter) from callers. However, an automatic telephone answering apparatus may include additional functions responsive to the remote control operation through the telephone line. In such an automatic telephone answering apparatus, for example, an owner or a subscriber of the automatic telephone answering apparatus is able to operate his or her automatic telephone answering apparatus from outside through a remote telephone set, so as to play back recorded ICM signals from callers in his or her absence, or to record new OGM signals or renew the OGM signals. The remote control operation is usually performed by sending specific secret or personal codes, e.g., the DTMF signals through a remote telephone set. The DTMF signals correspond to each of twelve button codes of a standard telephone set, i.e., "0" to "9", "*" and "#".
In the remote control operation, first a subscriber calls his or her automatic telephone answering apparatus through a remote telephone set by dialing. The automatic telephone answering apparatus activates its own internal circuit in response to a calling signal from the remote telephone set. The subscriber then sends some DTMF signals to the automatic telephone answering apparatus by operating buttons of the remote telephone set. The automatic telephone answering apparatus is provided with a processor, such as a microcomputer, for controlling the remote control operations and other necessary controls in response to the received DTMF signals. The microcomputer identifies or discriminates the DTMF signals and then performs a prescribed control corresponding to the received DTMF signals.
Normally each DTMF signal comprises a specific combination of two signals, one selected from a group of four low frequency signals and the other from a group of three high frequency signals. The four low frequency signals typically are comprised of a 697 kHz signal, a 770 kHz signal, an 852 kHz signal and a 941 kHz signal, while the three high frequency signals are comprised of a 1,209 kHz signal, a 1,336 kHz signal and a 1,477 kHz signal. The twelve telephone buttons "0" to "9", "*" and "#" correspond to the four low frequency signals and the three high frequency signals in a matrix circuit, as shown in FIG. 1. Thus, when the telephone button "1", for example, is operated, a DTMF signal with a combination of the 697 kHz low frequency signal and the 1,209 kHz high frequency signal is transmitted from the telephone set. The high frequency signal and the low frequency signal in the same DTMF signal should be generated within a time difference of five (5) msec. (millisecond) or less from each other when a prescribed button is operated. Also, the high frequency signal should have a sound level not more than three (3) dB lower than the sound level of the low frequency signal in the same DTMF signal.
As shown in FIG. 2, such a conventional automatic telephone answering apparatus is equipped with a line coupling transformer 20, a bell signal detection circuit 22, a line switch circuit 24, an outgoing message signal source (referred to as OGM source hereafter) 26 such as a magnetic tape apparatus, an incoming message recorder (referred to as ICM recorder hereafter) 28 such as a magnetic tape apparatus and a circuit 30 for discriminating the DTMF signals. In FIG. 2, the conventional DTMF signal discriminating circuit 30 comprises a selective signal coupling circuit 32, a frequency signal extracting circuit 34 and a microcomputer 36. The line coupling transformer 20 is coupled to a telephone line TL through the line switch circuit 24. The line switch circuit 24 has a control terminal 24a connected to the microcomputer 36. The bell signal detection circuit 22 is coupled between a primary winding 20a of the line coupling transformer 20 and the microcomputer 36 for detecting a bell signal through the telephone line TL. The microcomputer 36 activates the line switch circuit 24 in response to a detection signal from the bell signal detection circuit 22. The OGM source 26 and the ICM recorder 28 are arranged so that the OGM source 26 generates an OGM signal and the ICM recorder 28 records an ICM signal under the control of the microcomputer 36 in a prescribed automatic telephone answering mode.
In the DTMF signal discriminating circuit 30, the selective signal coupling circuit 32 has an input terminal 32a, an input/output terminal 32b and an output terminal 32c. The input terminal 32a is provided for receiving the OGM signal applied from the OGM source 26. The input/output terminal 32b receives the ICM signal applied from a remote telephone set through the telephone line TL and the line coupling transformer 20. The output terminal 32c is connected to the microcomputer 36 through the frequency signal extracting circuit 34. The frequency signal extracting circuit 34 is comprised of first to seventh band pass filters (referred to as BPF circuits hereafter) 38a, 38b, 38c, . . . 38g, and also first to seventh phase locked loop circuits (referred to as PLL circuits hereafter) 40a, 40b, . . . 40g. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel between the selective signal coupling circuit 32 and the microcomputer 36. That is, input terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in common to the output terminal 32c of the selective signal coupling circuit 32, while output terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel to first to seventh input terminals 36-Ia, 36-Ib, . . . 36-Ig of the microcomputer 36. The first to seventh PLL circuits 40a, 40b, 40c . . . 40g are connected in parallel between the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36, respectively. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the first to seventh PLL circuits 40a, 40b, 40c . . . 40g are responsive to the frequency signals, i.e., the signals of 697 kHz, 770 kHz, 852 kHz, 941 kHz, 1,209 kHz, 1,336 kHz and 1,477 kHz, respectively.
The operation of the conventional automatic telephone answering apparatus shown in FIG. 2, in particular, the the DTMF signal discriminating operation of the DTMF signal discriminating circuit 30 now will be described. When a subscriber calls his or her automatic telephone answering apparatus from a remote telephone set (not shown), the bell signal detection circuit 22 detects bell signals transmitted from the remote telephone set and applies a detection signal to the microcomputer 36. The microcomputer 36 then activates the line switch circuit 24 in response to the detection signal so that a communication channel is established between the remote telephone set and the automatic telephone answering apparatus. The microcomputer 36 also drives the OGM source 26 so that the OGM source 26 transmits an OGM signal prerecorded therein to the selective signal coupling circuit 32. The selective signal coupling circuit 32 is arranged so that the OGM signal applied to the input terminal 32a is selectively transmitted to the input/output terminal 32b. An ICM signal applied to the input/output terminal 32b through the line coupling transformer 20 is selectively transmitted to the output terminal 32c. Therefore, the OGM signal is transmitted to the input/output terminal 32b of the selective signal coupling circuit 32, but is prevented from being transmitted to the output terminal 32c. The audible OGM signal on the input/output terminal 32b of the selective signal coupling circuit 32 is transmitted to the remote telephone set through the line coupling transformer 20. Thus, the subscriber on the remote telephone set recognizes that the automatic telephone answering apparatus is ready to respond for remote control operations from the remote telephone set.
Referring now to FIG. 3, the operation of the prior art DTMF signal discriminating circuit 30 will be described, for example, in discriminating two DTMF signals corresponding to the button codes "1" and "3". When the subscriber sequentially operates the telephone buttons "1" and "3" for carrying out a prescribed remote control operation, first, the DTMF signal corresponding to the telephone button "1" (referred as DTMF signal "1" hereafter), is generated from the telephone set. This signal is shown by a waveform a1 in the graph A of FIG. 3, and is composed of the 697 kHz low frequency signal and the 1,209 kHz high frequency signal. Next, the other DTMF signal corresponding to the telephone button "3" (referred as DTMF signal "3" hereafter), is generated from the telephone set. This signal is shown by a waveform a2 in the graph A of FIG. 3, and is composed of the 697 kHz low frequency signal and the 1,477 kHz high frequency signal. The DTMF signals "1" and "3" are applied to the input/output terminal 32b of the selective signal coupling circuit 32 through the telephone line TL and the line coupling transformer 20. In the selective signal coupling circuit 32, the DTMF signals "1" and "3" are selectively transmitted to the input/output terminal 32b, as described above. The DTMF signals "1" and "3" are then applied to the frequency signal extracting circuit 34. In the frequency signal extracting circuit 34, the 697 kHz signal component in each of the DTMF signals "1" and "3" are extracted by the BPF circuit 38a sequentially at the times T1 and T2 corresponding to the times when the caller activates telephone buttons "1" and "3". The 1,209 kHz signal component of the DTMF signal "1" is extracted by the BPF circuit 38e at the time T1. Further the 1,477 kHz signal component of the DTMF signal "3" is extracted by the BPF circuit 38g at the time T2. The 697 kHz signal, the 1,209 kHz signal and the 1,447 kHz signal are applied to the PLL circuits 40a, 40e and 40g, respectively. The first to seventh PLL circuits 40a, 40b, 40c . . . 40g are arranged so that their outputs have a high (H) level when they are supplied with no extracted signals from their corresponding first to seventh BPF circuits 38a, 38b, 38c, . . . 38g, while their outputs have a low (L) level when they are supplied with extracted signals from their corresponding first to seventh BPF circuits 38a, 38b, 38c, . . . 38g. Thus, the output of the PLL circuit 40a has the L level twice, as shown by L level signals b1 and b2 in the graph B of FIG. 3, corresponding to receipt of the 697 kHz signal and the 1,209 kHz signal. The output of the PLL circuit 40 e has the L level once, as shown by L level signal c1 in the graph C of FIG. 3, corresponding to receipt of the 1,209 kHz signal. The output of the PLL circuit 40g also has the L level once, as shown by L level signal d2 in the graph D of FIG. 3, corresponding to receipt of the 1,477 kHz signal.
The respective outputs b1, b2, c1 and d2 of the PLL circuits 40a, 40e and 40g are applied to the input terminals 36-Ia, 36-Ie and 36-Ig of the microcomputer 36. The microcomputer 36 then discriminates the DTMF signal "1" by detecting that the output b1 of the PLL circuit 40a and the output c1 of the PLL circuit 40e both exhibit the L level at the time T1. Also the microcomputer 36 discriminates the DTMF signal "3" by detecting that the output b2 of the PLL circuit 40a and the output d2 of the PLL circuit 40g both exhibit the L level at the time T2. The periods of the DTMF signals "1" and "3", i.e., the L level periods of the outputs b1, b2, c1 and d2 of the PLL circuits 40a, 40e and 40g must be more than about thirty five (35) msec. so that the microcomputer 36 is capable of discriminating them.
This conventional DTMF signal discriminating circuit has some drawbacks. The conventional circuit may easily carry out some undesired remote control operation, without responding to the DTMF signals. In other words, the conventional DTMF signal discriminating circuit is easily influenced by undesired signals other than the DTMF signals. In an automatic telephone answering apparatus responsive to remote control, the OGM source 26 typically is used for providing callers with some subscriber's message, i.e., the OGM signal. The OGM signal is, of course, an audio frequency band signal, and the OGM signal applied to the selective signal coupling circuit 32 often leaks out to the output terminal 32c. When the leaking OGM signal includes frequency components corresponding to the specific frequency signal components of the DTMF signals, the OGM signal may be extracted by the frequency signal extracting circuit 34. As a result, the microcomputer 36 may wrongly carry out some remote control operation.
In the conventional circuit, it also is difficult to discriminate the frequency signals from the other frequency signals in the same frequency group. This is because the frequency signals in the same low or high frequency group are close in frequency to each other. Therefore, the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g can easily extract the other frequency signals in the same low or high frequency group by mistake, if the first to seventh BPF circuits 38a, 38b, 38b, . . . 38g have fairly sharp frequency selection characteristics. For example, FIG. 4 shows a frequency selection characteristic diagram for both the BPF circuits 38e and 38g. In FIG. 4, the characteristics are taken from the BPF circuits 38e and 38g with their selectivities Q being set to ten (10). As shown in FIG. 4, the 1,209 kHz signal and the 1,477 kHz signal extracted by the BPF circuits 38e and 38g overlap with one another over a relatively wide frequency range. The difference in the nonoverlapped portion between these frequency ranges is not more than three (3) dB. Therefore, the microcomputer 36 may not properly discriminate between these signals.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to accurately discriminate DTMF signals in a remote controlled telephone apparatus.
Another object of the present invention is to eliminate incorrect remote control operation of a telephone apparatus due to undesired signals other than the DTMF signals.
Additional objects and advantages will be obvious from the description which follows, or may be learned by practice of the invention.
In order to achieve the above objects, the DTMF signal discriminating circuit for a remote control apparatus, in which the DTMF signals correspond to a plurality of predetermined operating modes of the apparatus, and in which the apparatus includes OGM signal generating source responsive to an input signal from a remote source for indicating that the apparatus can receive DTMF signals, includes a signal coupling circuit for selectively supplying the OGM signal to the remote source and receiving the DTMF signals from the remote source, including a circuit for suppressing the OGM signal for substantially preventing operation of the apparatus in any of the predetermined operating modes in response to receipt of the OGM signal by the signal coupling circuit, a discrimination circuit for receiving the DTMF signals from the signal coupling circuit and a microcomputer responsive to the discrimination circuit for controlling operation of the apparatus in an operating mode corresponding to the received DTMF signals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is diagram showing a typical arrangement of telephone buttons in relation to DTMF signal components;
FIG. 2 is a block diagram showing an automatic telephone answering apparatus which is equipped with a conventional DTMF signal discriminating circuit;
FIG. 3 is a timing diagram for illustrating operation of the conventional DTMF signal discriminating circuit shown in FIG. 2;
FIG. 4 is a frequency selection characteristic diagram for both the BPF circuits 38e and 38g in FIG. 2;
FIG. 5 is a block diagram showing an automatic telephone answering apparatus which is equipped with a first embodiment of the DTMF signal discriminating circuit according to the present invention;
FIG. 6 is a circuit diagram showing the detail of the signal coupling circuit 32 in FIG. 5;
FIG. 7 is a block diagram showing an automatic telephone answering apparatus which is equipped with a second embodiment of the DTMF signal discriminating circuit according to the present invention;
FIG. 8 is a timing diagram for illustrating operation of the DTMF signal discriminating circuit shown in FIG. 7;
FIG. 9 is a block diagram showing an automatic telephone answering apparatus which is equipped with a third embodiment of the DTMF signal discriminating circuit according to the present invention;
FIG. 10 is a timing diagram for illustrating operation of the DTMF signal discriminating circuit shown in FIG. 9;
FIG. 11 is a block diagram showing an automatic telephone answering apparatus which is equipped with a modification of the third embodiment of the DTMF signal discriminating circuit according to the present invention; and
FIG. 12 is a timing diagram for illustrating operation of the DTMF signal discriminating circuit shown in FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the accompanying drawings, namely, FIGS. 5 through 12. Throughout the drawings, like reference numerals and letters are used to designate elements like or equivalent to those used in FIG. 2 (Prior Art Apparatus) for the sake of simplicity of explanation.
Referring now to FIGS. 5 and 6, an automatic telephone answering apparatus, which is equipped with a first embodiment of the DTMF signal discriminating circuit according to the present invention, will be described. In FIG. 5, the automatic telephone answering apparatus is comprised of a line coupling transformer 20, a bell signal detection circuit 22, a line switch circuit 24, an OGM source 26 such as a magnetic tape apparatus, an ICM recorder 28 such as a magnetic tape recorder and a DTMF signal discriminating circuit 30 for discriminating the DTMF signals. The DTMF signal discriminating circuit 30 comprises a selective signal coupling circuit 32, a frequency signal extracting circuit 34 and a microcomputer 36. The line coupling transformer 20 is coupled to a telephone line TL through the line switch circuit 24. The line switch circuit 24 has a control terminal 24a connected to a control signal output terminal of the microcomputer 36. The bell signal detection circuit 22 is coupled between the primary winding 20a of the line coupling transformer 20 and a bell detection signal input terminal 36b of the microcomputer 36 for detecting a bell signal applied through the telephone line TL. The DTMF signal discriminating circuit 30 activates the line switch circuit 24 in response to a detection signal from the bell signal detection circuit 22. The OGM source 26 and the ICM recorder 28 are arranged so that the OGM source 26 generates an OGM signal and the ICM recorder 28 records an ICM signal supplied through the telephone line TL and the line coupling transformer 20 under the control of the microcomputer 36 in a prescribed automatic telephone answering mode.
In the DTMF signal discriminating circuit 30, the selective signal coupling circuit 32 has an input terminal 32a, an input/output terminal 32b and an output terminal 32c. The input terminal 32a is provided for receiving the OGM signal applied from the OGM source 26. The input/output terminal 32b is provided for outputting the OGM signal and for receiving the ICM signal applied from a remote telephone set through the telephone line TL and the line coupling transformer 20. The output terminal 32c is connected to the microcomputer 36 through the frequency signal extracting circuit 34.
Referring now to FIG. 6, a circuit arrangement of the selective signal coupling circuit 32 will be described in detail. As shown in FIG. 6, the selective signal coupling circuit 32 mainly is comprised of a balanced resistance bridge circuit 42, an operational amplifier 44, a transistor 46 and a plurality of base resistors 48a, 48b, . . . 48n. The balanced resistance bridge circuit 42 includes four resistors 50a, 50b, 50c and 50d. The resistors 50a and 50b are connected in series between the input terminal 32a and an inverted input terminal (-) of the operational amplifier 44. A connection node 50e between the resistors 50a and 50b correspond to the input/output terminal 32b. The resistors 50c and 50d are connected in series between the input terminal 32a and a non-inverted input terminal (+) of the operational amplifier 44. The non-inverted input terminal (+) of the operational amplifier 44 is connected to a first power supply terminal 52 with a voltage of Vcc/2 through a resistor 54, while the inverted input terminal (-) of the operational amplifier 44 is connected to the output terminal 44a of the operational amplifier 44 through a feedback circuit 56. The feedback circuit 56 is comprised of two diodes 58a and 58b and a resistor 60 which are connected in parallel with each other. The diodes 58a and 58b are connected in opposite directions with each other. A connection node 50f between the resistors 50c and 50d is connected to the collector terminal of the transistor 46 through a capacitor 62 and a collector resistor 64. The transistor 46 has its emitter terminal connected to a reference potential source G and its base terminal connected to a second power supply terminal 66 with a voltage Vcc through a base bias resistor 68. The base terminal of the transistor 46 is further connected to the microcomputer 36 through the plurality of base resistors 48a, 48b, . . . 48n. That is, each of the base resistors 48a, 48b, . . . 48n is connected at one end thereof to the base terminal of the transistor 46, and at the other end thereof in parallel to output terminals 36-Oa, 36-Ob, 36-Oc, . . . and 36-On of the microcomputer 36. An output terminal 44a of the operational amplifier 44 is connected to the microcomputer 36, and to the frequency signal extracting circuit 34 (see FIG. 5) as the output terminal 32c.
The operation of the automatic telephone answering apparatus shown in FIG. 5, in particular the operation of the selective signal coupling circuit 32 shown in FIG. 6 now will be described. When a subscriber calls his or her automatic telephone answering apparatus from a remote telephone set (not shown) by dialing, the bell signal detection circuit 22 detects bell signals transmitting from the remote telephone set and applies a detection signal to the bell detection signal input terminal 36b of the microcomputer 36. The microcomputer 36 applies a prescribed control signal to the control terminal 24a of the line switch circuit 24 through the control signal output terminal 36a so as to activate the line switch circuit 24 in response to the detection signal. As a result, a communication channel is established between the remote telephone set and the automatic telephone answering apparatus. The microcomputr 36 also drives the OGM source 26 so that the OGM source 26 transmits the OGM signal prerecorded therein to the selective signal coupling circuit 32.
The OGM signal applied to the input terminal 32a is selectively transmitted to the input/output terminal 32b through the resistor 50a. The OGM signal obtained to the input/output terminal 32b then is transmitted to the subscriber on the remote telephone set through the line coupling transformer 20 and the telephone line TL. On the other hand, the OGM signal from the OGM source 26 is supplied in parallel to the inverted input terminal (-) and the non-inverted input terminal (+) of the operational amplifier 44 through the balanced resistance bridge circuit 42. When input impedances on the inverted input terminal (-) and the non-inverted input terminal (+) are in balance with each other, the OGM signals on the inverted input terminal (-) and the non-inverted input terminal (+) offset each other in the operational amplifier 44. However, the balancing state of the balanced resistance bridge circuit 42 is broken according to the impedance of the telephone line TL. That is, the impedance of the telephone line TL varies in accordance with line paths between the automatic telephone answering apparatus and telephone sets. Therefore, some amount of the OGM signal leaks to the output terminal 44a of the operational amplifier 44. The leaked OGM signal is led to the microcomputer 36 and its level is detected therein. The microcomputer 36 then controls activation or deactivation of the output terminals 36-Oa, 36-Ob, 36-Oc, . . . 36-On in response to the level of the OGM signal. For example, the microcomputer 36 changes one or more outputs of the output terminals 36-Oa, 36-Ob, 36-Oc, . . . 36-On to the H level, i.e., the activation state, but leaves the other outputs in the L level, i.e., the deactivation state. Thus, some of the base resistors 48a, 48b, 48c, . . . 48n are activated, but others of the base resistors 48a, 48b, 48c, . . . 48n remain deactivated so that the base impedance of the transistor 46 is controlled in accordance with the level of the leaked OGM signal. The conductivity of the transistor 46 varies according to the base impedance. As a result, the total impedance of the circuit between the resistor 50f and the ground potential source G varies to compensate for the line impedance between the node 50e (i.e., the input/output terminal 32b) and the remote telephone set. Thus, the OGM signal is selectively transmitted to the caller on the remote telephone set, but leaking of the OGM signal to the output terminal 44a of the operational amplifier 44, i.e., the output terminal 32c of the selective signal coupling circuit 32 is reduced. Upon receipt of the audible OGM signal, the subscriber on the remote telephone set recognizes that the automatic telephone answering apparatus is ready to respond for remote control operations from the remote telephone set. The subscriber then is able to apply a prescribed DTMF signal to the automatic telephone answering apparatus by using the remote telephone set. The DTMF signal discriminating circuit 30 of the automatic telephone answering apparatus accurately discriminates the DTMF signal without interference from leaking OGM signals which can cause incorrect operation.
Referring now to FIG. 7, an automatic telephone answering apparatus, which is equipped with a second embodiment of the DTMF signal discriminating circuit according to the present invention, now will be described. In FIG. 7, the automatic telephone answering apparatus is comprised of a line coupling transformer 20, a bell signal detection circuit 22, a line switch circuit 24, an OGM source 26 such as a magnetic tape apparatus, an ICM recorder 28 such as a magnetic tape recorder and a DTMF signal discriminating circuit 30 for discriminating the DTMF signals, similar to the first embodiment shown in FIG. 5. The DTMF signal discriminating circuit 30 comprises a selective signal coupling circuit 32, a frequency signal extracting circuit 34 and a microcomputer 36. The line coupling transformer 20 is coupled to a telephone line TL through the line switch circuit 24. The line switch circuit 24 has a control terminal 24a connected to a control signal output terminal 36a of the microcomputer 36. The bell signal detection circuit 12 is coupled between the primary winding line 20a of the line coupling transformer 20 and a bell signal detection input terminal 36b of the microcomputer 36 for detecting a bell signal applied through the telephone line TL. The DTMF signal discriminating circuit 30 activates the line switch circuit 24 in response to a detection signal from the bell signal detection circuit 22. The OGM source 26 and the ICM recorder 28 are arranged so that the OGM source 26 generates an OGM signal and the ICM recorder 28 records an ICM signal applied through the telephone line TL and the line coupling transformer 20 under the control of the microcomputer 36 in a prescribed automatic telephone answering mode.
The frequency signal extracting circuit 34 is comprised of first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and also first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel between the selective signal coupling circuit 32 and the microcomputer 36. That is, the input terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in common to the output terminal 32c of the selective signal coupling circuit 32, while the output terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel to first to seventh input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36. The first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g are connected in parallel between the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36, respectively. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the rectifier circuits 70a, 70b, 70c, . . . 70g are responsive to the frequency signals, i.e., the signals of 697 kHz, 770 kHz, 852 kHz, 941 kHz, 1,209 kHz, 1,336 kHz and 1,477 kHz, respectively.
Referring now to FIG. 8, the operation of the automatic telephone answering apparatus shown in FIG. 7, in particular the DTMF signal discriminating circuit 30, now will be described. FIG. 8 shows a time diagram for signals in the DTMF signal discriminating circuit 30. When a subscriber calls his or her automatic telephone answering apparatus from a remote telephone set (not shown) by dialing, the bell signal detection circuit 22 detects bell signals transmitted from the remote telephone set and applies a detection signal to the bell detection signal input terminal 36b of the microcomputer 36. The microcomputer 36 applies a prescribed control signal to the control terminal 24a of the line switch circuit 24 through the control signal output terminal 36a so as to activate the line switch circuit 24 in response to the bell detection signal. As a result, a communication channel is established between the remote telephone set and the automatic telephone answering apparatus. The microcomputer 36 also drives the OGM source 26 so that the OGM source 26 transmits the OGM signal prerecorded therein to the selective signal coupling circuit 32.
The OGM signal applied to the input terminal 32a is selectively supplied to the input/output terminal 32b through the resistor 50a. The OGM signal obtained on the input/output terminal 32b then is transmitted to the subscriber on the remote telephone set through the line coupling transformer 20 and the telephone line TL. The subscriber on the remote telephone set is able to recognize that the automatic telephone answering apparatus is ready to respond for remote-control operations from the remote telephone set, by hearing the OGM signal thus transmitted from the automatic telephone answering apparatus. The subscriber then is able to apply a prescribed DTMF signal to the automatic telephone answering apparatus by using the remote telephone set.
When the subscriber sequentially operates two telephone buttons, e.g., "1" and "3" for carrying out a prescribed remote control operation, first, the DTMF signal "1", composed of the 697 kHz low frequency signal and the 1,209 kHz high frequency signal, is generated from the telephone set. Next, the DTMF signal "3", composed of the 697 kHz low frequency signal and the 1,477 kHz high frequency signal, is generated from the telephone set. The low frequency signal and the high frequency signal in the same DTMF signal are generated within five (5) msec. of each other, as described before. Also, the overlap time of the low frequency signal and the high frequency signal in the same DTMF signal must last for at least thirty five (35) msec., as described before.
The DTMF signals "1" and "3" are applied to the input/output terminal 32b of the selective signal coupling circuit 32 through the telephone line TL and the line coupling transformer 20. In the selective signal coupling circuit 32, the DTMF signals "1" and "3" are selectively supplied to the output terminal 32c of the selective signal coupling circuit 32 with a sufficient level, as shown by a graph A in FIG. 8. In the graph A, waveforms a0, a1 and a2 denote undesired signals or noises received by the DTMF signal discriminating circuit 30, the DTMF signal "1" and the DTMF signal "3", respectively. The OGM signal generated from the OGM source 26 is, of course, an audio frequency band signal as described before. When the OGM signal applied to the selective signal coupling circuit 32 leaks out to the output terminal 32c at a sufficient level, the leaking OGM signal is received at the input terminal of the frequency signal extracting circuit 34 as a noise signal a0.
These signals a0, a1 and a2 are then applied to the frequency signal extracting circuit 34. In the frequency signal extracting circuit 34, the 697 kHz signal component in the noise signal a0, i.e., the OGM signal, and in the DTMF signals a1 and a2, i.e., "1" and "3", is extracted through the BPF circuit 38a. The 697 kHz signal component is then rectified in the rectifier circuit 70a so that rectified signals b0, b1 and b2, which correspond to the OGM signal and the DTMF signals "1" and "3" are obtained, as shown in the graph B. The 1,209 kHz signal component in the noise signal a0, i.e., the OGM signal, and in the DTMF signal a1, i.e., "1" is extracted through the BPF circuit 38e. The 1,209 kHz signal component is then rectified in the rectifier circuit 70e so that rectified signals c0 and c1, which correspond to the OGM signal and the DTMF signal "1" are obtained, as shown in the graph C. The 1,477 kHz signal component in the OGM signal a0, and in the DTMF signal a2, i.e., the DTMF signal "3", is also extracted through the BPF circuit 38g. The 1,477 kHz signal component is then rectified in the rectifier circuit 70g so that rectified signals d0 and d2, which correspond to the OGM signal and the DTMF signal "3" are obtained, as shown in the graph D.
The rectified signals b0, c0 and d0 corresponding to the noise signal a0, i.e., the OGM signal, generally last for a relatively short period. However, the DTMF signals are so provided that they overlap for more than about thirty five (35) msec. for the microcomputer 36 to be capable of discriminating the DTMF signals. Thus, the rectified signals b1, b2, c1 and d2 corresponding to the DTMF signals "1" and "3" last for a relatively long period, at least thirty five (35) msec. The rectified signals b1 and b2 arise at the times T11 and T21, respectively. The DTMF signals are so provided that the low frequency signal and the high frequency signal in the same DTMF signal should be generated within a time difference of five (5) msec. of each other when a prescribed button is operated, as described before. Thus, the rectified signal c1 arises at the time T12 within five msec. from the time T11. Also, the rectified signal d2 arises at the time T22 within five msec. from the time T21.
The outputs b0, b1, b2, c0, c1, d0 and d2 of the rectifier circuits 70a, 70e and 70g are applied to the input terminals 36-Ia, 36-Ie and 36-Ig of the microcomputer 36. The microcomputer 36 itself is equipped with a timer clock (not shown). The microcomputer 36 starts the clock when two rectified signals of a low frequency signal and a high frequency signal are applied within a time difference of less than the five msec. The microcomputer 36 judges that the two signals are of a prescribed DTMF signal, when the rectified signals remain at the H level for more than thirty five (35) msec. at the same time. Therefore, the microcomputer 36 discriminates the DTMF signals "1" and "3" by judging that the rectified signals b1 and c1 applied from the rectifier circuits 70a and 70e last for at least thirty five (35) msec. together and that the rectified signals b2 and d2 applied from the rectifier circuits 70a and 70g also last for at least thirty five (35) msec. at the same time. The microcomputer 36 is prevented from discriminating the rectified signals b0, c0 and d0 as with a DTMF signal due to the fact that the two rectified signals b0 and c0 or b0 and d0 do not overlap for the long period of more than thirty five (35) msec., even if the two signals arise at the same time. As a result, the microcomputer 36 is able to discriminate only the DTMF signals without error caused by noise signals.
Referring now to FIG. 9, an automatic telephone answering apparatus, which is equipped with a third embodiment of the DTMF signal discriminating circuit according to the present invention, will be described. In FIG. 9, the automatic telephone answering apparatus is comprised of a line coupling transformer 20, a bell signal detection circuit 22, a line switch circuit 24, an OGM source 26 such as a magnetic tape apparatus, an OGM muting switch 72, an ICM recorder 28 such as a magnetic tape recorder and a DTMF signal discriminating circuit 30 for discriminating the DTMF signals. The DTMF signal discriminating circuit 30 comprises a selective signal coupling circuit 32, a frequency signal extracting circuit 34 and a microcomputer 36. The third embodiment of the automatic telephone answering apparatus is different from the two prior embodiments in that the third embodiment has the OGM muting switch 72 between the OGM source 26 and the DTMF signal discriminating circuit 30. The OGM muting switch 72 has a control terminal 72a which is connected to a second control signal output terminal 36c of the microcomputer 36.
The line coupling transformer 20 is provided for being coupled to a telephone line TL through the line switch circuit 24. The line switch circuit 24 has a control terminal 24a connected to a first control signal output terminal 36a of the microcomputer 36. The bell signal detection circuit 22 is coupled between the primary winding 20a of the line coupling transformer 20 and a bell detection signal input terminal 36b of the microcomputer 36 for detecting a bell signal applied through the telephone line TL so that the microcomputer 36 activates the line switch circuit 24 in response to a detection signal from the bell signal detection circuit 22. The OGM source 26 and the ICM recorder 28 are arranged so that the OGM source 26 generates an OGM signal and the ICM recorder 28 records an ICM signal applied through the telephone line TL and the line coupling transformer 20 under the control of the microcomputer 36 in a prescribed automatic telephone answering mode, similar to the above two embodiments.
The frequency signal extracting circuit 34 is comprised of first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and also first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38gare connected in parallel between the selective signal coupling circuit 32 and the microcomputer 26. That is, the input terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in common to the output terminal 32c of the selective signal coupling circuit 32, while the output terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel to first to seventh input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36. The first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g are connected in parallel between the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36, respectively. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g and the first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g are responsive to the frequency signals, i.e., the signals of 697 kHz, 770 kHz, 852 kHz, 941 kHz, 1,209 kHz, 1,336 kHz and 1,477 kHz, respectively.
Referring now to FIG. 10, the operation of the automatic telephone answering apparatus shown in FIG. 9, in particular the DTMF signal discriminating circuit 30, will be described. FIG. 10 shows a time diagram for signals in the DTMF signal discriminating circuit 30. When a subscriber calls his or her automatic telephone answering apparatus from a remote telephone set (not shown) by dialing, the bell signal detection circuit 22 detects bell signals transmitted from the remote telephone set and applies a detection signal to the bell detection signal input terminal 36b of the microcomputer 36. The microcomputer 36 applies a prescribed control signal to the control terminal 24a of the line switch circuit 24 through the first control signal output terminal 36a so as to activate the line switch circuit 24 in response to the bell detection signal. As a result, a communication channel is established between the remote telephone set and the automatic telephone answering apparatus. The microcomputer 36 also drives the OGM source 26 so that the OGM source 26 transmits the OGM signal prerecorded therein to the selective signal coupling circuit 32.
The OGM signal applied to the input terminal 32a is selectively supplied to the input/output terminal 32b of the selective signal coupling circuit 32. The OGM signal obtained on the input/output terminal 32b then is transmitted to the subscriber on the remote telephone set through the line couling transformer 20 and the telephone line TL. The subscriber on the remote telephone set is able to recognize that the automatic telephone answering apparatus is ready to respond for remote control operations from the remote telephone set, by hearing the OGM signal thus transmitted from the automatic telephone answering apparatus. The subscriber then is able to apply a prescribed DTMF signal to the automatic telephone answering apparatus by using the remote telephone set.
When the subscriber sequentially operates two telephone buttons, e.g., "1" and "3" for carrying out a prescribed remote control, first, the DTMF signal "1", composed of the 697 kHz low frequency signal and the 1,209 kHz high frequency signal, is generated from the telephone set. Next, the DTMF signal "3" composed of the 697 kHz low frequency signal and the 1,477 kHz high frequency signal is generated from the telephone set. The low frequency signal and the high frequency signal in the same DTMF signal are timed so that they are generated within five (5) msec. from each other, as described before. Also, the low frequency signal and the high frequency signal in the same DTMF signal overlap for at least thirty five (35) msec., as described before.
The DTMF signals "1" and "3" are applied to the input/output terminal 32b of the selective signal coupling circuit 32 through the telephone line TL and the line coupling transformer 20. In the selective signal coupling circuit 32, the DTMF signals "1" and "3" are selectively supplied to the output terminal 32c of the selective signal coupling circuit 32 at a sufficient level, as shown in graph A of FIG. 10. In the graph A, waveforms a0, a1 and a2 denote undesired signals or noises received by the DTMF signal discriminating circuit 30, the DTMF signal "1" and the DTMF signal "3", respectively. The OGM signal generated from the OGM source 26 is, of course, an audio frequency band signal, as described before. When the OGM signal applied to the selective signal coupling circuit 32 leaks out to the output terminal 32c at a sufficient level, the leaking OGM signal is received on the input terminal of the frequency signal extracting circuit 34 as a noise signal a0.
These signals a0, a1 and a2 are then applied to the frequency signal extracting circuit 34. In the frequency signal extracting circuit 34, the 697 kHz signal component in the noise signal a0, i.e., the OGM signal, and in the signals a1 and a2, i.e., the DTMF signals "1" and "3", is extracted through the BPF circuit 38a. The 697 kHz signal component is then rectified in the rectifier circuit 70a so that rectified signals b0, b1 and b2, which correspond to the OGM signal and the DTMF signals "1" and "3" are obtained, as shown in the graph B. The 1,209 kHz signal component in the noise signal a0, i.e., the OGM signal, and in the DTMF signal a1, i.e., the DTMF signal "1", is extracted through the BPF circuit 38e. The 1,209 kHz signal component is then rectified in the rectifier circuit 70e so that rectified signals c0 and c1, which correspond to the the OGM signal and the DTMF signal "1" are obtained, as shown in the graph C. The 1,477 kHz signal component in the OGM signal a0, and in the DTMF signal a2, i.e., the DTMF signal "3", is also extracted through the BPF circuit 38g. The 1,477 kHz signal component is then rectified in the rectifier circuit 70g so that rectified signals d0 and d2, which correspond to the OGM signal and the DTMF signal "3" are obtained, as shown in the graph D.
The rectified signals b0, c0 and d0 corresponding to the noise signal a0, i.e., the OGM signal, generally overlap for a relatively short period. However, the DTMF signals are so provided that they last for more than about thirty five (35) msec. for the microcomputer 36 to be capable of discriminating the DTMF signals. Thus, the rectifier signals b1, b2, c1 and d2 corresponding to the DTMF signals "1" and "3" last for a relatively long period, at least thirty five (35) msec. The rectified signals b1 and b2 arise at the times T11 and T21, respectively. The DTMF signals are so provided that the low frequency signal and the high frequency signal in the same DTMF signal should be generated within five (5) msec. of each other when a prescribed button is operated, as described before. Thus, the rectified signals c1 arises at time T12 within five msec. from the time T11. Also, the rectified signals d2 arises at the time T22 within five msec. from the time T21.
The outputs b0, b1, b2, c0, c1, d0 and d2 of the rectifier circuits 70a, 70e and 70g are applied to the input terminals 36-Ia, 36-Ie and 36-Ig of the microcomputer 36. The microcomputer 36 itself is equipped with a timer clock (not shown). The microcomputer 36 starts the clock when the microcomputer 36 has received any one of the rectified signals (referred to as the first rectified signal hereafter). The microcomputer 36 then examines whether the other rectified signal (referred as second rectified signal hereafter) of a different frequency range is applied thereto within a time lag less than a first standard examination period, e.g., about five msec. from the occurrence of the first rectified signal. That is, when the first rectified signal has been applied to one of the input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig of the microcomputer 36, the microcomputer 36 examines whether the second rectified signal is applied to one of the input terminals 36-Ia, 36-Ib, 36-Ic, . . . 36-Ig within the first standard examination period. The microcomputer 36 further examines whether a level difference between the first and second rectified signals is in a standard level range, e.g., about three (3) dB. The microcomputer 36 outputs a muting signal from the microcomputer 36c and supplies it to the control terminal 72a of the OGM muting switch 72, when the time lag and the level difference between the first and second rectified signals fall within the standard examination period and level range, respectively. On the other hand, the microcomputer 36 resets the timer clock until any other rectified signal is applied to the microcomputer 36, when the time lag or the level range between the first and second signals is out of the standard period or level range. The OGM muting switch 72 disconnects the OGM source 26 from the DTMF signal discriminating circuit 30 in response to the muting signal applied to the control terminal 72a. The muting signal is applied for a standard muting period, e.g., about five (5) msec. The microcomputer 36 still maintains its examinations of the first and second rectified signals during the standard muting period. If the first or second rectified signal has disappeared within the standard muting period, the microcomputer 36 judges that the first and second rectified signals originated from the OGM signal. The microcomputer 36 also continues the examination for a second standard examination period, e.g., about thirty five msec. from the occurrence of the second rectified signal. The microcomputer 36 then judges whether the first and second rectified signals originated from the DTMF signals, if the first and second rectified signals are successively applied to the microcomputer 36 during the second standard examination period. As a result, the DTMF signal discriminating circuit 30 accurately judges whether the first and second rectified signals are originated from a noise signal, such as the OGM signal, or from the DTMF signals.
Referring now to FIG. 10, some examples of the examination operation of the microcomputer 36 will be described in regard to the discrimination of the DTMF signals "1" and "3". When the rectified signal c0 corresponding to the 1,209 kHz signal in the leaking OGM signals a0, as shown by the graph C in FIG. 10, is first applied to the input terminal 36-Ie of the microcomputer 36 as the first rectified signal at a time T01, the microcomputer 36 starts the timer clock. The microcomputer 36 generates a first muting signal E0, when another rectified signal b0 corresponding to the 697 kHz signal in the leaking OGM signals a0, as shown by the graph B in FIG. 10, is applied to the input terminal 36-Ia of the microcomputer 36 as the second rectified signal at a time T02 within the first examination period following the time T01. The first muting signal E0 is applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T03 to a time T04. The first and second rectified signals c0 and b0 are prevented from being applied to the microcomputer 36 for the muting period. Thus, the microcomputer 36 judges that the rectified signals c0 and b0 did not originate from the DTMF signals. As a result, the microcomputer 36 resets the timer clock and stops the examination for the rectified signals c0 and b0.
Next, the rectified signal b1 corresponding to the 697 kHz signal in the DTMF signal a1 of the DTMF signal "1", as shown by the graph B in FIG. 10, is applied to the input terminal 36-Ia of the microcomputer 36 as the first rectified signal at a time T11, and the microcomputer 36 again starts the timer clock. The microcomputer 36 generates a second muting signal E1, when another rectified signal c1 corresponding to the 1,209 kHz signal in the same DTMF signal "1", as shown by the graph C in FIG. 10, is applied to the input terminal 36-Ie of the microcomputer 36 as the second rectified signal at a time T12 within the first examination period after the time T11. The second muting signal E1 is also applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T13 to a time T14. However, the first and second rectified signals b1 and c1 are successively applied to the microcomputer 36 for the muting period, in spite of the muting operation. The microcomputer 36 then continues the examination for the first and second rectified signals b1 and c1 during the second standard examination period from the occurrence of the second rectified signal, i.e., until a time T15. If the first and second rectified signals b1 and c1 are applied to the microcomputer 36 without interruption, during the second standard examination period, the microcomputer 36 judges that the first and second rectified signals b1 and c1 originated from the DTMF signal "1". The timer clock is then reset after when both the first and second rectified signals b1 and c1 have stopped.
Next, the rectified signal b2 corresponding to the 697 kHz signal in the DTMF signal a2 or the DTMF signal "3", as shown by the graph B in FIG. 10, is applied to the input terminal 36-Ia of the microcomputer 36 as the first rectified signal at a time T21, and the microcomputer 36 again starts the timer clock. The microcomputer 36 generates a third muting signal E2, when another rectified signal d2 corresponding to the 1,477 kHz signal in the same DTMF signal "3", as shown by the graph D in FIG. 10, is applied to the input terminal 36-Ig of the microcomputer 36 as the second rectified signal at a time T22 within the first examination period from the time T21. The third muting signal E2 is also applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T23 to a time T24. However, the first and second rectified signals b2 and d2 are successively applied to the microcomputer 36 for the muting period, in spite of the muting operation. The microcomputer 36 then continues the examination for the first and second rectified signals b2 and d2 during the second standard examination period after the occurrence of the second rectified signal d2, i.e., until a time T25. If the first and second rectified signals b2 and d2 are applied to the microcomputer 36 without interruption during the second standard examination period, the microcomputer 36 judges that the first and second rectified signals b2 and d2 originated from the DTMF signal "3".
Referring now to FIG. 11, an automatic telephone answering apparatus, which is equipped with a modified example of the third embodiment of the DTMF signal discriminating circuit according to the present invention, will be described. In FIG. 11, the automatic telephone answering apparatus is comprised of a line coupling transformer 20, a bell signal detection circuit 22, a line switch circuit 24, an OGM source 26 such as a magnetic tape apparatus, an OGM muting switch 72, an ICM recorder 28 and a DTMF signal discriminating circuit 30 for discriminating the DTMF signals. The DTMF signal discriminating circuit 30 comprises a selective signal coupling circuit 32, a frequency signal extracting circuit 34 and a microcomputer 36. The modified embodiment of the automatic telephone answering apparatus is different from the third embodiment in that the frequency signal extracting circuit 34 is constructed with only the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g, i.e., without the first to seventh rectifier circuits 70a, 70b, 70c, . . . 70g.
The OGM muting switch 72 has a control terminal 72a which is connected to a second control signal output terminal 36c of the microcomputer 36. The line coupling transformer 20 is coupled to a telephone line TL through the line switch circuit 24. The line switch circuit 24 has a control terminal 24a connected to a first control signal output terminal 36a of the microcomputer 36. The bell signal detection circuit 22 is coupled between the primary winding 20a of the line coupling transformer 20 and a bell detection signal input terminal 36b of the microcomputer 36 for detecting a bell signal applied through the telephone line TL. Thus, the microcomputer 36 activates the line switch circuit 24 in response to a detection signal from the bell signal detection circuit 22. The OGM source 26 and the ICM recorder 28 are arranged so that the OGM source 26 generates an OGM signal and the ICM recorder 28 records an ICM signal applied through the telephone line TL and the line coupling transformer 20 under the control of the microcomputer 36 in a prescribed automatic telephone answering mode, similar to the above two embodiments.
The frequency signal extracting circuit 34 is comprised of first to seventh BPF circuits 38a, 38b, 38c, . . . 38g. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel between the selective signal coupling circuit 32 and the microcomputer 36. That is, the input terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in common to the output terminal 32c of the selective signal coupling circuit 32, while the output terminals of the first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are connected in parallel to first to seventh input terminals 36-Ia, 36-Ia-b, 36-Ic, . . . 36-Ig of the microcomputer 36. The first to seventh BPF circuits 38a, 38b, 38c, . . . 38g are responsive to the frequency signals, i.e., the signals of 697 kHz, 770 kHz, 852 kHz, 941 kHz, 1,209 kHz, 1,336 kHz and 1,477 kHz, respectively.
Referring now to FIG. 12, the operation of the automatic telephone answering apparatus shown in FIG. 11, and in particular the DTMF signal discriminating circuit 30, will be described. FIG. 12 shows a time diagram for signals in the DTMF signal discriminating circuit 30. When a subscriber calls his or her automatic telephone answering apparatus from a remote telephone set (not shown) by dialing, the bell signal detection circuit 22 detects bell signals transmitted from the remote telephone set and applies a detection signal to the bell detection signal input terminal 36b of the microcomputer 36. The microcomputer 36 applies a prescribed control signal to the control terminal 24a of the line switch circuit 24 through the first control signal output terminal 36a so as to activate the line switch circuit 24 in response to the bell detection signal. As a result, a communication channel is established between the remote telephone set and the automatic telephone answering apparatus. The microcomputer 36 also drives the OGM source 26 so that the OGM source 26 transmits the OGM signal prerecorded therein to the selective signal coupling circuit 32.
The OGM signal applied to the input terminal 32a is selectively supplied to the input/output terminal 32b of the selective signal coupling circuit 32. The OGM signal obtained on the input/output terminal 32b then is transmitted to the subscriber on the remote telephone set through the line coupling transformer 20 and the telephone line TL. The subscriber on the remote telephone set is able to recognize that the automatic telephone answering apparatus is ready to respond for remote control operations from the remote telephone set, by hearing the OGM signal thus transmitted from the automatic telephone answering apparatus. The subscriber then is able to apply a prescribed DTMF signal to the automatic telephone answering apparatus by using the remote telephone set.
When the subscriber sequentially operates two telephone buttons, e.g., "1" and "3" for carrying out a prescribed remote control, first, the DTMF signal "1", composed of the 697 kHz low frequency signal and the 1,209 kHz high frequency signal, is generated from the telephone set. Next, the DTMF signal "3" composed of the 697 kHz low frequency signal and the 1,477 kHz high frequency signal is generated from the telephone set. The low frequency signal and the high frequency signal in the same DTMF signal are timed so that they are generated within five (5) msec. from each other, as described before. Also, the low frequency signal and the high frequency signal in the same DTMF signal overlap for at least thirty five (35) msec., as described before.
The DTMF signals "1" and "3" are applied to the input/output terminal 32b of the selective signal coupling circuit 32 through the telephone line TL and the line coupling transformer 20. In the selective signal coupling circuit 32, the DTMF signals "1" and "3" are selectively supplied to the output terminal 32c of the selective signal coupling circuit 32 at a sufficient level, as shown in graph A of FIG. 12. In the graph A, waveforms a0, a1 and a2 denote undesired signals or noises received by the DTMF signal discriminating circuit 30, the DTMF signal "1" and the DTMF signal "3", respectively. The OGM signal generated from the OGM source 26 is, of course, an audio frequency band signal, as decribed before. When the OGM signal applied to the selective signal coupling circuit 32 leaks out to the output terminal 32c at a sufficient level, the leaking OGM signal is received on the input terminal of the frequency signal extracting circuit 34 as a noise signal a0.
These signals a0, a1 and a2 are then applied to the frequency signal extracting circuit 34. In the frequency signal extracting circuit 34, the 697 kHz signal component in the noise signal a0, i.e., the OGM signal, and in the signals a1 and a2, i.e., the DTMF signals "1" and "3", is extracted through the BPF circuit 38a. The 697 kHz signals b0, b1 and b2, as shown by the graph B in FIG. 12, are then supplied to the input terminal 36-Ia of the microcomputer 36, in correspondence with the OGM signal a0 and the DTMF signals a1 and a2, i.e., the DTMF signals "1" and "3". The 1,209 kHz signal component in the noise signal a0, i.e., the DTMF signal the OGM signal and the DTMF signal a1, i.e., "1" is extracted through the BPF circuit 38e. The 1,209 kHz signals c0 and c1, which correspond to the OGM signal a0, and in the DTMF signal a1, i.e., the DTMF signal "1" as shown by the graph C in FIG. 12, are then supplied to the input terminal 36-Ie of the microcomputer 36. The 1,477 kHz signal component in the OGM signal a0 and the DTMF signal a2, i.e., the DTMF signal "3" is also extracted through the BPF circuit 38g. The 1,477 kHz signals d0 and d2, as shown by the graph D in FIG. 12, are then applied to the input terminal 36-Ig of the microcomputer 36, in correspondence to the OGM signal a0 and the DTMF signal a2, i.e., the DTMF signal "3".
The 697 kHz signal b0, the 1,209 kHz signal c0 and the 1,477 kHz signal d0 respectively corresponding to the noise signal a0, i.e., the OGM signal, generally last for a relatively short period. However, the DTMF signals are so provided that they overlap for more than about thirty five (35) msec. for the microcomputer 36 to be capable of discriminating the DTMF signals with a sufficient time. Thus, the 697 kHz signals b1 and b2, the 1,209 kHz signal c1 and the 1,477 kHz signal d2 corresponding to the DTMF signals "1" and "3" last for a relatively long period, at least thirty five (35) msec. The the 697 kHz signals b1 and b2 arise at the times T11 and T21, respectively. The DTMF signals are so provided that the low frequency signal and the high frequency signal in the same DTMF signal should be generated within five (5) msec. of each other when a prescribed button is operated, as described before. Thus, the 1,209 kHz signal c1 arises at time T12 within five msec. from the time T11. Also, the signal d2 arises at the time T22 within five msec. from the time T21.
The outputs b0, b1, b2, c0, c1, d0 and d2 of the 38a, 38e and 38g are applied to the input terminal 36-Ia, 36-Ie and 36-Ig of the microcomputer 36. The microcomputer 36 itself is equipped with a timer clock (not shown). The microcomputer 36 starts the clock when the microcomputer 36 has received any one of the frequency signals (referred to as the first frequency signal hereafter). The microcomputer 36 then examines whether another frequency signal (referred to as the second frequency signal hereafter) of a different frequency range is applied thereto within a time lag of a first standard examination period, e.g., about five msec. from the occurrence of the first frequency signal. That is, when the first frequency signal has been applied to one of the input terminals 36-Ia, 36-Ib, 36-Ic and 36-Id of the microcomputer 36, the microcomputer 36 examines whether the second frequency signal is supplied to one of the input terminal 36-Ie, 36-If and 36-Ig within the first standard examination period. The microcomputer 36 further examines whether an amplitude difference between the first and second frequency signals is in a standard amplitude range, e.g., about three (3) dB. The microcomputer 36 outputs a muting signal from the microcomputer 36c and supplies it to the control terminal 72a of the OGM muting switch 72, when the time lag and the level difference between the first and second frequency signals fall within the standard examination period and amplitude level range, respectively. The microcomputer 36 resets the timer clock until any other frequency signal is applied to the microcomputer 36, when the time lag or the level range between the first and second signals is out of the standard period or range. The OGM muting switch 72 disconnects the OGM source 26 from the DTMF signal discriminating circuit 30 in response to the muting signal applied to the control terminal 72a. The muting signal is applied for a standard muting period, e.g., about five (5) msec. The microcomputer 36 still maintains its examinations of the first and second frequency signals during the standard muting period. If the first or second frequency signal has disappeared within the standard muting period, the microcomputer 36 judges that the first and second frequency signals originated from the OGM signal. The microcomputer 36 also continues the examination for a second standard examination period, e.g., about thirty five msec. from the occurrence of the second frequency signal. The microcomputer 36 then judges whether the first and second frequency signals are originated from the DTMF signals, if the first and second frequency signals are successively applied to the microcomputer 36 during the second standard examination period. As a result, the DTMF signal discriminating circuit 30 accurately judges whether the first and second frequency signals are originated from a noise signal, such as the OGM signal, or from the DTMF signal.
Referring now to FIG. 12, some examples of the examination operation of the microcomputer 36 will be described in regard to the discrimination of the DTMF signals "1" and "3". When the frequency signal c0 corresponding to the 1,209 kHz signal in the leaking OGM signals a0, as shown by the graph C in FIG. 12, is first applied to the input terminal 36-Ie of the microcomputer 36 as the first frequency signal at a time T01, the microcomputer 36 starts the timer clock. The microcomputer 36 generates a first muting signal E0, when another frequency signal b0 corresponding to the 697 kHz signal in the leaking OGM signals a0, as shown by the graph B in FIG. 12, is applied to the input terminal 36-Ia of the microcomputer 36 as the second frequency signal at a time T02 within the first examination period following the time T01. The first muting signal E0 is applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T03 to a time T04. The first and second frequency signals c0 and b0 are prevented from being applied to the microcomputer 36 for the muting period. Thus, the microcomputer 36 judges that the frequency signals c0 and b0 did not originate from the DTMF signals. As a result, the microcomputer 36 resets the timer clock and stops the examination for the frequency signals c0 and b0.
Next, the rectified signal b1 corresponding to the 697 kHz signal in the DTMF signal a1 of the DTMF signal "1", as shown by the graph B in FIG. 12, is applied to the input terminal 36-Ia of the microcomputer 36 as the first frequency signal at a time T11, and the microcomputer 36 again starts the timer clock. The microcomputer 36 generates a second muting signal E1, when another frequency signal c1 corresponding to the 1,209 kHz signal in the same DTMF signal "1", as shown by the graph C in FIG. 12, is applied to the input terminal 36-Ie of the microcomputer 36 as the second frequency signal at a time T12 within the first examination period after the time T11. The second muting signal E1 is also applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T13 to a time T14. However, the first and second frequency signals b1 and c1 are successively applied to the microcomputer 36 for the muting period, in spite of the muting operation. The microcomputer 36 then continues the examination for the first and second frequency signals b1 and c1 during the second standard examination period from the occurrence of the second frequency signal, i.e., until a time T15. If the first and second frequency signals b1 and c1 are applied to the microcomputer 36 without interruption, during the second standard examination period, the microcomputer 36 judges that the first and second frequency signals b1 and c1 originated from the DTMF signal "1". The timer clock is then reset after both the first and second frequency signals b1 and c1 have stopped.
Next, the frequency signal b2 corresponding to the 697 kHz signal in the DTMF signal a2 or the DTMF signal "3", as shown by the graph B in FIG. 12, is applied to the input terminal 36-Ia of the microcomputer 36 as the first frequency signal at a time T21, and the microcomputer 36 again starts the timer clock. The microcomputer 36 generates a third muting signal E2, when another frequency signal d2 corresponding to the 1,477 kHz signal in the same DTMF signal "3", as shown by the graph D in FIG. 12, is applied to the input terminal 36-Ig of the microcomputer 36 as the second frequency signal at a time T22 within the first examination period from the time T21. The third muting signal E2 is also applied to the control terminal 72a of the OGM muting switch 72 so that the OGM source 26 is disconnected from the DTMF signal discriminating circuit 30 during the muting period, e.g., from a time T23 to a time T24. However, the first and second frequency signals b2 and d2 are successively applied to the microcomputer 36 for the muting period, in spite of the muting operation. The microcomputer 36 then continues the examination for the first and second frequency signals b2 and d2 during the second standard examination period after the occurrence of the second frequency signal d2, i.e., until a time T25. If the first and second frequency signals b2 and d2 are applied to the microcomputer 36 without interruption during the second standard examination period, the microcomputer 36 judges that the first and second frequency signals b2 and d2 are originated from the DTMF signal "3".
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A DTMF signal discriminating circuit for a remote control apparatus, the DTMF signals corresponding to a plurality of predetermined operating modes of the apparatus, the apparatus including in OGM signal generating source responsive to an input signal from a remote source for indicating that the apparatus can receive DTMF signals. The DTMF signal discriminating circuit includes a signal coupling circuit for selectively supplying the OGM signal to the remote source and receiving the DTMF signals from the remote source, including a circuit for suppressing the OGM signal for substantially preventing operation of the apparatus in any of the predetermined operating modes in response to receipt of the OGM signal by the signal coupling circuit, a discrimination circuit for receiving the DTMF signals from the signal coupling circuit and a microcomputer responsive to the discrimination circuit for controlling operation of the apparatus in an operating mode corresponding to the received DTMF signals.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Japanese Patent Application Nos. 2005-161047 and 2006-051540. The entire disclosure of Japanese Patent Application Nos. 2005-161047 and 2006-051540 is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a packaging system configured to package a product by covering the top surface of the product with a film.
[0004] 2. Background Information
[0005] In conventional practice, some packaging systems package products with films by means of raising a container, such as a tray or the like, having a product contained therein onto a packaging station arranged thereabove. One example of such a packaging system is shown in FIGS. 8 and 9 .
[0006] When a product M is placed on a tray supply device 20 shown in FIG. 8 by an operator, the rear end Tb of the tray (container) T carrying the product M is pushed by a conveying bar (contact member) 13 , and the tray T is conveyed onto a lifter 201 . The posts 210 of the lifter 201 are disposed directly beneath the packaging station S of a packaging unit 200 . The posts are capable of being raised and lowered by a hoisting device 208 . The lifter 201 lifts the product M up to the packaging station S when the product M is supplied from the tray supply device 20 thereto.
[0007] Before the packaging operation, a film F cut to a specific length is supplied to and stretched over the packaging station S in FIG. 9A by a film supply device 202 (shown in FIG. 8 ). This film F adheres to the top surface of the product M when the product M is pressed upward. In this state, a film folding unit 203 packages the product M by folding the edges on all four sides of the film F onto the bottom side of the tray T with a pair of left and right folding plates 204 , 204 , a rear folding plate 205 , a rod-shaped front folding member 206 , and a pusher 207 (shown in FIG. 8 ), and the packaged product M is ejected onto an ejecting conveyor 209 shown in FIG. 8 .
[0008] However, the tray T may be somewhat misaligned to the left or right because it is placed on the tray supply device 20 by an operator. In order to solve this problem in this type of conventional packaging system, as disclosed in Japan Patent Application Publication 2001-48109 (particularly FIG. 5 thereof), the amount by which the tray T is misaligned in the width direction on the tray supply device 20 is determined, and this widthwise misalignment is corrected in order to improve the finished state of packaging.
[0009] In a conventional packaging system, as shown in FIG. 6A , the tray T is photographed from above by a camera when the tray T is placed on the tray supply device 20 (shown in FIG. 8 ). The amount of misalignment from the center of the tray T is calculated based on this photograph information. After the photographing, the tray T is conveyed by a conveying bar 13 , as shown in FIG. 6B , and then the tray T is moved towards the center by a movement unit (not shown in the figures) according to the amount of misalignment, as shown in FIG. 6C .
[0010] However, sometimes the amount of misalignment changes when the conveying bar contacts with the tray, due to factors such as the weight of the materials to be packaged, the center of gravity, and the friction between the underside of the tray and the scale tray, even if the tray is positioned in the same manner and at the same position. For example, when the tray T is placed so as to be tilted with respect to the conveying bar 13 , as shown in FIGS. 6D and 6E , the amount of post-conveyance misalignment of the tray T after it is conveyed and in contact with the conveying bar 13 may differ from the calculated misalignment, as shown in FIGS. 6D and 6E . Therefore, sometimes the misalignment cannot be sufficiently corrected, even if the tray T is moved towards the center in accordance with the amount of misalignment determined by the camera.
[0011] Thus, sometimes the misalignment in the width direction, which is substantially orthogonal to the conveying direction of the products, cannot be resolved from the time conveying is initiated by the conveying unit until the time conveying is completed.
[0012] An inadequately corrected misalignment sometimes brings about a misalignment in the position of the product during packaging or a misalignment in the label attachment position. As a result, packaging is unsatisfactory, or the attachment position is misaligned. In addition, a large misalignment may even cause the tray T to be crushed.
[0013] Furthermore, misalignment can also occur in the conveying direction of the product.
[0014] FIGS. 7A-7H are schematic side views showing the vicinity of the tray supply device 20 and a lifter 201 . FIGS. 7A and 7B show a normal conveying state of the tray T. The tray T shown in FIG. 7A is pushed by the conveying bar 13 , and is conveyed onto the lifter 201 as shown in FIG. 7B . The position (stopping position) of the end of the advancing movement of the conveying bar 13 is set in advance for each tray T, and the tray T is pushed and conveyed to a specific position on the lifter 201 according to this set stopping position.
[0015] However, in cases such as when a tray T carrying a product is light in weight, as shown in FIGS. 7C and 7D , the conveying bar 13 sometimes slips underneath the tray T, and the tray T will not be conveyed to the specified position on the lifter 201 even if the conveying bar 13 stops at the set stopping position.
[0016] In addition, if the tray T is deep, as shown in FIGS. 7E and 7F , the conveying bar 13 sometimes slips in underneath the edge of the tray T, and the tray T will not be conveyed to the specified position on the lifter 201 .
[0017] In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved packaging system. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.
SUMMARY OF THE INVENTION
[0018] The packaging system of the present invention can be applied to a packaging device that uses stretched films or the like.
[0019] A primary object of the present invention is to provide a packaging system that is capable of packaging products based on the amount of misalignment that occurs in the conveying direction of the product and the width direction of the product after the product is conveyed.
[0020] In the invention disclosed in Japan Patent Application Publication No. 2001-48109, when the misalignment of the product is corrected, the conveying surface itself is moved in the width direction of the product according to the amount of misalignment of the product. Since the conveying surface is accommodated within the main body frame of the packaging system, the product sometimes protrudes past the outside of the conveying surface and cannot be conveyed in a stable manner when the product is too wide, or when the amount of misalignment in the width direction is too great. Moreover, since there is a natural limit to the moveable range of the conveying surface in the width direction, the amount of misalignment of the product cannot be corrected to a great extent.
[0021] Therefore, another object of the present invention is to provide a packaging system that can convey products in a more stable manner, and is capable of correcting a large amount of misalignment.
[0022] In order to achieve these objects, the packaging system according to a first aspect of the present invention is a packaging system configured to package a product by supplying a product onto a lifter by means of a supply device, pushing the product on the lifter up to a packaging station, and covering the top surface of the raised product with a film. The packaging system comprises a conveying unit that contacts the rear end in the conveying direction of a product on the supply device and configured to convey the product onto the lifter, a detection unit configured to determine the amount of misalignment in the conveying direction and/or the width direction that is orthogonal to the conveying direction of the product, while the product is being conveyed by the conveying unit, and a control unit configured to control the devices in the system to perform in accordance with the amount of misalignment detected.
[0023] According to the first aspect, it is possible to determine the misalignment of a product, including the misalignment that did not exist before the product began to be conveyed, or, in other words, the misalignment that occurs as a result of the product being conveyed. Therefore, a highly precise positioning of the product is possible because the final amount of misalignment of the product will be detected after the conveyance of the product begins.
[0024] According to the first aspect, in situations in which the amount of misalignment in the width direction is detected, it is preferable that the detection unit also determine the amount of misalignment of the product in the width direction after the product is placed on the supply device and before the product begins to be conveyed.
[0025] The initial amount of misalignment of the product can thereby be quickly detected, immediately after the product is placed, and therefore, it is possible to quickly respond to the misalignment of the product. In addition, a highly precise positioning of the product is possible, because the final amount of misalignment of the product is detected after the conveyance of the product begins.
[0026] According to the first aspect, in situations in which the misalignment in the width direction is corrected, it is preferable that the packaging system further comprises a moving unit that is configured to move the position of the product on the supply device in the width direction, wherein the control unit drives the moving unit to move the position of the product in accordance with the amount of misalignment in the width direction as detected by the detection unit, to correct the misalignment of the product in the width direction.
[0027] As a result, a well finished packaging can be expected because it is possible to correct a misalignment in the width direction that occurs after the conveyance of the product begins.
[0028] According to the first aspect, the packaging system may include a film supply device configured to convey the film in the width direction of the product, wherein the control unit drives the film supply device to convey the film according to the amount of misalignment in the width direction as detected by the detection unit, and stretches the film to a position in the width direction corresponding to the misalignment of the product.
[0029] As a result, a well finished packaging can be expected because the film supply position can be adjusted according to the misalignment in the width direction that occurs after the conveyance of the product begins.
[0030] According to the first aspect, when the product includes a tray, the type of tray may be identified by the system after the tray begins to be conveyed.
[0031] The precision in identifying the tray is thereby improved, because the tray is identified after the position of the tray is corrected, and after conveyance has started.
[0032] According to the first aspect, it is preferable that the control unit drive the conveying unit to convey the product in accordance with the amount of misalignment in the conveying direction as detected by the detection unit, and correct the misalignment of the product in the conveying direction.
[0033] As a result, a well finished packaging can be expected because it is possible to correct the misalignment in the conveying direction that occurs after the conveyance of product has started.
[0034] According to the first aspect, in situations in which the amount of misalignment in the conveying direction is detected, it is preferable that the detection unit detects the position of a contact member that comes into contact with the rear end of the product and the position of the rear end of the product, and detects the amount of misalignment of the product in the conveying direction based on the detected positional relationship between the contact member and the rear end of the product.
[0035] The product can thereby be supplied to a specific position on the lifter because even if relative misalignment occurs between the contact member and the product, the misalignment thereof will be detected.
[0036] According to the first aspect, the packaging system may further include a label attaching device configured to attach a label to a packaged product, wherein the position where the label is to be attached by the label attaching device is controlled by the control unit, and the label is attached to a position in accordance with the amount of misalignment of the product in the conveying direction and/or the width direction, as detected by the detection unit.
[0037] As a result, the label can still be attached to the correct position even if the product is misaligned.
[0038] The packaging system according to a second aspect is a packaging system configured to package a product by supplying a product onto a lifter, pushing the product on the lifter up to a packaging station, and covering the top surface of the raised product with a film. The packaging system comprises a first conveying surface on which a product is placed; a second conveying surface that is provided downstream of the first conveying surface and formed separately from the first conveying surface, and capable of moving within a specific range in a first or a second width direction that is substantially orthogonal to the conveying direction of the product; a conveying unit configured to convey the product from the first conveying surface onto the lifter through the second conveying surface; a detection unit configured to determine the direction of misalignment and the amount of misalignment of the product in the width direction on the first conveying surface; a moving unit configured to move the position of the product on the second conveying surface in the width direction by moving the second conveying surface in the width direction within the moveable range; and a control unit configured to drive the moving unit to pre-move the second conveying surface in a first or a second width direction in accordance with the direction and amount of misalignment in the width direction detected by the detection unit before the product is conveyed onto the second conveying surface, and also to move the second conveying surface in a first or a second width direction that is opposite the pre-moved width direction after the product has been conveyed onto the second conveying surface, to correct the misalignment of the product in the width direction.
[0039] It is possible to correct a considerable misalignment of a product in the width direction on the first conveying surface, by moving the second conveying surface in the width direction in advance. An excellent packaging finish can therefore be expected.
[0040] In a second embodiment of the present invention, the width of the second conveying surface is smaller than the width of the first conveying surface.
[0041] Since the second conveying surface is moved in advance according to the misalignment of the product, the entire product is transferred onto the second conveying surface when the product is transferred from the first conveying surface to the second conveying surface, even if the width of the second conveying surface is smaller than the width of the first conveying surface. Therefore, an excellent packaging finish can be expected because the position of the product is not disoriented while the product is being conveyed.
[0042] In another preferred embodiment of the present invention, the conveying unit comprises a first conveying unit that is in contact with the rear end of the product on the first conveying surface and configured to convey the product in the conveying direction, and a second conveying unit configured to move the second conveying surface along a direction orthogonal to the conveying direction, wherein the second conveying speed of the second conveying unit is set to a greater value than the first conveying speed of the first conveying unit.
[0043] In this embodiment, since the conveying speed of the second conveying surface is greater than that of the first conveying surface, the product on the second conveying surface is separated from the first conveying unit that pushes on the rear end of the product. Frictional force is therefore unlikely to act between the rear end of the product and the first conveying unit when the product is displaced in the width direction. Therefore, an excellent packaging finish can be expected because the position of the product is not likely to be disoriented.
[0044] These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] Referring now to the attached drawings which form a part of this original disclosure:
[0046] FIG. 1 is a schematic perspective view showing a weighing, packaging, and pricing device in a packaging system according to a first embodiment of the present invention;
[0047] FIG. 2 is a partial cross-sectional, schematic perspective view showing the structure of the supply device;
[0048] FIG. 3 is a partial cross-sectional, schematic perspective view showing a correcting conveyor;
[0049] FIG. 4A is a schematic structural view of the system, and FIGS. 4B and 4C are tables showing the stored content of a storage unit;
[0050] FIG. 5A is a schematic view showing a method for determining the amount of misalignment of the tray, and FIG. 5B is a plan view of the correcting conveyor;
[0051] FIGS. 6A through 6C are schematic plan views showing a conventional method of conveying a product, FIGS. 6D and 6E are schematic plan views showing the manner in which the position of the product is misaligned during conveying, and FIGS. 6F through 6I are schematic plan views showing a detection method of the present invention;
[0052] FIGS. 7A through 7H are schematic elevation views showing the manner in which a product on the supply device is conveyed;
[0053] FIG. 8 is a schematic section view showing an example of a packaging unit;
[0054] FIGS. 9A and 9B are schematic perspective views showing an example of a packaging method;
[0055] FIGS. 10A and 10B are plan views showing a tray and a film used in a system according to a second embodiment of the present invention;
[0056] FIG. 11 is a partial cross-sectional, schematic perspective view showing the structure of a supply device in a packaging system according to a third embodiment of the present invention;
[0057] FIG. 12 is a partial cross-sectional view of a conveyor;
[0058] FIGS. 13A and 13B are schematic plan views showing the manner in which the position of a product is disoriented when the product is conveyed from a first conveying surface to a second conveying surface;
[0059] FIGS. 14A and 14B are schematic plan views showing the manner in which a product is conveyed smoothly from the first conveying surface to the second conveying surface; and
[0060] FIGS. 15A and 15B are elevation views showing a modification of the conveying bar.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] Selected embodiments of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments of the present invention are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
First Embodiment
[0062] FIG. 1 shows a weighing, packaging, and pricing device in a packaging system in accordance with a first embodiment of the present invention. The weighing and packaging units of this device are somewhat similar to those in the conventional packaging system shown in FIG. 8 , and thus only the components of the present invention that are different from this conventional packaging system will be described below. The following description relates to a situation in which a product M is conveyed after being placed on a tray T. The term “product M” includes both the tray T and the contents included therein.
[0063] In FIG. 1 , the weighing, packaging, and pricing device is provided with a tray supply device 20 that protrudes forward from the main body thereof. As shown in FIG. 2 , the tray supply device 20 comprises a weighing conveyor 100 and a correcting conveyor (moving unit) 21 . A label attaching device 12 configured to attach a label to a packaged product M is provided above the ejecting conveyor 209 in FIG. 1 .
[0064] The weighing conveyor 100 shown in FIG. 2 comprises a resin plate 105 that forms a first conveying surface 102 , a conveying bar 13 configured to convey the tray T on the first conveying surface 102 , and a drive motor 16 (shown in FIG. 4A ) and a driving chain 104 configured to drive the conveying bar 13 . Therefore, the conveying bar 13 , the drive motor 16 , and the driving chain 104 constitute part of the first and second conveying units for conveying the product M onto the lifter 201 .
[0065] In the weighing conveyor 100 , the resin plate 105 that forms the first conveying surface 102 is supported on a weight determining unit (loading cell) 101 shown in FIG. 4A . The weight detected by the weight determining unit 101 is outputted to weighing unit 106 and inputted to a microcomputer (control unit) 3 .
[0066] The correcting conveyor 21 is provided downstream of the resin plate 105 of the weighing conveyor 100 shown in FIG. 2 . This correcting conveyor 21 comprises a conveyor (part of the second conveying unit) 22 and a cam unit (part of the moving unit) 23 , as shown in FIG. 3 . The conveyor 22 forms a second conveying surface 22 a. The conveyor 22 is arranged to freely move in the width direction Y orthogonal to the conveying direction X of the product M, and is supported by the cam unit 23 .
[0067] The cam unit 23 comprises a cam groove 23 a formed on a flat panel, and an engaging pin 23 b that engages with the cam groove 23 a. The engaging pin 23 b is coupled with the output axle 26 of a motor 25 via a drive arm 24 . In the cam unit 23 , the engaging pin 23 b rotates in the directions shown by the arrows, corresponding to the rotation of the motor 25 rotating in a forward and backward direction, which moves the conveyor 22 in the width direction Y. The movement of the conveyor 22 causes the position of the product M on the tray supply device 20 to move in the width direction Y.
[0000] Control Configuration
[0068] FIG. 4A shows the control configuration of this packaging system.
[0069] The microcomputer (control unit) 3 is equipped with a CPU 4 and a memory 5 . A touch screen 10 , a keyboard unit 11 , a label printer 12 , and a weighing, packaging, and pricing control unit 14 are connected to the microcomputer 3 . In addition, a CCD camera (part of the detection unit) 2 and the weighing unit 106 are connected to the microcomputer 3 .
[0070] The CCD camera 2 is arranged above the first conveying surface 102 as shown in FIG. 2 , and almost the entire first conveying surface 102 is in view thereof. As shown in FIG. 6F , when the product M (tray T) is placed on the first conveying surface 102 by an operator, the weight determining unit 101 detects a change in weight, which triggers the camera 2 to photograph the product M, and a first video signal is outputted to the microcomputer 3 (shown in FIG. 4A ).
[0071] Then, as shown in FIGS. 6G and 6H , the camera 2 photographs the conveyed product M again when the product M is conveyed to a specific position by the conveying bar 13 , and a second video signal is outputted to the microcomputer 3 in FIG. 4A .
[0000] Misalignment Correction in Width Direction Y
[0072] The CPU 4 of the microcomputer 3 in FIG. 4A calculates the amount of misalignment in the width direction Y of the product M with the method described below.
[0073] The CPU 4 comprises an image processing unit 40 , a first and a second misalignment calculating unit 41 and 42 , and the like in the interior thereof. The image processing unit 40 locates the two edges Te, Te of the product M (tray T) in FIG. 5A in the width direction Y based on the video signals inputted from the CCD camera 2 . The first misalignment calculating unit 41 detects the amount of misalignment of the product M by finding the distances Y 1 and Y 2 , from the edge Te and edge Te to the center reference line C respectively, and subtracting the distance Y 2 from the distance Y 1 .
[0074] The amount of misalignment is calculated for both the first and second video signals.
[0075] The memory 5 shown in FIG. 4A comprises a product information storage unit 50 , a tray information storage unit 51 , and a reference value storage unit 52 .
[0076] A reference value YS is stored in the reference value storage unit 52 . Based on the first video signal, the CPU 4 moves the correcting conveyor 21 from its original position in advance when the first amount of misalignment calculated by the first misalignment calculating unit 41 is equal to or greater than the reference value YS, for example, 25 mm.
[0077] Subsequently, a second photograph is then taken when the product M is conveyed to a specific position by the conveying bar 13 .
[0078] The CPU 4 moves the correcting conveyor 21 shown in FIG. 5B to the left or right (in the width direction Y) to correct the misalignment of the product M, according to the second amount of misalignment calculated by the second misalignment calculating unit 42 based on the second video signal. Specifically, the motor 25 rotates only a rotation angle corresponding to the amount of misalignment to move the correcting conveyor 21 carrying the product M in the width direction Y, and correct the misalignment of the product M in FIG. 5A in the width direction Y.
[0000] Misalignment Correction in Conveying Direction X
[0079] The conveying bar 13 is driven by a drive motor 16 provided with a rotary encoder (part of the detection unit) 15 shown in FIG. 4 , for example. The position of the conveying bar 13 is calculated by the CPU 4 based on a detection signal (rotation signal) from the rotary encoder 15 . Meanwhile, the rear end Tb of the product M (tray T) is detected by the camera 2 , as shown in FIG. 7G .
[0080] The second misalignment calculating unit 42 is included in the CPU 4 . The second misalignment calculating unit 42 detects the amount of misalignment of the product M in the conveying direction based on the positional relationship between the conveying bar 13 and the rear end Tb of the product M.
[0081] The conveying bar 13 herein sometimes slips in underneath the product M while the product M is being conveyed, as shown in FIGS. 7D and 7F . In such cases, the position of the conveying bar 13 differs from the position of the rear end Tb of the product M.
[0082] The second misalignment calculating unit 42 compares the position of the rear end Tb of the product M, as detected based on the second video signal from the camera 2 , with the position of the conveying bar 13 at the time the photograph was taken, as shown in FIG. 7G , and calculates the amount of misalignment Δx in the conveying direction X. As shown in FIG. 7H , the CPU 4 moves the front end of the conveying bar 13 forward by the distance of Δx according to the amount of misalignment Δx in the conveying direction X, whereby the product M is conveyed to a specific position on the lifter 201 , and the misalignment in the conveying direction X is corrected.
[0000] Specifying the Tray T
[0083] Referring to FIG. 4A , the product information storage unit 50 stores the product name, the price, the position where the label is attached, and other such information, as well as the scheduled tray number to be used, for each product, according to the access number of the product in FIG. 4B . In addition, the size of the tray T, including the width and depth of the tray T, is stored for each type of tray T in the tray information storage unit 51 , shown in FIG. 4C .
[0084] The CPU 4 identifies the type of tray T based on the second video signal of the product M, after the product M has begun to be conveyed. The size information corresponding to the tray T and other such information is read by the CPU 4 from the tray information storage unit 51 according to the type of tray T identified.
[0000] Operation Description
[0085] Next, the operation and the manner in which the system is used will be described.
[0086] First, the operator inputs the access number of the product and other such information from the touch screen 10 and the keyboard unit 11 shown in FIG. 1 . The operator then places the tray T (product M) having contents therein on the first conveying surface 102 of the tray supply device 20 , as shown in FIG. 2 . When the product M is in place, a weight signal is outputted from the weighing unit 106 , shown in FIG. 4A , to the microcomputer 3 . When the weight signal stabilizes, a first video signal is sent from the CCD camera 2 to the image processing unit 40 .
[0087] Then, the first misalignment calculating unit 41 calculates the amount of misalignment (Y 1 −Y 2 )=Δy 1 of the product M, as shown in FIG. 4A , in the width direction Y, and compares the absolute value of the amount of misalignment (Y 1 −Y 2 ) with a reference value YS. The CPU 4 outputs a first correction command and a first misalignment amount Δy 1 to the weighing, packaging, and pricing control unit 14 when the absolute value of the amount of misalignment (Y 1 −Y 2 ) is equal to or greater than the reference value YS.
[0088] When the first misalignment amount (initial misalignment amount) Δy 1 exceeds a specific amount, the motor 25 is rotated to move the correcting conveyor 21 in advance by a distance equal to Δy 1 in the direction opposite the correcting direction. This makes it possible to accommodate even greater amounts of misalignment.
[0089] After the weight signal is stabilized, the driving chain 104 in FIG. 2 is driven according to a specific sequence, and the conveying bar 13 begins to push on the product M. When the conveying bar 13 reaches a specific position P, the camera 2 photographs the product M, and a second video signal is sent to the image processing unit 40 . The second misalignment calculating unit 42 calculates a second misalignment amount Δy 2 and compares the absolute value of the second misalignment amount Δy 2 with the reference value YS. The CPU 4 outputs a second correction command and the second misalignment amount Δy 2 to the weighing, packaging, and pricing control unit 14 when the absolute value of the second misalignment amount Δy 2 is equal to or greater than the reference value YS.
[0090] In addition, the CPU 4 identifies the type of tray T based on the second video signal, which is taken after the orientation of the tray T has been corrected by the pushing of the conveying bar 13 . The CPU 4 obtains the size information and other such information corresponding to the tray T from the tray information storage unit 51 , according to the type of tray T identified.
[0091] The product M is transferred from the first conveying surface 102 onto the second conveying surface 22 a of the correcting conveyor 21 . When the product M has been completely transferred onto the correcting conveyor 21 , the misalignment of the product M is corrected as follows.
[0092] Specifically, the weighing, packaging, and pricing control unit 14 to which the correction commands are inputted rotates the motor 25 , shown in FIG. 3 , by a rotation angle corresponding to the second misalignment amount (the final misalignment amount). The drive arm 24 and the engaging pin 23 b rotate in accordance with the rotation of the motor 25 , the conveyor 22 moves a certain amount in the width direction Y, and the misalignment of the product M in the width direction Y is corrected.
[0093] The second conveying surface 22 a is herein moved by a distance equal to Δy 2 when the first misalignment amount Δy 1 is less than the reference value YS, and the second misalignment amount Δy 2 is greater than the reference value YS. On the other hand, when both the first and second misalignment amounts Δy 1 and Δy 2 are greater than the reference value, the second conveying surface 22 a is moved by a distance equal to (Δy 2 −Δy 1 ).
[0094] The misalignment in the conveying direction X is also corrected while the product M is being conveyed.
[0095] The second misalignment calculating unit 42 calculates the position of the rear end Tb of the product M based on the second video signal processed by the image processing unit 40 . The second misalignment calculating unit 42 also calculates the position of the conveying bar 13 based on a signal from the rotary encoder 15 . The second misalignment calculating unit 42 compares the position of the rear end Tb of the product M with the position of the conveying bar 13 , and calculates the amount of misalignment in the conveying direction X. The CPU 4 moves the front end of the conveying bar 13 forward by a distance of Δx according to the misalignment amount Δx in the conveying direction X, as shown in FIG. 7H . As a result of this operation, the product M is conveyed to a specific position on the lifter 201 , and the misalignment in the conveying direction X is corrected.
[0096] The product M, shown in FIG. 2 , is pushed by the conveying bar 13 and transferred onto the lifter 201 . The specific packaging operation described above is then performed. Meanwhile, the correcting conveyor 21 returns to its original position.
Second Embodiment
[0097] In the first embodiment of the present invention, the misalignment was corrected by moving the product M according to the amount of misalignment of the product M. In the second embodiment of the present invention, the product M is not moved, instead, the film F is moved in the width direction Y of the product M according to the amount of misalignment of the product M.
[0098] As shown in FIG. 10A , the product M is conveyed while the misalignment thereof from the center line CY (reference line C) in the width direction Y of the lifter 201 remains uncorrected. The CPU 4 calculates the final amount of misalignment of the product M based on the second video signal that is photographed by the camera 2 . The CPU 4 drives the film supply device 202 (shown in FIG. 8 ) according to the amount of misalignment, and moves the film F to a position (shown by the dashed line in FIG. 10A ) in the width direction Y according to the misalignment of the product M.
[0099] Then, as shown in FIG. 10B , a label L is attached by a label attaching device 12 (shown in FIG. 1 ) to the top surface of the product M that is wrapped by the film F. According to the amount of misalignment of the product M, the transverse distance Ly of the label L, which is the distance from the edge Te of the product M to the attached position, is changed. Moreover, the longitudinal distance Lx of the label, which is the distance from the rear end Tb of the product M to the attached position, is also changed. Specifically, the horizontal distance Ly is calculated by adding the amount of misalignment of the product M in the width direction Y to a pre-set distance Ly. Similarly, the longitudinal distance Lx is calculated by adding the amount of misalignment of the product M in the conveying direction X to a predetermined distance.
Third Embodiment
[0100] Referring now to FIGS. 11 to 14 , a packaging system in accordance with a third embodiment will now be explained. The third embodiment of the present invention is largely similar to the first embodiment of the present invention, shown in FIGS. 1 through 9 , in terms of the configuration, function, and operation thereof.
[0101] In FIG. 11 , the correcting conveyor 21 is comprised of a moving plate 29 arranged below a conveyor belt 21 b that constitutes the second conveying surface 22 a. A cam groove 23 a , similar to the one in FIG. 3 , is formed in the moving plate 29 , whereby the moving plate 29 is capable of moving in the width direction Y.
[0102] Specifically, the second conveying surface 22 a is provided downstream of the first conveying surface 102 in order to convey the product M received from the first conveying surface 102 to the lifter 201 . The second conveying surface 22 a is formed separately from the first conveying surface 102 , and configured to be movable within a specific range in the first and second width directions Y 11 and Y 12 that are substantially orthogonal to the conveying direction X of the product M. The width of the second conveying surface 22 a is smaller than the width of the first conveying surface 102 . However, the size of the moveable range of the second conveying surface 22 a is approximately corresponds to the width of the first conveying surface 102 . The moving unit 23 displaces the position of the product on the second conveying surface 22 a in the width direction Y by moving the second conveying surface 22 a in the width direction Y within the moveable range.
[0103] As shown in the cross section in FIG. 12 , the moving plate 29 has a curved cross section, and comprised of a supporting unit 29 a having concave shape in the mid-section thereof and disposed below the correcting conveyor 21 b , and a pair of exposed parts 29 b protruding to the left and right sides of the second conveying surface 22 a and formed integrally with the supporting unit 29 a. The top surfaces of the exposed parts 29 b are formed to be slightly lower in height than the top surface of the second conveying surface 22 a , whereby the exposed parts 29 b do not interfere with the conveying of the product M by the second conveying surface 22 a.
[0104] Fixing covers 28 are arranged at the left and right ends of the moving plate 29 . The ends of the exposed parts 29 b and the ends of the fixing covers 28 overlap each other, even when the correcting conveyor 21 b moves to the very left or very right end within the moving range, whereby the contents of the tray T will be prevented from falling under the conveyor 22 , shown in FIG. 11 .
[0105] In accordance with the direction of misalignment and the amount of misalignment in the width direction Y as detected by the camera 2 , the microcomputer (control unit) 3 (shown in FIG. 4A ) drives the moving unit 23 before the product M is conveyed onto the second conveying surface 22 a , and moves the second conveying surface 22 a in advance in the first or second width direction Y 11 , Y 12 . The microcomputer 3 drives the moving unit 23 , after the product M has been conveyed onto the second conveying surface 22 a , and moves the second conveying surface 22 a in the first or second width direction Y 11 , Y 12 , that is opposite the previous width direction, to correct the misalignment of the product M in the width direction. In the present embodiment, the misalignment of the product M is corrected regardless of the extent of the misalignment of the product M in the width direction Y.
[0106] The conveying unit conveys the product M from the first conveying surface 102 onto the lifter 201 via the second conveying surface 22 a. The conveying unit is comprised of a conveying bar 13 that comes into contact with the rear end of the product M on the first conveying surface 102 and configured to convey the product in the conveying direction, a driving chain 104 (first conveying unit), and a motor 25 (second conveying unit) configured to move the second conveying surface 22 a along the conveying direction Y. The second conveying speed V 2 of the second conveying unit is set to a higher value than the first conveying speed V 1 of the first conveying unit.
[0107] Before describing the operation of the supply device according to the present embodiment, the disadvantages in the case that the second conveying surface 22 a is not moved in advance, but rather, the second conveying surface 22 a is moved in the width direction Y after the product M is conveyed onto the second conveying surface 22 a will now be described.
[0108] As shown in FIG. 13A , when the second conveying surface 22 a is moved in the width direction Y after the product M placed on the first conveying surface 102 is conveyed onto the second conveying surface 22 a , the tray T sometimes could protrude in the width direction Y out of the second conveying surface 22 a , as shown by the dashed line. In this situation, the frictional conveyance force F applied by the second conveying surface 22 a to the bottom surface of the tray T is misaligned with the center of gravity G of the product M. Therefore, a moment acts around the tray T, which prevents the tray T from being conveyed in a sufficiently stable manner, and easily results in the disorder of the orientation of the tray T, as shown in FIG. 13B .
[0109] Next, the operation of the supply device 20 according to the third embodiment of the present invention will be described with reference to FIG. 14 .
[0110] When the product M is placed on the first conveying surface 102 , as shown in FIG. 14A , the distances Y 1 and Y 2 are determined with a specific timing. Moreover, the misalignment amount Δy in the width direction Y and the misalignment directions Y 11 and Y 12 are calculated by the method described in the first embodiment of the present invention. Based on the calculated results, the second conveying surface 22 a moves in the width direction Y by a distance equal to the amount Δy, which is the misalignment amount Δy of the product M in the direction of misalignment, as shown by the dashed line, before the downstream end of the product M or the center of gravity G of the tray T (generally the geometric center of the tray) is conveyed to the upstream end 22 b of the second conveying surface 22 a.
[0111] When the position of the tray T is not tilted as shown in FIG. 14B , the centers Tc and 21 c of the tray T and the second conveying surface 22 a in the width direction Y nearly align with each other as a result of the movement.
[0112] After the movement, when the tray T begins to be transferred onto the second conveying surface 22 a , as shown by the solid line in FIG. 14B , or when the entire tray T is completely transferred onto the second conveying surface 22 a , the second conveying surface 22 a moves in the direction opposite the previous movement direction by a distance equal to Δy, as shown by the dashed line. The centers of the tray T and the correcting conveyor 21 in the width direction thereby nearly align with each other, as shown by the dashed line. Specifically, the product M is centered.
[0113] Since there is no danger of the tray T protruding in the width direction Y out of the second conveying surface 22 a during the transfer, there is also no danger of the tray T being tilted, like the situation shown in FIG. 13B that was previously described. In other words, a stable conveyance of the tray T can be expected, in which the tray T is conveyed without being tilted, as shown by the dashed line in FIG. 14B . As a result, an excellent packaging finish can be expected.
[0114] However, since the pushing surface 13 f of the conveying bar 13 shown in FIG. 11 is formed in a comb-teeth pattern with many notches, if the tray is soft, the rear end of the tray T sometimes is caught in the gaps of the pushing surface 13 f during the conveyance. Therefore, when the second conveying surface 22 a moves in the width direction Y, there is a danger that the rear end of the tray T will be caught on the pushing surface 13 f of the conveying bar 13 , which could disorient the position of the tray T, or the specific movement amount Δy in the width direction Y might not be achieved.
[0115] The same problem also occurs when the product M, after packaged with a film, is weighed and priced. More specifically, because the product M has already been packaged and the stretched film is highly viscoelastic, the rear end of the product M may adhere to the pushing surface 13 f , and with the frictional force, it may stick to the pushing surface 13 f . Therefore, there is a danger of the disorientation of the position of the product M, similar to the situation previous described.
[0116] Accordingly, in the present embodiment, the conveying speed V 2 of the conveyor 22 is set to a higher value than the conveying speed V 1 of the conveying bar 13 . Therefore, when the tray T begins to be transferred onto the second conveying surface 22 a as shown by the solid line in FIG. 14B , the rear end of the tray T begins to separate from the pushing surface 13 f that is shown in FIG. 11 . Therefore, there is no danger that the movement of the tray T in the width direction Y will be hindered by the comb tooth-shaped pushing surface 13 f. In addition, there is no danger of the disorientation of the position of the product M or the specific movement amount Δy not achieved. As a result, an excellent packaging finish can be expected.
[0117] In the present embodiment, the misalignment amount Δy in the width direction, illustrated in FIG. 14A , and the direction of misalignment may be determined only prior to the time the tray T is conveyed after it is placed on the conveyor, only after the tray begins to be conveyed, or both before and after the tray begins to be conveyed.
[0118] In addition, in this embodiment, there is no need to move the second conveying surface 22 a by a distance corresponding to the entire misalignment amount Δy determined. For example, the misalignment may be corrected by first determining the first misalignment amount Δy 1 in the width direction on the first conveying surface 102 before the tray begins to be conveyed, and then determining the second misalignment amount Δy 2 in the width direction after the tray begins to be conveyed, and moving the second conveying surface 22 a in one width direction Y in advance by an amount equal to Δy 1 before the tray T begins to be transferred onto the second conveying surface 22 a , and then moving the second conveying surface 22 a in the other width direction Y (opposite the previous width direction) by a distance of (Δy 2 −Δy 1 ) after the tray T is transferred onto the second conveying surface 22 a. In this case, the second conveying surface 22 a is moved by a distance equal to Δy 2 , and returned to its original position after the misalignment is corrected.
[0119] Furthermore, the second conveying surface 22 a may be moved twice in advance so as to accommodate both the two determined misalignment amounts Δy 1 and Δy 2 . Specifically, the second conveying surface 22 a may be immediately moved in advance by a distance equal to Δy 1 after the first misalignment amount Δy 1 of the tray T is determined, and the second conveying surface 22 a may be immediately moved in advance by a distance equal to (Δy 2 −Δy 1 ) after the second misalignment amount Δy 2 of the tray T is determined.
[0120] There is also no need for the tray to be completely centered. For example, the second conveying surface 22 a may be moved in advance by a distance equal to only one of the determined misalignment amounts Δy 1 or Δy 2 .
[0121] FIGS. 15A and 15B show the preferred shapes and structures of the conveying bar 13 that will prevent the tray from turning over. As shown in FIG. 11 , the conveying bar 13 is rotatably driven by a driving chain 104 such as a roller chain, for example. Since a small gap is formed between the pins and rollers in the roller chain, the conveying bar 13 shown in FIG. 15A is rotated to slightly rise in the direction of the arrow R when encountering the gaps. In this case, the angle formed by the pushing surface 13 f of the conveying bar 13 that pushes the tray T increases, and there is a danger that the tray T will be scooped up and overturned from underneath.
[0122] The conveying bar 13 shown in FIG. 15A is inclined in the conveying direction X, such that the top end 13 t extends farther in the direction X than the bottom end 13 u. Therefore, the danger that the tray T will be scooped up from underneath is thereby eliminated, even if the conveying bar 13 is slightly rotated so as to rise up in the direction of the arrow R.
[0123] The position of the center of gravity in the product M is sometimes off centered in the conveying direction X. In this case, there is a danger that the rear end Tb of the tray T shown in FIG. 15B will rise up in the direction U, and the product M will be overturned when the conveying bar 13 pushes the tray T.
[0124] In FIG. 15B , an overhanging member 13 a is fixed in place at the top end 13 t of the conveying bar 13 . This overhanging member 13 a protrudes from the top end 13 t to a greater distance in the conveying direction X than the top end 13 t. Therefore, it is possible to prevent the product M from being overturned even if the rear end Tb of the tray T rises up in the direction U.
[0000] Modification A
[0125] The amount of misalignment of the product M may be determined by aligning a plurality of reflective light quantity detectors in the width direction Y.
[0000] Modification B
[0126] In addition, in the first embodiment of the present invention, it is not necessary to move the conveyor 22 in advance according to the amount of misalignment of the product M in the width direction Y. Alternatively, the conveyor 22 may be moved in advance in the width direction according to the second misalignment amount.
[0000] Modification C
[0127] Moreover, in the first and third embodiments of the present invention, the second conveying surface 22 a is formed on the surface of the belt of the conveyor 22 . However, the second conveying surface 22 a may be formed on the surface of a resinous flat plate or a roller, or the like. Furthermore, the amount of misalignment of the product may be corrected by a guiding member or the like, instead of the conveyor 22 .
[0000] Modification D
[0128] In the first and third embodiments of the present invention, the position of the conveying bar 13 in the conveying direction X was specified by an encoder provided to the drive motor of the conveying bar 13 . However, the position of the conveying bar 13 may be specified by the rotational position of the driving chain 104 , or directly detected by using an optical sensor or the like.
[0000] Modification E
[0129] In addition, as another example of a packaging system to which the present invention is applied, instead of the folded packaging as exemplified in the previous embodiments, the present invention can also be similarly applied to a so-called top-sealing packaging device. One example of a top-sealing packaging device is the packaging device disclosed in U.S. Pat. No. 6,666,005.
General Interpretation of Terms
[0130] In understanding the scope of the present invention, the term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function. In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Finally, terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. For example, these terms can be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies.
[0131] While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
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A packaging system is disclosed that packages a product by supplying the product onto a lifter by means of a supply device, pushing the product on the lifter up to a packaging station, and covering the top surface of the product with a film. The packaging system includes a conveying unit that contacts the rear end in the conveying direction of the product on the supply device and configured to convey the product onto the lifter, a detection unit configured to determine the amount of misalignment of the product in the conveying direction and/or the width direction that is orthogonal to the conveying direction, while the product is being conveyed by the conveying unit, and a control unit configured to control the devices in the system to perform in accordance with the amount of misalignment.
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This application claims priority from Korean Patent Application No. 10-2007-0089504 filed on Sep. 4, 2007 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a laundry treatment machine and a door switch thereof, and more particularly, to a laundry treatment machine and a door switch thereof, which contributes to the improvement of the durability and the safety of a laundry treatment machine by preventing the infiltration of water into a switch housing unit.
2. Description of the Related Art
Laundry treatment machines are classified into washing machines removing dirt or dust from clothes or bedclothes by using water and detergent and using mechanical operations, dryers drying wet laundry by using a dry, hot wind generated by a heater and using mechanical operations, and combination washer dryers performing both a washing function and a drying function.
Drum-type washing machines, which are one type of washing machine, include a cabinet, a tub installed in the cabinet and holding wash water, and a drum installed in the tub and holding laundry.
The cabinet includes a cabinet main body which is open at the top and the front of the cabinet main body, a top cover which is installed on top of the cabinet main body, and a front panel which is installed at the front of the cabinet main body and has a laundry inlet/outlet hole formed at the front of the front panel. A door is connected to the front panel 8 by a hinge so as to open or close the laundry inlet/outlet hole. A door switch is provided on the front panel and determines whether the door is open or closed. The door switch includes a pressing pin which can be pressed by the door, and a switch housing unit which is connected to the pressing pin and includes a contact terminal.
Conventionally, water flown along the front panel is highly likely to infiltrate into the switch housing unit during a water leak test or during a typical washing operation. If water infiltrates into the switch housing unit, the contact terminal of the switch housing unit may be short-circuited, the door switch may malfunction due to an increase in voltage, and safety accidents may occur.
SUMMARY OF THE INVENTION
The present invention provides a laundry treatment machine and a door switch thereof, which contributes to the improvement of the durability and the safety of a laundry treatment machine by preventing the infiltration of water into a switch housing unit.
According to an aspect of the present invention, there is provided a door switch of a laundry treatment machine, the door switch including a switch contact unit which penetrates through a cabinet, is exposed at the front of the cabinet, and may or may not be placed in contact with a door according to whether the door is open or closed; a switch housing unit which is connected to the switch contact unit and is installed in the cabinet; and a water infiltration prevention unit which isolates the switch housing unit from the cabinet so that the switch housing unit and the cabinet can be a predetermined distance apart from each other, the water infiltration prevention unit preventing the infiltration of water flown along the cabinet into the switch housing unit.
The water infiltration prevention unit may include a coupler coupled to the cabinet and a plurality of connectors connecting the coupler and the switch housing unit.
The cabinet may include a switch hole and the coupler may be coupled to the cabinet by being inserted into the switch hole.
The coupler may be inserted into the switch hole in the direction of front and rear of the cabinet, and may be disposed at the front of the cabinet.
The coupler may be inserted into the switch hole in the direction of front and rear of the cabinet, and may be formed as a panel that covers the switch hole.
The connectors may include a plurality of ribs protruding from the switch housing unit toward the coupler and the ribs may be evenly spaced apart from one another.
The cabinet and the switch housing unit may be hook-coupled to each other.
The door switch may also include a mounting bracket, which is installed in the cabinet and is hook-coupled to the switch housing unit.
One of the switch housing unit and the mounting bracket may include a hook protruding therefrom, and the other one of the switch housing unit and the mounting bracket may include an engaging protrusion engaging with the hook.
According to another aspect of the present invention, there is provided a door switch of a laundry treatment machine, the door switch including a switch contact unit which penetrates through a cabinet, is exposed at the front of the cabinet, and may or may not be placed in contact with a door according to whether the door is open or closed; a switch housing unit which is connected to the switch contact unit and is installed in the cabinet; and a water infiltration prevention unit which isolates the switch housing unit from the cabinet so that the switch housing unit and the cabinet can be a predetermined distance apart from each other, the water infiltration prevention unit including a discharge unit and preventing the infiltration of water flown between the cabinet and the switch housing unit into the switch housing unit by discharging the water through the discharge unit.
According to another aspect of the present invention, there is provided a laundry treatment machine including a cabinet in which a tub and a drum are disposed, the cabinet including a laundry inlet/outlet hole formed at the front of the cabinet; a door which opens or closes the laundry inlet/outlet hole; a switch contact unit which penetrates through a cabinet, is exposed at the front of the cabinet, and may or may not be placed in contact with a door according to whether the door is open or closed; a switch housing unit which is connected to the switch contact unit and is installed in the cabinet; and a water infiltration prevention unit which isolates the switch housing unit from the cabinet so that the switch housing unit and the cabinet can be a predetermined distance apart from each other, the water infiltration prevention unit preventing the infiltration of water flown along the cabinet into the switch housing unit.
The water infiltration prevention unit may include a coupler coupled to the cabinet and a plurality of connectors connecting the coupler and the switch housing unit.
The cabinet may include a switch hole and the coupler may be coupled to the cabinet by being inserted into the switch hole.
The coupler may be inserted into the switch hole in the direction of front and rear of the cabinet, and may be disposed at the front of the cabinet.
The coupler may be inserted into the switch hole in the direction of front and rear of the cabinet, and may be formed as a panel that covers the switch hole.
The connectors may include a plurality of ribs protruding from the switch housing unit toward the coupler and the ribs may be evenly spaced apart from one another.
The cabinet and the switch housing unit may be hook-coupled to each other.
The door switch may also include a mounting bracket, which is installed in the cabinet and is hook-coupled to the switch housing unit.
One of the switch housing unit and the mounting bracket may include a hook protruding therefrom, and the other one of the switch housing unit and the mounting bracket may include an engaging protrusion engaging with the hook.
In short, the switch housing unit is a predetermined distance apart from the cabinet. Thus, water flown along the cabinet may be able to be discharged through the space between the cabinet and the switch housing unit. Therefore, it is possible to minimize the infiltration of water into the switch housing unit and to improve the durability and the safety of the door switch.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 illustrates a perspective view of a drum-type washing machine according to an exemplary embodiment of the present invention;
FIG. 2 illustrates a cross-sectional view of a door switch shown in FIG. 1 ; and
FIG. 3 illustrates a lateral view of the door switch shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention will hereinafter be described in detail with reference to the accompanying drawings in which exemplary embodiments of the invention are shown, and taking a drum-type washing machine as an example of a laundry treatment machine.
FIG. 1 illustrates a perspective view of a drum-type washing machine according to an exemplary embodiment of the present invention. Referring to FIG. 1 , the drum-type washing machine includes a cabinet, which forms the exterior of the drum-type washing machine, a tub (not shown), which is installed in the cabinet and holds wash water, and a drum 2 , which is installed in the tub and holds laundry.
The cabinet includes a cabinet main body 4 , which is open at the top or the front of the cabinet main body 4 , a top cover 6 , which is installed so as to cover the top of the cabinet main body 4 , and a front panel 8 , which is installed so as to cover the front of the cabinet main body 4 and has a laundry inlet opening through which laundry is placed into the drum-type washing machine.
A control panel 10 is installed on one side of an upper portion of the front panel 8 and displays various information regarding the operating state of the drum-type washing machine. A detergent container 12 is installed on the other side of the upper portion of the front panel 8 and contains detergent.
A door 14 is installed on the front panel 8 by a hinge so as to open or close the laundry inlet/outlet hole. A door switch 20 is provided on the front panel 8 and determines whether the door 14 is open or closed.
FIG. 2 illustrates a cross-sectional view of the door switch 20 shown in FIG. 1 , and FIG. 3 illustrates a lateral view of the door switch 20 shown in FIG. 2 . Referring to FIGS. 2 and 3 , the door switch 20 includes a switch contact unit 22 , which may or may not be placed in contact with the door 14 according to whether the door 14 is open or closed, a switch housing unit 24 , which is connected to the switch contact unit 22 , and a water infiltration prevention unit, which prevents the infiltration of water into the switch housing unit 24 by isolating the switch housing unit 24 from the front panel 8 so that the switch housing unit 24 from the front panel 8 can be a predetermined distance apart from each other.
The switch contact unit 22 protrudes from the switch housing unit 24 toward the door 14 . The switch contact unit 22 may be implemented as a pressing pin that can be pressed by the door 14 .
The switch housing unit 24 may be formed of a plastic material through injection molding. A number of electric elements such as terminals may be installed in the switch housing unit 24 .
The water infiltration prevention unit includes a coupler 26 , which is coupled to the front panel 8 , and a plurality of connectors 28 , which connect the coupler 26 and the switch housing unit 24 .
The coupler 26 may be formed as a panel. The coupler 26 may be inserted into a switch hole (not shown) in the direction of front and rear of the cabinet on the front panel 8 , and may be disposed at the front of the front panel 8 . The coupler 26 may cover the switch hole.
The connectors 28 may be formed as ribs that protrude from the switch housing unit 24 toward the coupler 26 . The connectors 28 may be evenly spaced apart from one another, and thus, a space s may be provided between the connectors 28 . The spaces s may serve to prevent water from accumulating between the front panel 8 and the switch housing unit 24 by permitting water to flow there between.
A mounting bracket 34 is installed on the front panel 8 , and is coupled to the switch housing unit 24 . The mounting bracket 34 has a hole in the middle. The hole of the mounting bracket 34 corresponds to the switch hole. First and second engaging protrusions 34 a and 34 b are formed on either side of the hole of the mounting bracket 34 .
The mounting bracket 34 and the switch housing unit 24 may be hook-coupled to each other by using a hook 30 and an engaging jaw 32 . More specifically, the hook 30 protrudes from one side of the switch housing unit 24 , and the engaging jaw 32 protrudes from the other side of the switch housing unit 24 . The hook 30 may extend long enough to have elasticity.
The hook 30 may be coupled to the first engaging protrusion 34 a , and the engaging jaw 32 may engage with the second engaging protrusion 34 b.
The operation of the door switch 20 will hereinafter be described in detail.
Laundry is inserted into the drum 2 , and then the door 14 is closed. Thereafter, the drum-type washing machine is driven by manipulating the control panel 10 .
When the door 14 is closed, the door 14 presses the switch contact unit 22 . If the switch contact unit 22 is pressed, the switch housing unit 24 may determine that the door 14 is closed.
If a liquid such as water flows toward the front panel 8 by accident or on purpose as part of a water leak test, the water may either flow downward along the front panel 8 or may flow through the spaces 6 between the connectors 28 away from the door switch 20 .
Since the switch housing unit 24 is isolated from the front panel 8 , it is possible to prevent the infiltration of water into switch housing unit 24 even when water flows along the front panel 8 .
Even when water flows between the front panel 8 and the switch housing unit 24 , the water is discharged through the spaces s, and thus, it is possible to prevent the infiltration of water into switch housing unit 24 .
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
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A laundry treatment machine and a door switch thereof are provided. The door switch includes a switch housing unit, which is a predetermined distance apart from a cabinet. Thus, water flown along the cabinet may be able to be discharged through the space between the cabinet and the switch housing unit. Therefore, it is possible to minimize the infiltration of water into the switch housing unit and to improve the durability and the safety of the door switch.
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RELATED FIELD OF INVENTION
The present invention is generally directed to network gateways, and in particular, to a gateway that routes network communications, received at the gateway, based on the utilities or transformations applied to the communications by the gateway.
BACKGROUND
Numerous network services are now available for communications on and between networks such as the Internet, wide area corporate networks as well as networks at a single site. Such services (also denoted “network services” herein) include firewall protection, network address translation (NAT), encryption/decryption, secure communication tunnels such as is provided in virtual private networks (VPN), file transfer protocol (FTP) services, voice over Internet protocol (VoIP), etc. For inter-network communication, these services are preferably performed at a small number of designated nodes on a network so that the services can be more easily maintained and supervised by network system administrators. In particular, for inter-network communication, these services may be concentrated at substantially only nodes of a network, wherein such nodes directly interface with other networks. One particular type of such network interface nodes at which such services are concentrated is known as a “gateway”, wherein each such gateway node performs one or more of the above-identified services as well as routes communications between the networks to which the gateway node is connected (e.g., has a corresponding network address thereon). Thus, such gateway nodes may be considered as value added intermediaries that provide enhanced communications (e.g., more secure, and/or more reliable communications) between two parties on different networks that communicate via the gateway.
Referring to FIG. 1 , heretofore such a gateway (e.g., gateway node 20 ) may provide network services such as those described above for data transmissions between the networks 14 , 16 , and 18 connected to the gateway. In particular, such services are generally applied for the benefit of users in certain predetermined networks (denoted “internal” networks herein”), e.g., networks 14 and 16 in FIG. 1 . Thus, for IP transmissions from the “external” network 18 that are bound for an IP address in one of the networks 14 and 16 (via the gateway 20 ), such network services can be applied by the gateway. However, the application of such network services has been limited and inflexible.
Prior to providing further description of such prior gateway limitations and inflexibility, the notation of FIG. 1 is briefly described. Representative IP addresses in FIG. 1 are shown as call-outs for many of the interfaces between network components. As one skilled in the art will understand, there is a unique IP address for each end of each communication path between any two network components. Thus, referring to the communications link between router 32 and router 48 of the network 14 , the router 48 knows the router 32 by the IP address 12.1.2.2, and the router 32 knows the router 48 by the IP address 12.1.2.1. Additionally, the routers 24 , 32 , and 36 that are directly connected to the gateway node 20 have respective IP addresses 172.16.1.1, 194.176.1.14, and 192.168.1.32.
The gateway node 20 of FIG. 1 may be substantially isolated from changes to IP addresses external to networks 14 and 16 by the router 24 . For example, the routing table 28 at the gateway node 20 has explicit routing information only for destination IP addresses: (a) in the IP address range 11.1.2.0/24 (i.e., the 254 IP addresses: 11.1.2.1 through 11.1.2.254, as one skilled in the art will understand) for routing via router 32 (having IP address 194.172.1.14), and (b) in the IP address range 10.1.1.0/24 (i.e., the 254 IP addresses: 10.1.1.1 through 10.1.1.254) for routing via the router 36 (having IP address 192.168.1.32). Thus, for any IP transmission encountered having a destination IP address not in the above ranges (a) and (b), the gateway node 20 assumes the IP transmission is for a destination external to the networks 14 and 16 . Accordingly, the gateway node 20 routes such an IP transmission to a default route which in the present case routes the transmission to the router 24 (i.e., IP address 172.16.1.1). Note that the router 24 is typically a network device on the Internet side of the gateway node 20 . Thus, if an IP transmission that has endpoint 40 of network 18 as a destination, the gateway node 20 does not have an IP address range for the endpoint 40 , but the gateway is able to route the transmission to the router 24 .
Heretofore, however, such gateway node 20 has not been isolated from network changes within the corresponding network(s) (e.g., 14 and 16 in FIG. 1 ) for which it provides network services. For example, for an IP transmission from endpoint 40 to, e.g., user station 44 having IP address 11.1.2.2, if the router 48 network connection is modified so that this router connects directly to the gateway node 20 and no longer connects to router 32 , then the routing table 28 at the gateway must be changed, replacing the entry:
<11.1.2.0/24 194.172.1.14> with the entry <11.1.2.0/24 12.1.2.1>.
Otherwise, the IP transmission will not reach user station 44 . Unfortunately, requiring the gateway node 20 to perform such detailed routing implies that for at least large networks, frequent routing table 28 changes can be required.
Additionally, heretofore there has been no effective way to configure a gateway node 20 so that the routing decision for an IP transmission is determined based upon what gateway supplied network services (e.g., firewall protection, NAT, encryption/decryption, VPN, file FTP, VoIP, etc.) are applied to the IP transmission. At most, such a prior art gateway node 20 may have specified gateway services performed depending on the source (e.g., originating IP address) of an IP transmission, or on an IP destination address determined by the gateway 20 . For example, such a gateway node 20 may have been configured so that a particular set of network services are applied to IP transmissions whose source is external to the networks 14 and 16 . Additionally, such a gateway node 20 may have been configured so that a second set of network services could be applied to intra-network IP transmissions (e.g., between user station 44 and user station 52 ). However, since there has been no effective way to configure a gateway node 20 to make its routing decision for an IP transmission based upon what gateway supplied network services are performed, routing configuration changes are always required when new networks are added that need these networks services.
Accordingly, it is desirable to provide enhancements to gateway nodes 20 wherein such enhancements both isolate such gateways from substantially all network addressing changes (i.e., both internal and external network addressing changes), and also provide enhancements so that such gateways can selectively route inter-network communications according to the services applied to such communications.
Terms and Descriptions
Data Packet: A single network frame transmission from one network endpoint to another. The term “data packet” is typically contrasted to a “Voice Packet” by the presumption that the delivery of data packets is less time-sensitive than the delivery of voice packets to achieve a productive level of communication.
Denial of Service Analysis: An analysis of network communications for detecting an illicit application that is transmitting certain types of requests to a user station (e.g., an IP telephone) so that the telephone becomes effectively non-responsive to one or more legitimate network requests. For example, the illicit application might send a high volume of requests or requests that are known to reset the user station.
DiffServ bits: The six most-significant bits (MSB) of the ToS field of IPv4, as one skilled in the art will understand.
DMZ zone: For a given organization or company, a DMZ zone (demilitarized zone) is a collection of one or more networks, wherein each network (N) of the networks allows users of the network N to access a public network (e.g., the Internet), and/or the network N provides a service that is publicly available to at least one party outside the organization or company. For example, the network 14 ( FIGS. 1 and 2 ) may provide access to a particular Internet page(s), or provide network access to customer support personnel. Additionally, users of the network 14 may need to access a public network for email, file transfer protocol (FTP) data transfers, Internet web servers, etc.
GRE: Generic Routing Encapsulation: Tunneling protocol developed by Cisco Systems Inc. that encapsulates a wide variety of protocol packet types inside an IP packet.
H 323: An ITU standard suite of IP-based protocols used for VoIP call signaling (e.g., for call setup, negotiation and call teardown, as one skilled in the art will understand).
H.323 Gatekeeper: A network entity that controls H.323 endpoints (e.g., IP Phones). The primary functions of the H.323 Gatekeeper are to control H.323 endpoints that are admitted to the network (by authenticating those endpoints), and translating the logical addresses (e.g., a phone extension: 123) to the corresponding IP addresses supporting that extension (e.g., to an IP address: 10.0.0.1).
H.323 Proxy: A network entity that establishes H.323 Call Signaling connections (i.e., TCP connections) on behalf of an H.323 endpoint (e.g., IP Phone).
H.323 Session: An ongoing VoIP call signaling connection (i.e., TCP connection) between an H.323 endpoint (e.g., an IP Phone), and an H.323 Gatekeeper.
ITU: Abbreviation for International Telecommunications Union, which is a standards body established by the United Nations to set international telecommunications standards.
Insecure zone: For a given organization or company, an insecure zone is a collection of one or more networks, wherein communications with each of the networks can not be assumed to be secure. For example, there may no guarantee (without taking explicit actions to provide such a guarantee) that communications with a source from an insecure zone: is not being intercepted or spoofed, is free of viruses, worms, malware, and/or spyware. There may be additionally no assurance that such communications are even from an intended source. Typically, the insecure zone will include the Internet and/or any other publicly accessible network whose access can not be controlled by the organization or company.
RTP: Abbreviation for Real Time Protocol, which is A UDP-based protocol for carrying media streams (e.g., voice, video, multi-media) as one skilled in the art will understand.
RSVP: Abbreviation for Resource Reservation Protocol, which a protocol used to provide quality of service (QoS) services. RSVP is an “end-to-end” protocol where each device in the network path between (and including) the endpoints participates in the RSVP negotiation to reserve the resources necessary (e.g., bandwidth, and DSPs) to deliver the agreed-upon level of service.
Secure zone: For a given organization or company, a secure zone is a collection of one or more networks, wherein each network is only accessible from known and authorized users (e.g., company employees). Typically, unauthorized access will be denied, and firewalls will be in place to prevent certain types of communications from entering the network (e.g., communications with executable downloads, scripts, viruses and/or advertising). Moreover, communication external to the secure zone may be via a virtual private network (VPN) as one skilled in the art will understand.
Semi-Secure zone: For a given organization or company, a semi-secure zone is a collection of one or more networks, wherein communications on each network is desired to be as secure as networks identified as being included in a secure zone. However, networks of a semi-secure zone use a transmission medium that may be more vulnerable to attack than another medium due to, e.g., the ease of interception of the network communications. For example, a network in a semi-secure zone may be partially or wholly wireless such as a wireless LAN. Accordingly, communications on such a network are likely to be encrypted or encrypted with a stronger encryption than communications with a network of another zone.
Stateful Inspection The ability of a network device, typically a firewall, to retain “state” information about ongoing network sessions. When a packet is allowed to traverse a stateful firewall according to the firewall's rules, the firewall will only permit traffic that would normally be returned in response to the original packet from the original packet's destination
ToS field: The second byte of the IP header in IPv4.
Zone: A collection of one or more communication networks that communicate with a network gateway via a single router, wherein each of the networks have a common security classification related to the security of communications from nodes of the networks to the gateway.
SUMMARY
The present invention is directed to a network gateway for routing communications between a plurality networks (or between collections of networks), wherein embodiments of the invention are such that substantially all network addressing changes in each (or at least some) of these networks are transparent to the gateway. Additionally, embodiments of the present invention may be directed to a network gateway wherein the gateway identifies and applies network services to communications received at the gateway according to the structure and/or contents of the data transmitted in the communications. Moreover, embodiments of the present invention may be directed to determining output destinations for gateway received communications, wherein for such a communication, the corresponding output destination is identified according to one or more of: (a) an identification of a source of a communication, (b) the structure of the data in a communication, (c) the contents of the data in the communication, (d) the services identified for application to the data of the communication, and/or (e) the services applied to the data of the communication.
It is an aspect of at least one embodiment of the invention that communications received at the gateway are analyzed for determining which (if any) gateway services are to be applied to such communications. In particular, such an analysis may classify the communications (or portions thereof, e.g., data packets of packetized communications) according to (a) through (e) immediately above. Moreover, it is yet another aspect of a gateway of the invention that the routing of communications out of the gateway is substantially dependent on such analysis. For example, such a classification of a gateway communication may be all that is needed to identify an output destination of the communication. Alternatively, such a classification in combination with the gateway services applied to such a communication may be sufficient for determining an output destination for the communication. Accordingly, in either case, gateway routing is substantially independent of network addressing changes.
In one embodiment of the gateway, it may provide one or more services for enhancing communications and/or providing additional security to at least one network communicating with the gateway. The following are representative examples of various services that an embodiment of a gateway according to the present invention may provide:
(1.1) Ensure or increase the security of at least one network that communicates with another network (e.g., the Internet) via the gateway. For example, such gateway services may be firewall services (also denoted “FW” herein) such as: virus scans, removal of spam email, prohibit certain types of executable communications from being transferred, prohibit web sites with certain administrator-defined content from being visited, blocking all IP communication considered improper (e.g., blocking all communication into the network that is sourced from a network providing such improper communications), all the while allowing legitimate IP communication to flow. (1.2) Provide appropriate network address translation (also denoted “NAT” herein) to connect a private IP network to a public network (e.g., the Internet) so that internal IP addresses can be hidden and publicly-assigned, routable IP addresses can be conserved. (1.3) Provide services for secure communications (also denoted “VPN” herein) such as encryption, and decryption, as well as, secure tunnels such as virtual private networks. (1.4) Monitor communications for illicit or improper communications to a user station such as: (i) denial of service attacks, wherein an illicit application floods a user station (e.g., an IP telephone) with a sufficiently high volume of requests so that the telephone is effectively non-responsive to one or more legitimate network requests, and/or (ii) “Man-in-the-middle” attacks, wherein an illicit application monitors communications at a user station, and intercepts a registration request by a legitimate application for spoofing a reply to the user station or to the legitimate application. In particular, the illicit application may provide the legitimate application with a false IP address for sending login information so that the illicit application can then login to the legitimate application. (1.5) Monitor application access so that such access conforms to the conditions of a license. (1.6) Provide “proxy” services which establish network communication connections to and/or through a public network (e.g., the Internet) on behalf of requesting user stations. This also allows the originators of such connections to be hidden from a public network and also provides the administrator with a central point of administration.
In at least one embodiment of the invention, at least some of the networks communicating with the gateway according to the present invention are classified by the characteristics of the networks. In particular, such a network may be classified according to how secure (or insecure) communications with the network are perceived to be. Such security classifications are referred to herein as “zones” (see the Terms and Description section hereinabove for further description of a zone, and representative examples such as a “secure zone”, and a “semi-secure zone”). Moreover, an embodiment of the gateway of the invention may use such zone classifications of networks to also assist in determining the destination of communications from these networks when routing such communications out of the gateway. However, it is within the scope of the invention that a gateway according to the present invention may utilize other classifications for networks communicating with the gateway than the zones described hereinabove. For example, networks (or collections of networks) may be classified according to the types of user stations supported. Thus, a network wherein each of the user stations is an IP enabled telephone may be classified differently from a network of personal computers with Internet access.
Further description of advantages, benefits and patentable aspects of the present invention will become evident from the accompanying drawings and description hereinbelow. All novel aspects of the invention, whether mentioned explicitly in this Summary section or not, are considered subject matter for patent protection either singly or in combination with other aspects of the invention. Accordingly, such novel aspects of the present invention disclosed hereinbelow and/or in the drawings that may be omitted from, or less than fully described in, this Summary section are fully incorporated herein by reference into this Summary. In particular, all claims of the Claims section hereinbelow are fully incorporated herein by reference into this Summary section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative example of a prior art gateway 20 in an operational context.
FIG. 2 is an illustrative example of an embodiment of a gateway 20 a according to the present invention.
FIG. 3 is an example of the structured data retained (or accessed) by the routing table/rule base 78 shown in FIG. 2 , wherein such structured data corresponds to rules for both processing data packets received at the gateway 20 a , and determining how to route such data packets out of the gateway.
FIG. 4 shows a high level flowchart of the steps performed by the gateway 20 a according to the present invention.
FIG. 5 shows another embodiment of the structured data retained (or accessed) by the routing table/rule base 78 shown in FIG. 2 .
DETAILED DESCRIPTION
FIG. 2 shows an embodiment of an enhanced network gateway 20 a according to the present invention, wherein this figure shows the gateway 20 a in a substantially similar context to that of the gateway 20 of FIG. 1 (e.g., the networks 14 and 16 may be considered identical to those described with reference to FIG. 1 ). Thus, the gateway 20 a can be considered as a device and system for routing communications between a plurality of networks operably connected to the gateway, wherein each of the networks: (i) includes a plurality of network nodes, each having a corresponding network address so that communications to nodes of the network are routed according to the network addresses, and (ii) the network addresses are administered (e.g., assigned, re-assigned, changed, deleted) independently of the other networks (e.g., a network configuration change to one of the networks does not affect the configuration of any of the other networks).
In particular, the gateway 20 a can:
(2.1) Route communications between the networks internal to an organization or company (e.g., networks for which the services and communication analysis of the gateway 20 a are intended to be of benefit); in FIG. 2 such internal networks are the networks 14 , 16 and 17 ; however, note that it is an aspect of the invention that such routing by the gateway 20 a can be substantially dependent upon the content and/or structure of the data packet(s) being routed as will be described further hereinbelow; and (2.2) Route communications between users of the internal networks, and one or more external networks (i.e., an external network is a network whose communications and configuration are not controllable by the organization or company responsible for the gateway 20 a ), e.g., network 18 represents one such external network.
Note that in FIG. 2 , the networks 14 and 16 are now further specified, respectively, as a network from a DMZ zone, and a network from a secure zone according the description of these zones in the Terms and Descriptions section hereinabove. Moreover, the network 17 is identified as a semi-secure zone according to the description in the Terms and Descriptions section.
The gateway 20 a includes a packet analyzer 70 for analyzing data packets received at the gateway. In particular, the packet analyzer 70 classifies such data packets according to one or more characteristics of the structure and/or content of the data packets. In particular, the packet analyzer 70 classifies such data packets according to their characteristics that identify, e.g., (i) the type of communication (e.g., its protocol, its encryption technique (if any)), (ii) the type of information provided in the packets (e.g., voice data, non-voice data, streaming data, multimedia data, etc.). The packet analyzer 70 determines at least some (if not most or all) of such characteristics substantially independently of both: any source or origination information included in the data packets, and destination information included in the data packets. Representative classifications for which the packets received at the gateway 20 a may be classified are:
(3.1) Data packets transmitted to the gateway 20 a from a particular zone classification, e.g., from a secure zone, an insecure zone, a DMZ zone, or a semi-secure zone; and (3.2) The type of data packets; e.g., data packets identified as one or more of:
(i) Internet packets identified as protocol data, e.g., the protocols: FTP, HTTP, telnet, SSH (i.e., Secure Shell, an application protocol commonly used to secure an interactive typing session between a user and a station under that user's control), DNS (i.e., Domain Name Service, an application protocol used by IP devices to map logical names to actual IP addresses), NetBios (i.e., an application protocol used primarily by Microsoft networking applications, e.g., domain login and Outlook). Note that such identification of Internet packets may be performed by examining the IP protocol being used (e.g., TCP, UDP) and the port being used. For example, SSH packets may be identified by the fact that they use the TCP protocol and are destined for TCP port 22 , as one skilled in the art will understand; (ii) A communication via a virtual private network, e.g., such identification may be performed by the steps at (4.2) below; (iii) Internet packets identified as non-voice packets, e.g., identifications may be performed by the steps at (4.3) below; (iv) Internet packets identified as having VoIP voice content (also referred to as, VoIP “bearer” traffic); e.g., such identification may be performed by the steps at (4.4) below; (iv) Internet packets identified as controlling VoIP calls (also referred to as, VoIP “control” traffic); e.g., such identification may be performed by the steps at (4.4) below; (v) data packets identified as having streaming and/or multimedia content therein; e.g., such identification may be performed by the steps at (4.5) below; (vi) Quality of Service classification of data (see Terms and Description section); e.g., such identification may be performed by the steps at (4.6) below.
The packet analyzer 70 is configured to recognize particular features and/or structures when classifying data packets. For example, the packet analyzer 70 can perform the following tasks to recognize various data packet structures and/or packet content:
(4.1) For determining the identity of the router transmitting data packets to the gateway 20 a , the packet analyzer 70 may inspect the transmission routing information associated with each such packet. Note that during configuration of the gateway 20 a , for each router known to the gateway 20 a as a source of data transmissions, the collection of the one or more networks from which the router receives such transmissions may be assigned a single zone classification such as one of the zones identified in the Terms and Descriptions section above. Thus, the identity (e.g., IP address, alternatively gateway 20 a port number) of each such router can be used to determine the zone type for the communications from the router. (4.2) For identifying data packets transmitted via a virtual private network, the packet analyzer 70 may perform at least one of the following steps:
(i) examine the source and destination IP addresses, and possibly the source and destination TCP and UDP ports of such data packets to determine if the IP addresses and ports match an administratively configured VPN policy, and (iii) identify the protocol of such data packets received at the gateway 20 a when routing to any zone other than a secure zone, e.g., such a protocol may be “ESP” (i.e., IP protocol 50 , Encryption Security Payload, as one skilled in the art will understand), or “AH” (IP protocol 51 , Authentication Header); (iv) identify the packet as received from the internal “Decryption” process; and (v) identify the packet as received from an internal decryption interface, as one skilled in the art will understand.
(4.3) For identifying Internet data packets containing non-voice data, the packet analyzer 70 may perform at least one of the following steps:
(i) examine IP headers of such data packets; in particular, examine the TOS field (described in the Terms and Definition section hereinabove), or the DiffSery bits (also described in the Terms and Definition section hereinabove) from such IP headers or examine the destination TCP or UDP ports, and (ii) examine packets for ports not belonging to those recognized as existing or to new H 323 sessions (identified via stateful inspection, as described in the Terms and Description section hereinabove).
(4.4) For identifying voice data packets, the packet analyzer 70 may perform at least one of the following steps:
(i) examine the TOS field or DiffSery bits from the IP header or examining the destination TCP or UDP ports, and (ii) examine packets identified to be arriving for sessions established through H.323 (identified via stateful inspection).
(4.5) For identifying streaming and/or multimedia data packets, the packet analyzer 70 may: identify the communication protocol for the data packets as, e.g., one of RTP or RSVP, (these terms are described in the Terms and Descriptions section hereinabove). (4.6) For determining a quality of service (QoS) classification for the data packets, the packet analyzer 70 may inspect the IP Packet Header (i.e., TOS field or DiffSery bits) for a bit pattern matching a “highest Class of Service” bit pattern. (4.7) For identifying data packets that are to be processed by a particular application, the packet analyzer 70 may: determine the protocol and the port number of the gateway 20 a for which such packets are to be routed (e.g., FTP packets may be transmitted to port 21 , telnet may be transmitted to port 23 , DNS may be transmitted to port 53 , HTTP may be transmitted to port 80 ). (4.8) For determining packets arriving from a particular interface or network port, the packet analyzer may perform a step of identifying the data by identifying the interface or network port on which the packet was received.
Note that each data packet may be classified into one or more classifications, or the data packet may be classified into a default classification in the event that the packet analyzer 70 identifies no other classification. For example, a data packet may be classified as received from the insecure zone, and being an FTP data packet.
The packet analyzer 70 provides the one or more classifications, for each data packet, to a services analyzer 74 , wherein the services analyzer determines the (any) services to be applied to each data packet. The services analyzer 74 accesses the predetermined routing table/rule base 78 for obtaining data identifying the services to be performed for various data packet classifications as will be described in further detail hereinbelow. Note that the routing table/rule base 78 replaces the routing table 28 of FIG. 1 in that the routing table/rule base is a substantial enhancement of the routing table 28 . In particular, the routing table/rule base identifies services to be applied to various data packets transmitted through the gateway 20 a . An example of such a routing table/rule base 78 is shown in FIG. 3 which is described below.
However, for at least some embodiments of the invention, it is important to note that processing performed by the gateway 20 a also provides the benefits of packet source transparency. That is, the gateway 20 a may only utilize the IP addresses for routers: (a) that are directly connected to the gateway 20 a , and (b) that are available for receiving transmissions from the gateway 20 a . Thus, the operation of the gateway 20 a can be substantially insensitive to IP address changes in the networks that communicate with the gateway. In particular, as long as the zone type designation does not change for the network(s) providing data transmissions to the gateway 20 a , via one of the routers known to the gateway, then the gateway will not need to be reconfigured to reflect such network IP address changes such as adding or deleting IP networks, or assigning different IP addresses to existing user stations. That is, only IP address changes of the routers connected directly to the gateway 20 a need be reflected in the routing table/rule base 78 .
Once the services analyzer 74 determines which (if any) of the one or more gateway 20 a services are to be applied to a data packet, the data packet and the identity of the service(s) (if any) to be applied are provided to the gateway services module 82 for applying the designated services to the data packet. Note that the services may include:
(5.1) Virtual private network processing such as:
(i) encryption of packet data, (ii) decryption of packet data, (iii) application of a signature to a packet (e.g., attaching electronic signature data to a packet for authenticating a source of the packet), (iv) verification of a packet's signature, (v) encapsulation of the packet (i.e., taking the original packet and adding an additional layer 3 header, e.g., IP header, and possibly other headers, e.g., GRE, to the packet, as one skilled in the art will understand), and (vi) decapsulation of the packet (i.e., stripping the encapsulating layer 3 and any other headers, to get the original packet).
(5.2) Network address translation, e.g., for translating an initial destination network address of a data packet into another address that reflects the current network addressing of, e.g., one of the networks 14 , 16 , and 17 . (5.3) Voice over IP processing such as:
(i) prioritization of one or more packets within the outgoing transmission queues of gateway 20 a to improve and/or maintain the voice quality of the transmission, and (ii) establishing H 323 Call setup through an H.323 proxy (see Terms and Descriptions section for a description of these terms).
(5.4) Firewall processing such as examining a packet's content and/or the packet's IP addresses, and discarding the packet if any firewall rules are violated, e.g., rules related to Stateful inspection, and Denial of Service Attack Analysis (see Terms and Descriptions section for a description of these terms). (5.5) Virus processing such as removing email attachments that meet the criteria of known viruses. (5.6) Quality of service processing such as prioritization of one or more packets within the outgoing transmission queues of gateway 20 a to meet configured Service Level Agreements. (5.7) “Proxying” connections on behalf of requesting and/or protected network stations (wherein “proxying” a connection is the establishment, by a third party, of a communication connection between at least two networked stations, and in particular through a public network (e.g., the Internet) on behalf of the networked stations).
Upon application of (zero or more) gateway 20 a services to a data packet, the data packet is provided to an output router module 86 for routing the data packet to its intended destination. Note that the output router module 86 may also access the routing table/rule base 78 for determining where to route the data packet. However, as will be described further hereinbelow, the output router 86 may utilize more information for routing the data packet than is available in, e.g., the routing table 28 of FIG. 1 . In particular, routing may be dependent upon information describing the data packet's source (e.g., its zone, but not its originating IP address), the characteristics of the data packet determined by the packet analyzer 70 , and/or the gateway services applied to the data packet.
The gateway 20 a also includes an administrative interface 90 that, e.g., allows a system administrator 94 (either a person or a network configuration intelligent agent) to reconfigure the gateway 20 a when necessary. In particular, the system administrator 94 may:
(6.1) Modify the routing table/rule base 78 to change, e.g., the services to be applied to particular data packets, to route certain data packets to different routers identified in the routing table/rule base 78 , and/or to specify a different combination of gateway services to apply to data packets; (6.2) Modify the services provided by the gateway 20 a , e.g., add, or delete a gateway service, or, change the operation of an existing gateway service; and/or (6.3) Specify different zone identifiers for the network connections to the gateway 20 a.
FIG. 3 shows a representative example of the routing table/rule base 78 according to the present invention, wherein the data therein is structured in table form (although other data structures are well within the scope of the invention, e.g., tree structures, intelligent agent data repositories, expert system rule bases, etc.). As shown, there is a column (in order from left to right) for each of the following:
(7.1) The zone designations of the source of data packet transmissions. Note that in addition to the zones described hereinabove in Terms and Descriptions section, other and/or alternative zone classifications are within the scope of the invention. For example, there may a zone for communications with one or more third parties wherein substantially all communication via the gateway 20 a with such third parties is via a virtual private network (VPN). Additionally, if the zone of one or more networks can not be clearly established, then such networks (and the router which connects them to the gateway 20 a ) may be assigned a default zone (e.g., categorized as being in an insecure zone). (7.2) Data packet characteristic(s) as determined by the packet analyzer 70 . Note, that FIG. 3 shows only a few representative combinations of such characteristics that may be identified by the packet analyzer 70 . (7.3) Gateway 20 a services sets, wherein this column identifies various combinations of services that are to be applied to particular data packets by, e.g., the gateway 20 a . For example, in the first data row for data packets identified as coming from a secure zone and wherein the data packets may be of any type, no services will be performed by the gateway 20 a . However, in the second row, IP data packets identified as non-voice, non-FTP packets from any zone, except for the secure zone, will have firewall processing applied thereto. Moreover, it is within the scope of the present invention for designating such services to be performed in a particular order; e.g., firewall services may be performed prior to any network address translation service. Accordingly, in FIG. 3 , the notation “→” between identifications of gateway services to be performed designates that the services are to be performed in left to right order. However, other operators are also within the scope of the invention. For example, in the event that such services can be asynchronous (e.g., can be performed in parallel, or the order is not substantially important, such as network address translation, and firewall services), the order of service performance may be determined at the time the data packets are to be processed. In FIG. 3 , the “+” designates such an asynchronous operator between designated services. (7.4) Target IP addresses, wherein entries of this column identify IP addresses of routers directly connected to the gateway 20 a , wherein data packets can be forwarded by the gateway to these routers after the (any) corresponding gateway services are applied.
Each data row of the routing table/rule base 78 may be considered as an “if-then” rule, wherein when the conditions corresponding to the first two columns of the row are satisfied, then the actions corresponding to the second two columns of the row are performed. For example, the third data row is equivalent to the following pseudo-code:
IF (the data packet is not from the secure zone) AND (the data packet is an IP non-voice VPN packet) THEN
Perform VPN processing; Then perform network address translation; and Then transmit the resulting data packet to the router identified by the IP address 192.168.1.32 (e.g., router 36 , FIG. 2 ).
Note that in the embodiment shown in FIG. 3 , the first data row of the routing table/rule base 78 specifies that any data packet from a secure zone is routed, without any services applied, to the router 24 that transfers data packets to the Internet (or another network of an insecure zone). The motivation for such a routing rule is that the only transmissions from the secure zone (e.g., network 16 ) to the gateway 20 a are assumed to be those that are bound for the insecure zone. Accordingly, if a user at a user station within the secure zone transmits a message to a user at a user station in, e.g., the DMZ zone, then, e.g., each of the routers 32 , 36 and 48 may be able to route to one another through a route that bypasses the gateway 20 a , or there may be one or more additional routers (not shown) for routing between such zones and bypassing the gateway 20 a . That is, in the present embodiment of FIG. 3 , it is assumed that the gateway 20 a is primarily intended for routing communications between the insecure zone (e.g., the Internet), and one of the other zones.
Additionally, note that the last two rows of the routing table/rule base 78 are default rules, wherein one of these rules applies if no other rule applies. Thus, in the next to last row, the corresponding rule is equivalent to the following pseudo-code:
IF (the data packet is from any zone except an insecure zone) AND (the data packet is not processed according to a row above the present row) THEN
Perform firewall processing; Then transmit the resulting data packet to the router identified by the IP address 86.33.7.2 (e.g., router 48 ).
FIG. 4 is a flowchart of the steps performed by the embodiment of the present invention illustrated in FIGS. 2 and 3 . In step 404 , the security gateway 20 a receives one or more data packets from one of the routers directly connected to the gateway 20 a via an interface of the gateway (e.g., a private interface, a.k.a., an interface attached to a “Secure” zone such as network 16 of FIG. 2 ). In step 408 , the packet analyzer 70 determines one or more characteristics of the data packet as described hereinabove. In one embodiment, the packet analyzer 70 may terminate packet analysis if it is determined that the data packet is received from a secure zone as per the rule corresponding to the first data row of the routing table/rule base 78 . However, such an embodiment may require configuration of the packet analyzer 70 so that its analysis is data-driven by the information residing in the routing table/rule base 78 . In such an embodiment, the packet analyzer 70 may have a configuration component (not shown) that prioritizes or ranks the various types of analysis to be performed according to, e.g., the most likely data packet characteristics to occur, and/or data packet characteristics that can make further packet analysis unnecessary.
Subsequently, since the first row of the routing table/rule base 78 corresponds to a rule whose only condition is that the packet is from the secure zone, this rule is represented in step 412 . Note that the packet analyzer 70 or the services analyzer 74 may perform step 412 for determining whether the data packet is from the secure zone. In the embodiment where the packet analyzer 70 performs step 412 , and if the determination is positive, the packet analyzer 70 ceases any further packet analysis as described in the enhanced embodiment of the packet analyzer 70 above. In another embodiment, the services analyzer 74 performs step 412 after all packet analysis has been performed. In either case, the services analyzer 74 uses the packet identification results received from the packet analyzer 70 for determining which rule of the rules corresponding to the rows of the routing table/rule base 78 is to be performed. In particular, the rule for each row, sequentially from the top to the bottom of the data rows of FIG. 3 , is inspected to determine whether the conditions of the “SOURCE ZONE” and the “DATA PACKET CHARACTERISTIC(S)” columns are satisfied by the results from the packet analyzer 70 .
If the result from step 412 is negative, then step 416 is performed. If the packet analyzer 70 is still processing the data packet at this step, then the packet analyzer continues to identify characteristics of the data packet as in substep (A) of step 416 . Regardless of whether the packet analyzer 70 performs an analysis of the data packet characteristics or terminates early, the services analyzer 74 evaluates the rules of the routing table/rule base 78 for determining a rule whose conditions according to the first two columns of FIG. 3 can be satisfied. Note that if substep (A) of step 416 is performed, then the services analyzer 74 commences rule evaluation with the rule corresponding to the first data row of FIG. 3 . Alternatively, if substep (A) is not performed, then the services analyzer 74 may commence rule evaluation with the rule corresponding to the second data row of FIG. 3 .
Subsequently, once a rule is found whose conditions are satisfied, the services analyzer 74 identifies the services to be performed according to the “Services Set” column of FIG. 3 , and outputs to the gateway services module 82 the data packet together with an identification of the (any) service(s) to be applied to the data packet (and any designated order to apply such services). In step 420 , the services module 82 applies the identified services (in the order, if any, specified) to the data packet. Additionally, upon application of a service, the services module 82 may associate a label or tag with the data packet indicating that the service was performed on the data packet. Such labels or tags can be useful when there is a plurality of available services that may be performed. In particular, a primary function of the gateway services module 82 can be to efficiently schedule activation of the various services for various data packets. Since such scheduling is likely to depend on the rate at which data packets are received and the activation frequency of the services, the services module 82 may (if there are no constraints otherwise) dynamically and in real-time determine which services are going to be applied to which data packets. Thus, of two data packets requiring services corresponding to the expression “FW+NAT”, the first of these data packets may be processed by a firewall service first and subsequently processed by a network address translation service, and the second of these data packets may be processed by the network translation service first and subsequently processed by a firewall service. Note that such labeling can provide a way to ensure that each service to be applied to the data packet is indeed applied. Additionally, in another embodiment where the gateway 20 a identifies the service(s) to be performed, but the gateway services module 82 does not have the resources to perform one or more of the services (e.g., due to time constraints on the delivery of the packets, e.g., due to a large volume of data packets to be processed, or one of the services is experiencing a failure or malfunction due to, e.g., a software bug or a platform running the service malfunctioning), such labels may be provided with their corresponding data packets when the data packets are routed by the gateway 20 a . In this embodiment, if network nodes along the route of the incompletely processed data packet also have the ability to apply the additionally needed services, then the data packet labels can be checked by other downstream network components and apply appropriate services as necessary. Note that such downstream network components may be additional embodiments of the gateway 20 a wherein such embodiments may analyze the contents of the data packets, determine from their (any) labeling whether there are services that still must be applied to the data packets and apply such services.
Subsequently, once the gateway services module 82 has applied the available services to the data packet, in step 424 , the output router 86 routes the data packet to the destination router identified by the rule applied from the routing table/rule base 78 . Note that in one embodiment, the output router 86 may receive the identification of the destination router from services analyzer 74 since it has already identified the row/rule of the routing table/rule base 78 for the data packet. However, in an alternative embodiment, the output router 86 may also query the routing table/rule base 78 for determining the row/rule and thereby obtain the identity of the destination router. In particular, such a query may use the classification of data packet (from at least one of steps 408 and 416 ) together with any labeling data indicative of services, e.g., applied to the data packet.
Following step 424 , step 428 is performed wherein the gateway 20 a waits (if necessary) for another data packet to be received. However, it is important to note that data packets are likely to be pipe-lined through the gateway packet processing components (i.e., the packet analyzer 70 , the services analyzer 74 , the gateway services module 82 , and the output router 86 ). In particular, each of these gateway 20 a components may be concurrently processing different data packets. Moreover, since data packets for a single communication (i.e., from a single source wherein all packets have the same packet characteristics) may arrive at the gateway without other intervening packets being received, such same communication packets may be processed as a group by each of the gateway packet processing components.
Returning now to step 412 , if it is determined that the data packet was received from the secure zone, then upon receiving information (or determining) that the data packet is from the secure zone, the services analyzer 74 determines that no services are to be applied to the data packet (as per the first data row of the routing table/rule base 78 ). Subsequently, the data packet and an indication that no services are to be performed are input to the gateway services module 82 which accordingly applies no services, and passes the data packet to the output router 86 , which (in step 432 ) transmits the data packet to the insecure zone (i.e., router 24 ). Following the transmittal (and/or concurrently therewith), the gateway 20 a processes (or waits for) the next data packet(s) (step 428 ).
It is worthwhile to note that the services analyzer 74 may be embodied as an expert system or other data-driven “intelligent” component that can decide what services need to be applied to various data packets based on the source of the data packets, the structure of data packets, the contents of the data packets. Moreover, an embodiment of the service analyzer 74 may use additional information in processing data packets. For instance, if a data packet's corresponding expression in the “Services Set” column of the routing table/rule base 78 identifies one or more of the services that the gateway services module 82 does not have the resources to appropriately perform, then the services analyzer 74 may be requested by the output router 86 to determine a router based additionally upon what services where actually applied to the data packet and/or what services still need to be applied.
FIG. 5 shows another embodiment of the routing table/rule base 78 , wherein routing and/or gateway services may be dependent on distinguishing between, e.g., the DMZ zone, and the semi-secure zone. Note that the next to the last data row in FIG. 5 is split for the last two columns thereby indicating that data packets identified by this row are duplicated so that for a first version or copy of the data packets (e.g., having substantially all of the content of the corresponding packets received at the gateway), no services are performed and these data packets are routed to the router 24 , and for a second version or copy of the data packets, firewall services are performed and these data packets are routed to the internal router 48 . Such gateway processing is desirable for logging and monitoring internal network transmissions. For example, such gateway processing can be used for providing the gateway services of (1.4) and (1.5). Assuming all rules corresponding to rows above the next to last row are not applicable, the pseudo-code for the rule corresponding to the this row is as follows:
IF (the data packet is from any zone except an insecure zone) THEN Duplicate the data packet;
Sent the original data packet to the router 24 ; Perform firewall processing on the duplicate data packet; Then transmit the firewall processed duplicate data packet to the router 48 .
The present invention may be embodied as a combination of both hardware devices and software (including firmware). Accordingly, suitable software for operatively enabling various aspects of the present invention, discussed herein and shown in the accompanying figures, can be provided on a computer-readable medium or media, and can be coded using any suitable programming or scripting language. However, it is to be understood that the invention as described herein is not dependent on any particular operating system, environment, or programming language. Illustrative operating systems include without limitation LINUX, UNIX, or any of the Windows™-family of operating systems, and illustrative languages include without limitation a variety of structured and object-oriented languages such as C, C++, Visual Basic, or the like, as well as various network communication languages such as Perl and Java.
As those skilled in the art will also understand, the program(s) of instructions for embodying the various aspects of the invention can be loaded and stored onto a program storage medium or device readable by a computer or other machine, executed by the machine to perform the various aspects of the invention as discussed and claimed herein, and/or as illustrated in the accompanying figures. The program storage medium can be implemented using any technology based upon materials having specific magnetic, optical, semiconductor or other properties that render them suitable for storing computer-readable data, whether such technology involves either volatile or non-volatile storage media. Specific examples of such media can include, but are not limited to, magnetic hard or floppy disks drives, optical drives or CD-ROMs, and any memory technology based on semiconductors or other materials, whether implemented as read-only or random access memory. In particular, an embodiment of the invention may reside on a medium directly addressable by a computer's processor (main memory, however implemented), and/or on a medium indirectly accessible to the processor (secondary storage media such as hard disk drives, tape drives, CD-ROM drives, floppy drives, or the like).
Moreover, although various components of the present invention have been described in terms of communications on an IP network, it is within the scope of the present invention to encompass other types of networks, for example, Novell (i.e., networks using the IPX network protocol), or AppleTalk networks. Furthermore, a program and data storage device (e.g., the services analyzer 74 and the routing table/rule base 78 ) can be affixed permanently or removably to a bay, socket, connector, or other hardware provided by a cabinet, motherboard, or another component of a given computer system or a given networked distributed computing system.
Those skilled in the art will also understand that networked computational components in accordance with the above teaching using known programming languages provides suitable means for realizing the various functions, methods, and processes as described and claimed herein and as illustrated in the accompanying figures attached hereto.
Those skilled in the art will further understand, when reading this description, that unless expressly stated to the contrary, the use of a singular or a plural number herein is generally illustrative, rather than limiting, of the instant invention. Accordingly, unless expressly stated otherwise or clear from the context, where a given item or aspect of the invention is discussed herein in the singular, it is to be understood that the invention also contemplates a plural number of such items.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, within the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described hereinabove are further intended to explain the best mode presently known of practicing the invention and to enable others skilled in the art to utilize the invention as such, or in other embodiments, and with the various modifications required by their particular application or uses of the invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
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A network gateway is disclosed, wherein for a received communication, the gateway determines a network component to which information for the communication is routed based upon one or more of: (a) a characterization of the source of the communication, (b) a characterization of non-address data in the communication, and (c) services applied to the communication by the gateway. The characterization of the communication source can be related to a perceived risk that the communication may be illicitly compromised or may cause a malfunction in a network component. The characterization of non-address data identifies a use of the communication, or service to be applied to the communication prior to reaching its destination, or a security feature (or lack thereof) of the communication. The services applied by the gateway are generally generic services for facilitating appropriate non-malicious communications, e.g., such services can be for a firewall, secure communications (virtual private network), FTP communications, voice over IP, email, and general Internet communications.
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This application is a continuation of U.S. Ser. No. 09/026,348, filed Feb. 19, 1998, now U.S. Pat. No. 6,077,873.
FIELD OF THE INVENTION
The present invention relates to a new class of steroid compounds, and in particular to a steroid compound having the formula (I)
wherein:
R 3 is ═O; —OH; ═NOR; —OR or —OOCR, in which R is an alkyl group having 1 to 6 carbon atoms;
R 6 is H; ═CH 2 or —(CH 2 ) m H with m is 1 or 2 wherein the steroid compound optionally may have one or more double bonds chosen from the group of Δ9(10); Δ5(10); Δ4(5); Δ11(12); Δ14(15); or any of the rings A or B may be aromatic; The presence or absence of hydrogen atoms that have not been depicted, depends on whether a given ring is saturated, unsaturated, or aromatic, and is immediately evident to the normally skilled person.
R 7 is H; C 1-4 -alkyl; C 2-5 alkenyl or C 2-5 -alkynyl, wherein the alkyl, alkenyl or alkynyl group may be substituted with 1 to 3 halogen atoms independently selected from the group of fluorine and chlorine atoms;
R 11 is H; C 1-4 -alkyl; C 2-4 -alkenyl; C 2-4 -alkynyl or C 1-4 -alkylidene, wherein the alkyl, alkenyl; alkynyl or alkylidene group may be substituted with 1 to 3 halogen atoms independently selected from the group of fluorine and chlorine atoms;
E represents, including carbon atoms 16 and 17 of ring D, a four to seven-membered ring, said ring being a with respect to the D-ring, substituted with R E and optionally comprising one or two endocyclic double bonds; The α-position of ring E vis-à-vis ring D is essential, as the corresponding steroids having a ring E in the β-position do not possess the required biological activity. It should be noted that, for reasons of nomenclature, some compounds according to the invention have a name which includes a reference to 16β and/or 17β substituents. However, irrespective thereof, in all compounds of the invention, the E-ring as a whole is α.
R E is H; C 1-6 -alkyl; C 2-6 -alkenyl; C 2-6 -alkynyl; C 1-6 -alkylidene; C 2-6 -spiro-annulated cycloalkyl; —OR; —SR; —OOCR; —NHR; —NRR; —NHCOR, wherein R (and in the case of R E being —NRR each R independently of the other) is an alkyl with 1 to 6 carbon atoms; —NCO; —(CH 2 ) n —N 3 or —(CH 2 ) n —CN, with n is 0 to 5, wherein the alkyl, alkenyl, alkynyl, alkylidene or cycloalkyl group may be substituted with 1 to 3 substituents independently selected from the group consisting of —OR; —SR; —OOCR; —NHR; —NRR; and —NHCOR, with R being defined as above, fluorine atoms and chlorine atoms;
R 17 is —OH; —OCH 2 OR; —OR or —OOCR wherein R is an alkyl with 1 to 6 carbon atoms;
Any alkyl alkenyl, alkynyl and alkylidene groups in the steroid compound having the formula (I) may be branched or unbranched. If R 3 , R 6 or R 11 is connected to the steroid skeleton through a single bond, the substituted carbon atom of the steroid skeleton either comprises a hydrogen atom or is involved in a double carbon-carbon bond. R E is connected to the E-ring through a single bond, the substituted carbon atom of the E-ring also comprises a hydrogen atom.
It was surprisingly found that the steroid compounds of the present invention have excellent and interesting estrogenic and/or progestagenic properties. Due to these specific characteristics, the steroid compounds of the present invention are very suitable for use in the prevention or treatment of peri-menopausal or post-menopausal complaints, including climacteric symptoms such as hot flushes and mood disturbances, urogenital complaints such as incontinence, skin (and vagina epithelium) atrophy, and other symptoms associated with estrogen-deficiency or estrogen withdrawal, such as osteoporosis, atherosclerosis, and Alzheimer's disease. The steroid compounds according to the invention are very suitable for the prevention or treatment of osteoporosis resulting from estrogen-deficiency.
Furthermore, the steroid compounds of the present invention can be used for contraceptive purposes.
BACKGROUND OF THE INVENTION
Steroid compounds having a 16, 17-ring substitution have been described. Chemical Abstracts 89: 215660p (Kamernitskii A V. et al.) describes a steroid compound comprising a 16,17 anellated 5- or 6-membered ring and an acetyl group at position 17. The compounds disclosed in this publication however differ from the steroid compounds according to the present invention in that the carbon atom at position 11 carries a hydrogen atom.
Chemical Abstracts 123: 285604t (Wang, J. et al.) discloses steroid compounds having a 10-membered E-ring with two triple bonds, a hydroxyl group at position 17, and a hydrogen atom at position 11.
EP 411.733 (Schering AG) discloses a steroid compound having a 6-membered E-ring, the carbon atom at position 17 being involved in a CO-bond. The compounds disclosed in EP 411733 however differ from the steroid compounds according to the present invention in that the carbon atom at position 11 carries a (substituted) aryl group. These compounds are disclosed to be competitive antagonists for progesterone.
SUMMARY OF THE INVENTION
Thus, none of this prior art references disclose the steroid compounds according to the present invention. The steroid compounds according to the present invention differ from those disclosed in the state of the art by the substitution at position 11, 16, and 17. More in particular, the steroid compounds according to the invention comprise a ring E, sharing carbon atoms at position 16 and 17 with the five-membered ring D and being α with respect to said D-ring. In addition, the carbon atom at position 17 is substituted with an oxygen atom-comprising group through a CO bond. The carbon atom at position 11 does not carry an aryl group.
Furthermore, none of the above publications suggests the interesting pharmaceutical properties of the steroid compound according to the present invention. Hence, the steroid compounds according to the present invention form a novel class of steroid compounds, as defined by their in vitro and in vivo activity.
Specifically for obtaining selective estrogen activities, in the steroid compounds according to the invention, the E-ring suitably is a five-membered ring. It is preferred that the E-ring is a six-membered ring, in view of the compounds' favourable estrogen/progestogen profiles, which include both potent, selective estrogens, and potent mixed estrogen/progestagen compounds. According to a preferred embodiment, the A-ring is aromatic and the remaining rings are saturated, wherein it is further preferred that R 7 is α-propyl. The most preferred compound, coded Org 38515, is further characterized in that R 3 and R 17 are OH, and R 6 , R 11 , and R E are H.
The present invention also relates to a pharmaceutical composition comprising the steroid compound according to the invention mixed with a pharmaceutically acceptable auxiliary, such as described in the standard reference, Gennaro et al., Remmington's Pharmaceutical Sciences, (18th ed., Mack publishing Company, 1990, see especially Part 8: Pharmaceutical Preparations and Their Manufacture.). The mixture of the steroid compounds according to the invention and the pharmaceutically acceptable auxiliary may be compressed into solid dosage units, such as pills, tablets, or be processed into capsules or suppositories. By means of pharmaceutically suitable liquids the compounds can also be applied as an injection preparation in the form of a solution, suspension, emulsion, or as a spray, e.g. nasal spray. For making dosage units, e.g. tablets, the use of conventional additives such as fillers, colorants. polymeric binders and the like is contemplated. In general any pharmaceutically acceptable additive which does not interfere with the function of the active compounds can be used. The steroid compounds of the invention may also be included in an implant, a vaginal ring, a patch, a gel, and any other preparation for sustained release.
Suitable carriers with which the compositions can be administered include lactose, starch, cellulose derivatives and the like, or mixtures thereof used in suitable amounts.
Furthermore, the invention relates to the use of the steroid compound according to the invention for the manufacture of a medicament having a peri- and/or post-menopausal complaints relieving activity, in particular an anti-osteoporosis activity. Thus the invention also pertains to the medical indications of peri- and/or post-menopausal (climacteric) complaints and osteoporosis, i.e. a method of treatment in the field of HRT (hormone replacement therapy), comprising the administration to a patient, being a woman, of a compound as described hereinbefore (in a suitable pharmaceutical dosage form).
Further, the invention relates to the use of the steroid compound according to the invention for the manufacture of a medicament having contraceptive activity. Thus the invention also pertains to the medical indication of contraception, i.e. a method of contraception comprising the administration to a subject, being a woman or a female animal, of a compound as described hereinbefore (in a suitable pharmaceutical dosage form).
Finally the invention relates to the use of the steroid compound for the manufacture of a medicament having selective estrogenic activity, such a medicament being generally suitable in the area of HRT (hormone replacement therapy).
DETAILED DESCRIPTION OF THE INVENTION
The synthesis of the 16α,17α-anellated steroids is accomplished generally by first attaching a suitably functionalized C3 or C4 fragment to the C 16 α-position of the steroid (for formation of 5-membered or 6-membered rings respectively). To facilitate this process the 17-keto function is generally converted first into a dimethylhydrazone, which is cleaved off again after assembly of the required side chain functionality's. Ring closure can be brought about by organometallic techniques, such as the treatment of ω-iodoalkyl derivatives with transition metals like samarium (in the case of 5-membered rings, exemplified in example I), or by the formation of organolithium derivatives by use of reagents like t-butyllithium (exemplified for the formation of 6-membered rings in example II). Alternatively the formation of five membered rings can be brought about via generation of anions by fluoride assisted cleavage of silicon groups in ω-silyl side chains, as found in example III.
ω-Acetylenes can serve similarly well as substrates for ring closure reactions in radical anion mediated reactions, using elements like sodium or lithium as exemplified example IV.
An entirely different approach consists in formation of anellated rings by applying olefin metathesis techniques, using catalysts derived from transition metals like ruthenium, molybdenum or tungsten. To this end 16α, 17α dialkenylated steroids serve as substrates. They are easily available by alkylation of steroidal ketones at C-16, followed by introduction of an alkene fragment via organometallic anionic derivatives (lithiates etc.). As an example of such a reaction the formation of both 5- and 6-membered rings has been demonstrated in example V.
Thus, in addition to the above compounds of the invention and the various uses of these compounds, the invention also provides the above methods of making 16,17 anellated steroids by generating a ring added to a steroid skeleton, which ring includes carbon atoms 16 and 17 of said skeleton. These methods, which have not been applied in the art of steroid chemistry, allow making a broad range of 16,17 anellated steroids. E.g. in DE 19709870 (not pre-published) a method is described which has serious restrictions in respect of the specific compounds that can be synthesized. The method involves a [4+2] cycloaddition reaction of butadiene or dimethylbutadiene with a strongly activated double bond at C 16-17 . This means that at C 17 always a strong electron-withdrawing substituent, such as —CN or -acyl, must be present, which seriously limits the number of options. Further, the method allows only 6-rings to be made, allows a limited number and variety of compounds, and requires a symmetric butadiene structure, as the methods lacks regioselectivity. The methods of the invention do not have these restrictions, and allow for the stereoselective and regioselective synthesis of a wide variety of 5- and 6-ring 16,17 anellated steroids as described hereinbefore. These methods thus make for an inventive contribution to the field of steroid chemistry.
The present invention will be illustrated by the following Figures and Examples without necessarily being restricted to the specific embodiments disclosed therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : schematic representation (2-13) of a process for the synthesis of two steroid compounds (12 and 13) according to the present invention as described in Example I.
FIG. 2 : schematic representation (14-21) of a process for the synthesis of three steroid compounds (19, 20, and 21) according to the present invention as described in Example II.
FIG. 3 : schematic representation of a process (22-33) for the synthesis of two steroid compounds (30 and 33) according to the present invention as described in Example III.
FIG. 4 : schematic representation of a process (34-39) for the synthesis of a steroid compound (39) according to the present invention as described in Example IV.
FIG. 5 : schematic representation of a process (40-44) for the synthesis of a steroid compound (44) according to the present invention as described in Example V.
FIG. 6 : schematic representation of a process (40-47) for the synthesis of a steroid compound (47) according to the present invention as described in Example VI.
The numbers between parentheses refer to the corresponding structural formula of compounds represented in the scheme.
EXAMPLE I
Although the required substrate 1 may be easily synthesized by dehydrogenation of steroids at C6C7 according to literature methods (e.g. by use of chloranil or DDQ) a new method was developed which allows a variety of 17-α-ethinyl, 17-β-hydroxy steroids to be used as well as substrates for gaining access to appropriate 17-keto steroids. They can be de-ethinylated by treatment with copper carbonate precipitated on Celite. Though a similar conversion has been described in literature using silver carbonate, the presently described method has the advantage of using a far more cheaper reagent. A batch of CuCO 3 on Celite was prepared as follows. A 100 gr of Celite was purified by stirring in a mixture of 500 ml of methanol and 100 ml of 6N HCl for 15 min. The mixture was filtered and washed several times with water until neutral. The material thus obtained was slurried into a solution of 60 g of Cu(NO 3 ) 2 .3H 2 O in 400 ml of water. To this was then added dropwise with efficient stirring a solution of 30 g of Na 2 CO 3 .H 2 O in 200 ml of water. After stirring for an additional 15 min. the material was filtered and washed with water (In order to remove most of the water prior to drying, the material was slurried in acetone and filtered and subsequently washed with pentane) Drying was finally performed in vacuo at 80° overnight, to yield 160 g of reagent.
4 G of (17β)-17-hydroxypregna-4,6-dien-20-yn-3-one and 20 gr. of CuCO 3 -Celite were suspended in 100 ml of toluene. The mixture was refluxed for about 6 hr with a Dean-Stark trap to remove some residual water. The progress of the reaction was monitored by tlc. After completion of the reaction the reaction mixture was filtered over Celite. The filtrate was concentrated and the residue treated with isopropylether-hexane to provide 2.4 g of pregna-4,6-dien-20-yn-3,17-dione, m.p. 182-184. Reduction of this with sodiumborohydride provided the required 17β alcohol, which upon acetylation with acetic anhydride provided the required substrate 1.
(7-alpha,17 beta)-17-(acetyloxy)-7-propylestr-4-en-3-one (2)
A solution of propyl lithium (prepared from 1.4 g of Li and 9 ml of propyl bromide in 60 ml of ether at −20 C) was added at −40 C to 7.6 g of CuI in 60 ml of dry THF.
After stirring for an additional 0.5 hr , a solution of 5.2 g of (17 beta)-17-(acetyloxy)estra-4,6-dien-3-one (1) in 20 ml of THF was added dropwise at −40 C. Upon stirring for an additional 15 minutes the reaction was complete, and the mixture was poured onto 300 ml of saturated NH 4 Cl solution, followed by extraction with ethyl acetate. The organic material, isolated after washing, drying and evaporation of the solvent, was taken up in 30 ml of THF and stirred in the presence of 3 ml of 6N H 2 SO 4 to isomerize some Δ5,6 isomer to Δ4,5 isomer. After 1 hr the mixture was neutralized with saturated NaHCO 3 solution and extracted with ethyl acetate. Chromatography of the crude product over silica gel (heptane/ethyl acetate 8/2) provided 2.1 g of 2, m.p. 97-100° C.
(7-alpha,17-beta)-7-propoylestra-1,3,5(10)-triene-3,17-diol 17-acetate (3)
To a solution of 15 g of 2 in 300 ml of acetoFitrile was added 12 g of CuBr 2 . The mixture was stirred for 20 hr, while monitoring the reaction by TLC (tlc plates were purchased from Merck A.G., Germany). The reaction was then poured onto water and extracted with ethyl acetate. Chromatography of the crude product over a short silica gel column (heptaine/ethyl acetate 4/1 as eluent) provided 13.5 g of 3 as white amorphous material. R f 0.57 (hept/ethylac. 7/3).
(7-alpha, 17 beta)-3-methoxy-7-propylestra-1,3,5(10)-trien-17-ol acetate (4)
To a solution of 13.5 g of 3 in 60 ml of DMF was added 2.4 g of NaH (60% dispersion in mineral oil) in portions. After stirring for 1 hr hydrogen evolution had subsided. Then 3 ml of methyl iodide was added dropwise. After one hour stirring at ambient temperature, the reaction mixture was poured into 300 ml of water, and the product was extracted with ethyl acetate. The residue which remained after evaporation of the volatiles was taken up in 20 ml of THF and a solution of 4 g of NaOH in 80 ml of CH 3 OH was introduced. After stirring for 1 hr the saponification was complete. The reaction mixture was neutralized by addition of 1N H 2 SO 4 , and the product was extracted into ethyl acetate, to provide 11.5 g of 4, R f 0.34 (hept./ethylac. 7/3).
(7-alpha)-3-methoxy-7-propylestra-1,3,5(1)-trien-17-one (5)
To a solution of 10.4 g of 3-O-methyl, 7α-propylestradiol 4 in 50 ml of methylene chloride were subsequently added 15 g. of powdered sodium acetate, 30 g of silicagel and 32 g of pyridinium chlorochromate. After stirring for 1 hr the oxidation was complete. Excess reagent was destroyed by addition of 1 ml of isopropanol, followed by 150 ml of hexane 10 min. later. All the precipitates were filtered over Celite, and the filtrate was concentrated to dryness. This provided 9.6 g of essentially pure ketone 5; R f 0.54 (hept./ethyl acetate 7/3).
(7-alpha)-3-methoxy-7-propylestra-1,3,5(10)-trien-17-one dimethylhydrazone (6)
To a solution of 11.2 g. of 7α-propyl-3-O-methylestrone 5 in 60 ml of toluene were added 6 ml of dimethylhydrazine and 0.5 ml. of trifluoroacetic acid.
The mixture was refluxed for 1.5 hr. After cooling to r.t. the reaction mixture was neutralized with 5% NaHCO 3 and the organic layer was washed several times with water and dried over sodium sulfate. After concentration and chromatography 11.4 g of the hydrazone 6 remained as an oil; R f 030 (hept/ethylac. 7/3).
[7-alpha,16-alpha (S)]-16-[3[[dimethyl(1,1-dimethylethyl)silyl]oxy]-2-methylpropyl]-3-methoxy-7-propylestr-1,3,5(10)-trien-17-one dimethylhydrazone (7)
To a solution of 2.6 g of 6 in 30 ml of dry THF was added at −40° C. 5.6 ml of BuLi (1. 5 N solution in hexane). After stirring for 0.5 hr at this temperature 2.7 g of (2R)-2-methyl-3-iodopropanol-O-tert.butyldimethylsilyl (TBDMS) ether in 5 ml. of THF was introduced. After stirring for an additional hr at −20° C. the reaction mixture was poured into water and extracted. Subsequent chromatography provided 4.6 g of 7; R f 0.50 (hept./ethylac. 7/3 0.50).
[7-alpha,16alpha (S)]-16-(3-hydroxy-2-methylpropyl)-3-methoxy-7-propylestra-1,3,5(10)trien-17-one dimethylhydrazone (8)
A solution of 4.6 g of 7 in 5 ml of THF was treated with 15 ml of 1M TBAF in THF for 1 hr at 50° C. The mixture was diluted with 100 ml of water and extracted with ethyl acetate. After passing the product through a short silicagel column 3.1 g of 8 was obtained as an oil; R f 0.18 (hept./ethylac. 7/3).
[7-alpha,16-alpha(S)]-16-[2-methyl-3-[[(4-methylphenyl)sulfonyl]oxy]propyl]-7-propylestra-1,3,5(10)-trien-17-one (10)
A solution of 2.8 g of 9 in 7 ml of pyridine was treated at 0° C. with 2.6 g of tosyl chloride. After stirring for 2 hr. excess reagent was decomposed by stirring with ice for 0.5 hr. The product was extracted by ethylacetate and purified by chromatography, to provide 3.2 g of 10 as a colorless oil; R f 0.35 (hept./ethylac. 7/3).
[7-alpha,16-alpha(S)]-16-(3-hydroxy-2-methylpropyl)-3-methoxy-7-propylestra-1,3,5(10)trien-17-one (9)
A mixture of 3.1 g of 8 in 30 ml. of acetone and 3 ml of water was treated with 3 g of amberlyst-15 acidic resin(Fluka AG.) for 2 hr at 55° C. Thereafter the reaction mixture was filtered and concentrated, to provide 2.8 g of 9 as an oil; R f 0.75 (heptane/acetone 1/1).
[7-alpha-16-alpha,(S)]-16-(3-iodo-2-methylpropyl)-7-propylestra-1,3,5(10)-trien-17-one (11)
A mixture of 3.2 g of 10 and 10 g of sodium iodide in 30 ml of acetone was heated at 65° C. for 1 hr. After pouring the reaction into water and extraction with ethyl acetate 2.9 g of iodide 11 were obtained; R f 0.55 (hept./ethylac. 7/3).
(4′S,7-alpha,16beta,17-beta)-3,4′,5′,16-tetrahydro-3-methoxy-4′-methyl-7-propyl-17H-cyclopenta[16,17]estra-1,3,5(10)-trien-17-ol (12)
A solution of SmI 2 was prepared from 3 g of samarium metal and 4.7 g of 1,2-diiodoethane in 70 ml of dry THE. To this solution was added at 0° C. 20 mg of tris(dibenzoylmethanato)iron, followed by a solution of 2.8 g of 11 in 10 ml of THF. After stirring for an additional hr the mixture was poured onto water, acidified with 2N H 2 SO 4 and extracted with ether.
The crude product thus obtained was chromatographed to remove some 16,17-beta isomer, and provided 1.6 g of 12; R f 0.32 (hept/ethylac. 7/3).
The related beta isomer has a R f value of 0.37.
(4′S,7-alpha,16-beta, 17-beta)-3′,4′,5′,16-tetrahydro-4′-methyl-7-propyl-17H-cyclopenta[16,17]estra-1,3,5(10)-trien-3,17-diol (13)
To a solution of 700 mg of 12 in 5 ml of toluene was added 15 ml of DIBAL (1M in toluene). The mixture was refluxed for 3 hr to effect ether cleavage. Excess reagent was destroyed by the addition of water, followed by further dilution with 40 ml of 2N HCl. The product was extracted with ethylacetate. After drying and concentration, the residue was triturated with diisopropyl ether, to provide 460 mg of crystalline 13; M.p. 166-168° C. R f 0.36 (hept./ethylac. 7/3).
EXAMPLE II
(7-alpha,16-alpha)-16-[4-[[dimethyl(1,1-dimethylethyl)silyl]oxy]butyl]-3-methoxy-7-propylestra-1,3,5(10)-trien-17-one dimethylhydrazone (14)
To a solution of 3.9 g of the hydrazone 6 in 45 ml of dry THF was added at −60° C. 8.5 ml of 1.5N BuLi solution in hexane. After stirring for 0.5 hr a solution of 4.2 g of 4-iodobutanol-TBDMS ether in 5 ml of THF was added dropwise. The mixture was subsequently stirred at −20 for 1 hr and then poured into 200 ml of water and extracted with ethyl acetate.
Chromatographic purification over silica gel provided 6.2 g of 14 as an oil; R f 0.52 (hept./ethylac. 7/3).
(7-alpha,16-alpha)-16-(4-hydroxybutyl)-3-methoxy-7-propylestra-1,3,5(10)-trien-17-one dimethylhydrazone (15)
A solution of 6 g of 14 in 5 ml of THF was treated with 20 ml of 1M tetrabutylammonium fluoride in THF for 2 hr. The reaction was poured into water and extracted with ethyl acetate. After chromatography 4.1 g of 15 remained as an oil; R f 0.17 (hept./ethylace. 7/3).
(7-alpha,16-alpha)-16-(4-hydroxbutyl)-3-methoxy-7-propylestra-1,3,5(10)-trien-17-one (16)
A mixture consisting of 4 g of 15, 40 ml of acetone, 4 ml of water and 4 g of Amberlyst-15 acid resin was stirred for 2 hr at 50° C. The mixture was filtered, concentrated, taken up in 40 ml of toluene, dried and concentrated, to provide 3.7 g of essentially pure 16; R f 0.61 (hept/acetone 1/1); starting material R f 0.65.
(7-alpha,16-alpha-16-[4-[[(4-methylphenyl)sulfonyl]oxy]butyl]-7-propylestra-1,3,5(10)trien-17-one (17)
A mixture of 3.7 g of 16 and 3.2 g of tosylchloride in 10 ml of dry pyridine was stirred at 0-5° C. for 3 hr. After dilution with water the product was extracted with ethyl acetate. Chromatographic purification provided 4.6 g of tosylate 17; R f 0.45 (hept./ethylac. 7/3) 0.45.
(7-alpha,17-alpha)-16-(4-iodobutyl)-3-methoxn-7-propylestra-1,3,5(10)-trien-17-one (18)
A mixture of 4.6 g of 17 and 20 g of sodium iodide in 50 ml of acetone was heated at 60° for 1.5 hr. The reaction mixture was concentrated, diluted with water and extracted with toluene. After drying and concentration 4.4 g of iodide 18 remained as essentially pure material; R f 0.50 (hept./ethylac. 7/3).
(7-alpha. 16-alpha, 17-alpha)-3-methoxy-7-propyl-16,24-cyclo-19,21-dinorchola-1,3,5(10)trien-17-ol (19)
A solution of 3.8 g of the iodide 18 in 20ml of dry THF was treated at 3-60° C. with 9 ml of a 1.7M solution of tertbutyllithium in heptane. After stirring for an additional 15 min. at −60° C., the mixture was poured into water and extracted with ethyl acetate. The crude product obtained after removal of the volatiles was triturated with heptane, to provide 1.9 g of essentially pure 19; M.p. 161-162° C. R f 0.40 (hept./ethylac. 7/3).
(7-alpha,16-alpha,17-alpha)-17-hydroxy-7-propyl-16,24-cyclo-19,21-dinorchol-4-en-3-one (21)
To a solution of 1 g of lithium in 90 ml of liquid ammonia was added at −33° C. a solution of 1.3 g of 19 in 30 ml of dry THF. After stirring in refluxing ammonia for an additional 4 hr, the reaction was treated with 20 ml of ethanol followed by evaporation of the ammonia under a steady stream of nitrogen. The residue was diluted with 50 ml of water and extracted with ethylacetate. Concentration of the organic phase, followed by trituration of the residue with heptane, provided 1.1 g of pure dienolether intermediate; M.p. 190-192° C.
This material was dissolved in 25 ml of THF and treated with 5 ml of 6N H 2 SO 4 . After stirring for 6 hr the mixture was neutralized with Na 2 CO 3 and the product extracted with ethyl acetate. Chromatographic purification of the crude material thus obtained gave 610 mg of 21 as a white foam; R f 0.25 (hept/ethylac. 7/3).
(7-alpha,16-alpha,17-alpha)-7-propyl-16,24-cyclo-19,21-dinorchola-1,3,5(10)-trien-3,17-diol (20)
To a solution of 600 mg of 19 in 5 ml of dry toluene was added 12 ml of 1M DIBAH (diisobutylaluminum hydride) in toluene. After 2 hr of refluxing the demethylation was complete; excess reagent was destroyed by careful addition of water and subsequently the mixture was poured onto 50 ml of 4N hydrochloric acid, and the product extracted into ethyl acetate. The organic layer was dried, concentrated and the residue treated with diisopropylether, to provide 310 mg of 20; M.p. 240° C., R f 0.20 (hept./ethylac. 7/3)
EXAMPLE III
(11-beta,16-alpha)-11-methyl-16-[2-[(trimethylsilylmethyl]prop-2-enyl]estr-5-ene-3,17-dione 3-cyclic(1,2-ethanediyl)acetal (23)
To a solution of 12.7 ml of hexamethyldisilazane in 50 ml of THF was added at −50° C. 40 ml of 1.5M BuLi in heptane solution. After stirring for 20 min. a solution of 16.5 g of 22 in 100 ml of THF was run in slowly at −50° C. After stirring for an additional 0.5 hr a solution of 25 g of 3-iodo-2-trimethylsilylmethylpropene in 25 ml of THF was introduced. The reaction mixture was stirred at −20° C. for an additional 3 hr, and then poured onto 400 ml of water. The product was extracted with ethyl acetate and chromatographed over silicagel. After trituration with heptane 12.5 g of product 23 was obtained; M.p. 184-185° C.; R f 0.55 (hept./ethylac. 7/3).
(11-beta,16-beta,17-beta)-4′,5′,16,17-tetrahydro-17-hydroxy-11-methyl-4′-methylene-3′H-cyclopenta[16,17]estra-5,16-dien-3-one 3-cyclic (1,2-ethanediyl acetal) (24)
A solution of 8.8 g of 23 in 200 ml of dry THF was treated with 4 ml of 1M tetrabutylammonium fluoride (TBAF) in THF. The mixture was refluxed for 15 min. to complete the ring closure reaction. An additional amount of 15 ml of 1M TBAF solution was then added and refluxing prolonged for 1 hr in order to cleave 17-O-silyl ether formed during the reaction. The mixture was subsequently concentrated to a small volume and diluted with water, followed by extraction with ethylacetate. Chromatographic purification provided 4.0 g of 24; M.p. 141-142° C., R f 0.28 (hept./ethylac. 7/3).
(4′S,11 -beta,16-beta,17-beta)-4′,5′,16,17-tetrahydro-17-hydroxy-4′-(hydroxymethyl)-11-methyl-3′H-cyclopenta[16,17]estra-5,16-dien-3-one 3-cyclic (1,2-ethanediyl acetal) (25), and its 4′R analog (26).
A solution of borabicyclononane (9-BBN) was prepared from 3 ml of 10M boranedimethylsulfide complex and 4 ml of 1,5-cyclooctadiene in 30 ml of dry THF. To this was added a solution of 3.8 g of 24 in 10 ml of THF.
The mixture was stirred for 2 hr and then excess reagent was destroyed by careful addition of 1 ml of ethanol, followed by 20 ml of 2N NaOH solution and 10 ml of 30%-H 2 O 2 . This mixture was stirred for another 3 hr and then further diluted with water and extracted with ethylacetate.
The crude product was chromatographed over silicagel (toluene/acetone as eluent) to provide 2.1 g of 25 (M.p. 178° C., R f 0.47 (tol./acet. 1/1)) and 1.2 g of 26 (R f 0.55 (tol./acet. 1/1)).
(4′R,11-beta,16-beta,17-beta)-4′,5′,16,17-tetrahydro-17-hydroxy-11-methyl-4-[[[(4-methylphenyly)sulphonyl]oxy]methyl]-3′H-cyclopenta[16,17]estra-5,16-dien-3-one-3-cyclic (1,2-ethandiyl acetal) (31)
A solution of 1.2 g of 26 and 0.8 g of to syl chloride in 5 ml of pyridine was stirred at 0-5° C. for 2 hr. Then the mixture was diluted with ice-water, stirred for 15 min. and extracted with ethyl acetate. Drying and concentration of the organic phase provided 1.6 g of essentially pure 31; R f 0.52 (tol./ethylac. 7/3).
(4′R,11-beta,16-beta,17-beta)-4′-butyl-4′,5′,16,17-tetrahydro-17-hydroxy-11-methyl-3′H-cyclopenta[16,17]estra-5,16-dien-3-one (32)
A cuprate reagent was prepared by adding 12 ml of a 2M propylmagnesiumbromide/ether solution to 2.3 g of CuI in 20 ml of THF at −20° C. After stirring for 15 min. a solution of 600 mg of 31 in 3 ml of THF was added. Stirring was continued for 2 hr more at −20° C. The reaction was worked up by addition of 60 ml of sat.NH 4 Cl and 10 ml of 10%-ammonia, followed by extraction with ethyl acetate. The crude product was chromatographed, to provide 420 mg of 32; M.p. 97-98° C., R f 0.45 (hex./ethylacet. 7/3).
(4′R,11-beta,16-beta-17-beta)-4′-butyl-4′,5′,16,17-tetrahydro-17-hydroxy-11-methyl-3′H-cyclopenta[16,17]estra-4,16-dien-3-one (33)
A solution of 400 mg of 32 in 5 ml of acetone was treated with 2 ml of 4N H 2 SO 4 . After 2 hr at r.t. the mixture was diluted with water and extracted with ethyl acetate. Chromatographic purification afforded 360 mg of essentially pure 33 as an amorphous material; R f 0.27 (hept./ethylac. 7/3).
(4′S,11-beta,16-beta,17-beta)-4′,5′,16,17-tetrahydro-4′-(hydroxymethyl-11-methyl-17-[(trimethylsilyloxy]-3′H-cyclopenta[16,17]estra-5,16-dien-3-one 3-cyclic(1,2-ethanediyl acetal) (27)
The protection of the 17-OH function was performed in a multistep procedure. First the primary alcohol was acetylated. Thus, to a solution of 750 mg of 25 in 2 ml of pyridine was added 5 mg of 4-dimethylaminopyridine (DMAP), followed by 0.5 ml of acetic anhydride. After stirring for 1 hr. 10 g of ice-water was added, followed by extraction of the product with ethyl acetate. Concentration of the organic material, and treatment of the residue with heptane-diisopropylether provided 730 mg of monoacetate; M.p. 112° C. This material was dissolved in 3 ml of DMF containing 200 mg of irnidazole. Then 240 μl of TMS-chloride was added, and the mixture was stirred for 0.5 hr at room temperature. After addition of 15 ml of water, the product was extracted with ether. Upon drying and concentration 900 mg of essentially pure silylether derivative was obtained; R f 0.54 (hept./ethylac. 7/3).
This product was dissolved in 3 ml of dry THF and 70 mg of LiAlH 4 was added. After stirring for 10 min. the mixture was subsequently treated with 0.3 ml of water and 0.1 ml of 2N NaOH and 1 g of NaSO 4 . Then it was filtered through Celite and concentrated to provide 700 mg of 27 as an amorphous material; R f 0.29 (hept./ethylac. 7/3).
(4′S, 11-beta, 16-beta,17-beta)-3,3-[1,2-ethanediylbis(oxy)]-4′,5′,16,17-tetrahydro-11-methyl-17-[(trimethylsilyl)oxy]-3′H-cyclopenta[16,17]estra-5,16-dien-4′-carboxaldehyde (28)
To a solution of 600 mg of 27 in 15 ml of methylene chloride was added 1.5 g of anhydrous sodium acetate, 2.5 g of silica gel followed by 2 g of pyridiniumchlorochromate. The mixture was stirred for 1 hr at room temperature. Then 50 ml of ether was added and after additional stirring for 15 min. the reaction was filtered through Celite, followed by evaporation of the volatiles, to provide 420 mg of essentially pure carboxaldehyde 28; a compound slowly solidifying on standing; R f 0.48 (hept./ethylac. 7/3).
(4′S,11-beta,16-beta,17-beta)-4′-ethenyl-4′,5′,16,17-tetrahydro-11-methyl-17-[(trimethylsilyl)oxy]3′H-cyclopenta[16,17]estra-5,16-dien-3-one 3-cyclic (1,2-ethanediyl acetal) (29)
To 1.3 g of methyltriphenylphosphonium chloride in 25 ml of TMF was added 1.7 ml of 1.5M BuLi in hexane solution at −40° C. After stirring for 30 min. 400 mg of 28 in 2 ml of THF was added. The mixture was allowed to warm to room temperature in about 0.5 hr and then quenched by pouring into 100 ml of water. The product was extracted with diethyl ether, and subsequently chromatographed to provide 280 mg of 29 as an oil; R f 0.53 (hept./ethylac. 7/3); starting material R f 0.23.
4′S,11-beta,16-beta,17-beta)-4′-ethenyl-4′,5,′16,17-tetrahydro-11-methyl-17-hydroxy-3′H-cyclopenta[16,17]estra-4,16-dien-3-one (30)
A solution of 260 mg of 29 in a mixture of 3 ml of THF and 3 ml of 4N H 2 SO 4 was stirred for 2 hr at 45° C. Then the reaction was neutralized with 5% NaHCO 3 solution and the product extracted into ethyl acetate.
Short path silica gel chromatography provided 150 mg of 30; R f 0.25 (hept./ethylac. 7/3).
EXAMPLE IV
3-[[(1,1-dimethylethyl)dimethylsilyl]oxy]estra-1,3,5(10)-trien-17-one dimethylhydrazone (35)
To a solution of 15.5 gr. of 3-hydroxyestra-1,3,5(10)-trien-17-one dimethylhydrazone (34) in 200 ml of DMF was added 13 gr. of imidazole, followed by dropwise addition of 15 gr. of TBDMSCl in 20 ml of ether. After stirring for an additional 16 hr the reaction mixture was poured onto 2 liters of water and the resulting mixture was stirred for an additional 10 minutes. The precipitate was filtered and dried in vacuo, to provide 20 g of 35, M.p. 100-103° C.
(16alpha)-3-[[(1,1-dimethylethyl)dimethylsilyl]oxy]-16-(4-butynyl)estra-1,3,5(10)-trien-17-one dimethylhydrazone (36)
The alkylation of the steroid was performed with the anion generated first of 4-bromo-1-butyne. The procedure was as follows. A solution of 11.9 gr. of 35 in 100 ml of THF was treated at −20° C. with 20 ml of a solution of 1.5M BuLi in hexane. After stirring for 1 hr at −20° C. the reaction mixture was cooled to −70° C. A cold solution of the anion of 4-bromo-1-butyne (prepared by addition of 36 ml of BuLi to 7.7 g of 4-bromo-1-butyne in 50 ml of THF at −78° C.) was added dropwise and the reaction mixture was allowed to warm up to room temperature. The mixture was then stirred for an additional 1 hr and then poured into 300 ml of 10% aq. NH 4 Cl. The product was extracted with ethyl acetate. After chromatography 9.5 g of 36 was obtained as an oil. R f 0.85 (toluene/ethylacetate 6/4).
(16alpha)-3-[[(1,1-dimethylethyl)dimethylsilyl]oxy]-16-(4-butynyl)estra-1,3,5(10)-trien-17-one (37)
To a solution of 9 g of 36 in 100 ml of THF and 70 ml of 1M acetate buffer (pH 4,5) was added 15 g of periodic acid in 40 ml of ethanol. The mixture was stirred for 24 hr. Then 500 ml of water was added and the product was extracted with ethylacetate. Chromatography of the crude material thus obtained provided 4.2 g of 37.
(16alpha,17alpha)-3-[[(1,1-dimethylethyl)dimethylsilyl]oxy]-16,23-cyclo-19,24-dinorchola-1,3,5(10),20-tetraen-17-ol (38)
A solution of lithium naphtalenide was prepared from 3.4 g of naphtalene and 150 mg of lithium chips in 30 ml of dry THF. This solution was added dropwise to a solution of 560 mg of 37 in 5 ml of THF until a dark green color of the reaction mixture persisted. After stirring for an additional 10 minutes the reaction mixture was poured into 30 ml of NH4Cl and the product was extracted with ethyl acetate. Chromatographic purification provided 150 mg of crystalline 38.
(16alpha,17alpha)-16,23-cyclo-19,24-dinorchola-1,3,5(10),20-tetraene-3,17-diol (39)
A solution of 130 mg of 35 in 5 ml of 5% HCl in methanol was stirred for 2 hr at room temperature. The reaction mixture was then treated with 3 ml of pyridine and concentrated and diluted with 10 ml of water. The product was extracted in ethylacetate and finally purified by chromatography, to provide 65 mg of 39; M.p. 203-205° C.
EXAMPLE V
(7α,16α)-7-methyl-16-(prop-2-enyl)-estr-5(10)-ene-3,17-dione 3,3-dimethylacetal (41)
A solution of lithium diisopropylamide was prepared from 16.6 ml of 1.5M of butyllithium in hexane and 3.85 ml of diusopropylamine in 35 ml of THF at −20° C. After stirring for 20 min. a solution of 8.3 g of steroid 40 in 30 ml of THF was added and the mixture was stirred for 20 minutes at −20°. Then after cooling to −40°, 2.2 ml of allylbromide was added and then stirring was continued for an additional 4 hr at −20°, after which period tlc monitoring showed completion of the reaction. The mixture was quenched by addition of 200 ml of 5% NaHCO 3 solution, followed by extraction with ethylacetate. Chromatography over silicagel (hexane-5% ethylacetate as eluent) provided 7.2 g of 41 as a white solid; M.p. 85-86°.
(7α,16α,17β)-7-methyl-16,17-bis(prop-2-enyl)-17-hydroxy-estr-5(10)ene-3-one 3,3-dimethylacetal (42)
To a solution of 15 ml of 1 M allylmagnesium bromide in 30 ml of THF was added at −40° a solution of 4.5 g of 41 in 30 ml of THF. After stirring for 30 min. at this temperature, the mixture was poured onto 250 ml of 10% NH 4 Cl solution and extracted with ethylacetate. The product thus obtained was chromatographed, to provide 3.2 g of the 16α,17α diallyl derivative 42 as white amorphous material.
(7α,16α,17α)-7-methl-17-hydroxy-16,24-cyclo-19,21-dinorchola-5(10),22-dien-3-one 3,3-dimethylacetal (43)
To a solution of 1.3 g of 42 in 30 ml of methylenedichloride was added 200 mg of bis(tricyclohexylphosphine)benzylideneruthenium dichloride. The reaction was stirred until completion. The solvent was removed partially by concentration and the residual material chromatographed on a silicagel column to provide 1.1 g of 43 as an amorphous white material. R f =0.38 (heptane/ethyl acetate 7/3 v/v).
(7α,16α,17α)-7-methyl-17-hydroxy-16,24-cyclo-19,21-dinorchola-4,22-dien-3-one (44)
A solution of 1 g of 43 in 30 ml of acetone was treated with 5 ml of 2N HCl. After stirring for 2 hr at room temperature the reaction was complete. After neutralization with 5% NaHCO 3 solution the mixture was extracted with ethyl acetate and the product passed through a short silicagel column. The product thus obtained was treated with diisopropylether, to provide 0.65 g of 44; M.p. 130-131; R f (heptane/ethylacetate 7/3) 0.14.
EXAMPLE VI
(7α,16α,17α)-7-methyl-16-(prop-2-enyl)-17-hydroxy-pregna-5(10),20-dien-3-one 3,3-dimethylacetal (45)
A solution of vinyllithium was prepared by addition of 0.8 ml of a 1.6M solution of butyllithium in hexane to 0.32 ml of vinyltributyltin in 3 ml of THF at −50° C. After stirring for 20 min. a solution of 300 mg of 41 in 2 ml of THF was added dropwise. Upon stirring for an additional 15 min. the mixture was quenched by addition of 20 ml of 10% NH 4 Cl solution, followed by extraction of the product into ethylacetate. Subsequent chromatographic purification provided 120 mg of 45 as an amorphous material; R f 0.56 (heptane/ethylacetate 7/3 v/v).
(7α,16β,17β)-16,17-dihydro-17-hydroxy-5′H-cyclopenta[16,17]estra-5(10),16-dien-3-one 3,3-dimethylacetal (46)
To a solution of 120 mg of 45 in 4 ml of methylene dichloride was added 30 mg of bis(tricyclohexylphosphine)benzylideneruthenium dichloride. After stirring for 2 hr the mixture was concentrated and filtered through a silica gel column, to provide 80 mg of 4.6 R f 0.40 (heptane/ethyl acetate 7/3 v/v).
(7α,16β,17β)-7-methyl-16,17-dihydro-17-hydroxy-5′H-cyclopenta[16,17]estra-4,16-dien-3-one (47)
A solution of 80 mg of 46 in 2 ml of acetone was treated with 0.2 ml of 2N HCl. After stirring for 2 hr at room temperature the reaction mixture was neutralized by addition of NaHCO 3 , and diluted with water. The product was extracted with ethylacetate and passed through a short silica column, to provide 45 mg of 47. Mp 175-176° C., R f 0.49 (heptane/ethylacetate 1/1 v/v).
EXAMPLE VII
Test for Prevention of Ovariectomy-induced Bone Loss in Rats (anti-osteoporosis test)
Introduction
Ovariectomy induces in rats bone loss, which is due to oestrogen deficiency. Administration of oestrogenic compounds prevents this effect. The test is used to evaluate a compound for anti-osteoporotic activity in ovariectomised rats. The effect on bone mass can be evaluated by peripheral Quantitave Computed Tomography (pQCT) measurement of trabecular bone mineral density.
Test Animal
Mature virgin female Wistar rats preferentially, 225-250 g. Strain: Hsd/Cpd:Wu, SPF-bred by Harlan, CPB, Zeist, The Netherlands.
Experiment
On day 1 of the experiment the rats are weighed and distributed over the cages in order of body weight. The rat with the lowest body weight in the first cage and the heaviest rat in the last cage. Treatments are randomized over the rats per block. A block (group of 3+n treatments) consists of 1 Intact placebo rat, 1 OVX placebo rat, 1 OVX reference rat and 1 rat of each n treatments.
Sham-operation and ovariectomy are performed under ether anaesthesia. After recovery from the anaesthesia, within 24 h, vehicle, reference compound or test compound is administered once or twice daily for 4 weeks.
Bone mineral density measurement by pQCT
Trabecular bone mineral density (mg/cm 3 ) of the metaphyseal part of the femur was measured with a pQCT (peripheral Quantitative Computed Tomography machine; XCT 960A, Stratec, Birkenfeld, Germany) directly after autopsy on fresh tissue. Two 360° scans, which have, due to the X-ray beam, a standard thickness of 1 mm were taken. The scans have a resolution of 0.148×0.148 mm. One scan was taken at 5.5 mm from the distal end of the femur, where trabecular bone mineral density of the metaphyseal part was measured. The other scan was taken in the diaphysis at 13.5 mm from the distal end, which contains no trabecular bone. In the latter scan cortical bone mineral density and the geometrical parameters, such as cortical thickness, total bone area, outer and inner diameter, were determined. Intra- and inter-assay variation for the measurement of trabecular bone mineral density in the distal femur were about 2-3%. The XCT-960A was calibrated with a standard of hydroxyapatite embedded in acrylic plastic.
Interpretation of Results
Ovariectomy causes a statistically significant decrease in trabecular bone mineral density (P≦0.05, 2 way ANOVA). Test compounds are considered to be active when mean bone mineral density values of the distal femur are significantly increased as compared to the ovariectomised control group.
The active dose (ED 50 ) is the dose where a mean proportional difference in trabecular bone mineral density between 40 and 60% is reached as compared to the sham and ovariectomised group.
References
Wronski T. J. and Yen C. F.: The ovariectomised rat as an animal model for postmenopausal bone loss. Cells and Materials, Supp. 1 (1991): 69-76.
Yamazaki I. and Yamaguchi H.: Characteristics of an ovariectomised osteopenic rat model. J. Bone Min. Res. 4 (1989): 12-22.
Ederveen A. G. H., Spanjers C. P. M., Quaijtaal J. H. M. and Kloosterboer H. J.: Effect of treatment with tibolone (Org OD 14) or 17α-ethinyl estradiol on bone mass, bone turnover and biomechanical quality of cortical and trabecular bone in mature ovariectomised rats. Osteoporosis Int. in press, 1998.
EXAMPLE VIII
Test for Receptor-binding In vitro
The relative progesterone receptor binding affinity of the compounds of the invention was measured for cytoplasmic progesterone receptors present in human breast tumor cells (MCF-7 cells, incubation time 16 h., temperature 4° C.) and compared with the affinity of (16α)-16-ethyl-21-hydroxy-19-norpregn-4-ene-3,20-dione (according to the procedure described by E. W. Bergink et al., J. Steroid Biochem., Vol. 19, 1563-1570 (1983)). The relative estradiol receptor binding affinity was measured in the same manner as described above but using 17βestradiol as a reference.
Test for Estrogenic Activity In vivo
The in vivo estrogenic activity was determined by means of the well known Allen Doisy test, described in F. Allen, L. A. Doisy, J. Amer. Med. Assoc., 81,819-821 (1923).
Test for Proyestaienic Activity In vivo
The in vivo progestagenic activity was determined by means of the well known McPhail test, described in McPhail, M. K.: The assay of progestin, Journal of Physiology, 1934, 83:145-156.
Several of the compounds according to the Examples I-VI, as well as other compounds according to the invention synthesized in analogous manner, were subjected to the tests described in the Examples VII and VIII. The results are described in the Table, in which the type of A-ring and the substitution at carbon atoms nos. 7, 11, and 17 is indicated. In the columns captioned E and P, the relative binding affinities for the estrogen and progesterone receptors are given; the ED 50 results of the AllenDoisy and the McPhail tests have been indicated in μg/kg. In the column captioned “Osteoporosis”, the ED 50 results of the anti-osteoporosis test are given (dose in μg/kg, day, as described above).
Table Representing The Relative Binding Affinities To The Human Estradiol (E)
Or Progesterone (P) Receptor And
The In Vivo Hormonal Activities (ED 50 ) Upon Oral Administration
E
P
AllenDoisy
McPhail
Osteoporosis
A-ring
7α
11β
16α,17α
Code
(%)
(%)
(μg/kg)
(μg/kg)
(μg/kg, day)
Δ4 = 5
H
H
5-ring + 4′S-methyl
38541
58
>500
125
>1000
Δ4 = 5
H
H
5-ring + 4′S propyl
37977
151
>4000
500
>1000
Δ4 = 5
H
H
6-ring
37518
115
>4000
125
>2000
Δ4 = 5
H
methyl
5-ring + 4′R-butyl
38276
115
>500
125
>1000
Δ4 = 5
H
methyl
5 ring + 4′S azidomethyl
38322
44
>500
63
>1000
Δ4 = 5
H
ethyl
6-ring
37943
96
192
1000
400
Δ4 = 5
H
ethyl
5 ring + 4′S-ethyl
38610
0.3
32
>125
125
Δ4 = 5
H
ethyl
5-ring + 4′S-propyl
38577
139
192
>500
250
Δ4 = 5
methyl
H
5-ring
37352
36
1000
250
500
Δ4 = 5
propyl
H
5-ring + 4′R methyl
38550
36
125
>125
125
Δ4 = 5
methyl
H
5-ring + 4″S methyl
38049
250
>2000
1000
>1000
Δ5 = 10
methyl
H
5-ring
37351
4
4000
2000
1000
Δ5 = 10
H
ethyl
5-ring + 4′R propyl
38151
8
125
>1000
ND
Δ5 = 10
H
H
6-ring
37516
13
>4000
1000
>2000
aromatic
H
H
6-ring
37469
1
23
>4000
>2000
>4000
aromatic
H
H
5-ring + 4′R-propyl
37968
1
6
>1000
>4000
ND
aromatic
H
H
5-ring + 4′S-propyl
37969
3
25
>1000
4000
>1000
aromatic
H
ethyl
6-ring
37862
96
2
32
ND
<16
aromatic
methyl
H
5-ring + 4′S-methyl
37893
38
11
500
>4000
500
aromatic
methyl
H
β 5-ring + 4′S-propyl
38079
<1
1
>4000
ND
ND
aromatic
methyl
H
6-ring
37828
11
10
192
—
500
aromatic
propyl
H
5-ring + 4′R-methyl
38514
11
4
24
>2000
<32
aromatic
propyl
H
5-ring + 4′S-methyl
38481
23
6
64
>4000
125
aromatic
propyl
H
6-ring
38515
16
10
96
4000
190
aromatic
propyl
H
β 5-ring + 4′R-methyl
38513
0.2
—
2000
>125
ND
NC Not Competitive; ND Not Determined;
|
The invention relates to a steroid compound having the formula (I)
comprising a ring E, said ring sharing carbon atoms at position 16 and 17 with the five-membered ring D and being α with respect to said D-ring. In addition, the carbon atom at position 17 is substituted with an oxygen atom-comprising group through a CO bond. The invention also relates to a pharmaceutical composition comprising said steroid compound. The steroid compounds of the present invention are very suitable for use in the prevention or treatment of peri-menopausal or menopausal complaints, more preferably the prevention or treatment of osteoporosis. Furthermore, the steroid compounds of the present invention can be used for contraceptive purposes.
| 2
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BACKGROUND OF THE INVENTION
This invention relates generally to a method and apparatus for decorating articles, and more particularly to one wherein the articles are decorated at a plurality of stations and registration of the article is maintained between stations.
Packaging trends have today made it desirable to employ multi-color designs having a high quality decoration to provide a more attractive and marketable package for the product. The hot stamping technique in this connection provides a system wherein a high quality and rich metallic decorative design may be applied to a variety of differently shaped containers including multi-color designs of an infinite variety.
In my earlier U.S. Pat. No. 3,718,517, issued on Feb. 27, 1973, a machine is disclosed which is readily adaptable for hot stamping and heat transfer decorating and which produces a high quality decorative design on a variety of differently shaped containers at a high production rate. As is the case in my earlier patent, where a multi-color design is being applied to a single container, each of the several colors is generally applied at a different decorating station. In those instances where several colors are applied to the same article or container, registration between the colors is important and in some cases critical. Furthermore, in certain instances when an article is being decorated at two or more decorating stations with the same color, registration between the design applied at one station must be maintained with respect to that applied at another station. Accordingly, in many instances where multi-station decorating is utilized, movement of the article between the stations must be controlled in order to accomplish the desired registration between the designs being applied.
In my earlier U.S. Pat. No. 3,718,517, a versatile machine is described wherein the outer surface of an article is decorated by means of a die disposed at a decorating station. The article being decorated is rotatably mounted on a rotary table which advances the article to each decorating station which in the case of the illustrated embodiment is two decorating stations. At each of the decorating stations, a layer of transfer material is interposed between the die and the article, the former causing the transfer material to engage the rotatable article. As the die is moved across the outer surface of the article, a portion of the transfer material is thereby adhered to the article in the form of the desired decoration.
A plurality of mandrels are mounted on the rotary table for supporting the articles to be advanced to the decorating stations. After decoration at the first station is completed, the rotary table advances the article to the subsequent station where the process is repeated. The two decorating stations may be employed to impart a multi-color design on to the article or imprint onto the article two different designs with separate dies either in one or more colors.
In my earlier patent, the plurality of mandrels mounted to the rotary table were interconnected with one another by means of flexible belts which resulted in all the mandrels being rotated simultaneously to maintain proper registration with respect to one another. Thus, when the mandrel at one of the decorating stations is rotated, the remaining mandrels simultaneously rotate therewith in order to register each of the articles mounted on the mandrels with respect to one another.
Although such a registration system is satisfactory for general purpose decorating, certain specialized applications exist wherein a greater degree of accuracy is required between the designs applied at the several decorating stations. One such situation occurs with a design such as a rectangle which includes within its border printing of a different color. The rectangle in this case is applied at one station in a first color along with certain other indicia. The design imparted at the other station is in a second color and includes the printing which appears within the border of the rectangle. In order to accomplish the positioning of the two designs with respect to one another it is necessary to position the article at the second station with the same orientation as existed at the first decorating station. Thus, the article must be rotated between the first and second decorating stations an angular distance such that the article arriving at the second station is rotated to the orientation with which it arrived previously at the first decorating station. In other words, the article must be rotated 360° plus the angular distance between the first and second decorating stations. A method and means are disclosed herein whereby the article is so positioned at the first and second decorating stations to facilitate a specialized decorating application of the types described above.
SUMMARY OF THE INVENTION
Briefly stated, the invention herein provides for decorating the outer surface of an article at a plurality of decorating stations and employs a rotary table upon which a plurality of mandrels are rotatably mounted. The articles being decorated are placed on the mandrels which in turn are moved from one decorating station to another. Disposed between the first and second decorating stations is a registration means which controls the rotation of the mandrel as it moves from the first to the second decorating station. A coupling, connected to the mandrel, is engagable with the registration means as the article is moved between the first and second decorating stations. The registration means and coupling are related to one another in such a manner so that the mandrel is positioned at the second decorating station in accordance with a predetermined relationship with respect to its orientation at the first decorating station.
More specifically, the registration means includes a plurality of spaced teeth or pins while the coupling means is a gear like member engagable therewith. The ratio of teeth on the registration means to the ratio of teeth on the gear is such that the mandrel is caused to rotate between the first and second decorating stations 360° plus the angular distance between the decorating stations. In this manner, the mandrel is positioned with the same orientation at the first and second decorating stations.
In operation, each article is mounted onto one of the mandrels positioned on the rotary table which in turn is advanced to each of the decorating stations. At each of the decorating stations, the die causes the transfer material to be applied in accordance with the predetermined design. As the article is moved from one decorating station to another, its movement is restricted by a locking means and the coupling or gear mounted to the article holding means is engaged with the registration means positioned between each of the decorating stations. In this manner, the article is positively driven and caused to rotate between the first and second decorating station a predetermined amount and against the force of the locking means resulting in the article being positioned at the second decorating station with a predetermined orientation.
Accordingly, it is an object of this invention to provide an effective and reliable means for accomplishing accurate decorating at a plurality of decorating stations.
It is another object of this invention to provide an article decorating means wherein registration is maintained between each of the decorating stations.
It is still another object of this invention to provide an article decorating means capable of imparting a multi-colored design with the colors appearing in registration with respect to one another.
These and other objects, advantages and features of the invention will become more apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the rotary table advancing articles to a decorating station and the article holding means of the machine of this invention;
FIG. 2 is a partial front elevation view of the article decorating means of FIG. 1;
FIG. 3 is an enlarged partial perspective view of the registration means disposed between the first and second decorating stations;
FIG. 4 is a partial front elevation view illustrating the article holding means positioned at the first and second decorating stations with the registration means disposed therebetween;
FIG. 5 is a partial front elevation view of the article holding means being moved between the first and second decorating stations;
FIG. 6 is a side elevation view, partially in cross-section, taken along the line 6--6 of FIG. 5;
FIG. 7 is an enlarged perspective view of an article on each of the decorating stations;
FIG. 8 is an enlarged fragmentary front elevation view of the die engaging the article at the decorating station;
FIG. 9 is an enlarged perspective view of an article to be decorated;
FIG. 10 is an enlarged perspective view of an article having been decorated at a first decorating station; and
FIG. 11 is an enlarged perspective view of an article having been decorated at a first and second decorating station.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The machine of this invention is of the same general type as described in my earlier patent. The drive means, particularly those for the rotary table, dies, transfer materials and the like are the same basically as those described previously in my U.S. Pat. No. 3,718,517. With reference to the drawings and particularly to FIGS. 1 and 2, a rotary table 10 is provided which includes a plurality of rotatable mandrels 11, onto which the article to be decorated 9, is mounted. Specifically, six identical mandrels 11 are provided and spaced 60° apart from one another. Each of the mandrels 11 is, as previously described in my earlier patent, mounted to the rotary table 10 by means of a base plate 12 which is radially adjustable with respect to the center of the table 10 by means of the adjustment screw 13. A hexagonal cam 14 is provided about the mandrel axis and adjacent the base plate 12. A pair of decorating stations 15 and 16 are spaced from one another with the dies at each station being capable of vertical movement into engagement with the article 9. Transfer material 17 is interposed between the die and the article to be decorated at the first decorating station 15 whereas a second transfer material 18 is interposed between the die and the article 9 at the second decorating station 16. Once the article to be decorated is indexed by the rotary table 10 into position at the respective decorating station 15 or 16, the die descends causing the transfer material 17 or 18 to be urged into engagement with the article 9 (FIG. 7). By a horizontal movement of the die across article 9, the predetermined design of the die engravings causes a portion of the transfer material to be adhered and decorated onto the surface of the article (FIG. 8). The article 9 is then advanced to the second station 16 whereat the decorating process is repeated and a second design is printed on the article.
Article 9, prior to decoration, is illustrated in FIG. 9. A decoration such as would be imprinted upon the article at the first decorating station is illustrated in FIG. 10 in the form of a rectangle 19 and two striped bands 19a and 19b. When, as is required in certain instances, a design or other printed indicia is desired to be positioned with respect to the first color such as is illustrated on FIG. 11, this is accomplished at the second station 16 with the article 9 being properly positioned so that the printing or indicia 19c is properly aligned with respect to that of the rectangle 19.
In order to register the two different colored designs with respect to one another such as is necessary in situations as illustrated in FIG. 11, the article as it arrives at the second decorating station 16 with the same orientation as that with which it arrived at the first decorating station 15. In other words, the article 9 as it is moved from the first decorating station 15 to the second decorating station 16 must be rotated 360° plus the angular distance between the first and second decorating station which in the illustrated embodiment is 60°.
With particular respect to FIGS. 3, 4 and 5, a registration or selector means 20 is disposed and centrally located between the first and second decorating stations 15 and 16 respectively. The registration or selector means 20 contains fourteen teeth or pins 21 and is mounted to the frame of the machine by means of the bolts 22. An adjustment screw 23 is in engagement with a threaded portion on the selector 20 and allows for proper positioning the latter between the two decorating stations 15 and 16. On the rearward side of the rotary table 10, each of the mandrel assemblies 11 is provided with a gear 24 which has twelve teeth and is engagable with the teeth 21 of the selector 20.
The registration or selector means 20 functions such that when the article 9 moves from the first to the second decorating station, the gear 24 engages the teeth 21 of the selector 20 and causes the article 9 to be rotated 420° (360° plus the 60° angular distance between the decorating stations 15 and 16). This is accomplished by the ratio of the teeth on the selector 20 and the teeth on the gear 24 being 14:12.
During movement between the first and second decorating stations 15 and 16 rotation of the article 9 is controlled by the registration or selector means 20. However, the article 9 as it is positioned at a decorating station is free to rotate and thereby facilitate printing. This is accomplished by means of a locking bar 30 being engaged with the hexagonal cam 14 provided at the base of each of the mandrel assemblies 11. The locking bar 30 functions such that it is removed or disengaged from the hexagonal cam 14 during movement between the first decorating station 15 and second decorating station 16 whereas it engages and locks in place the hexagonal cam 14 and mandrel assembly 11 during movement between the second decorating station 16 and first decorating station 15. As previously mentioned, when the rotary table 10 is not indexing, that is when an article is positioned at a decorating station, the locking bar 30 is disengaged from the hexagonal cam 14 and the mandrels 11 are free to rotate.
With particular reference to FIGS. 1-4, each locking bar 30 is pivoted about the screw 31 while at its other end a connecting link 32 couples it to the center drive wheel 33. The connecting link 32 is pivotally mounted to the drive wheel 33 by means of the screw 34. To insure that the locking bar 30 is biased into engagement with the hexagonal cam 14 a tension spring 35 is provided.
The locking bar arrangement functions such that as the articles are being decorated, the bar 30 is removed from the hexagonal cam 14 such as illustrated in FIG. 4 leaving the article free to rotate while engaged with the die. On the other hand, during indexing of the rotary table 10, bar 30 engages the hexagonal cam 14 and locks it in place. In the latter case, movement of the mandrel while advancing from the first decorating station 15 to the second decorating station 16 is controlled by the gear 24 engaging the teeth 21 of the registration means 20.
The mandrel 11 while at the printing station, as illustrated in FIG. 6, has its movement controlled by means of a front driving member 40 engaging the article 9 held on the mandrel 11 and a rear drive (not shown) engaging the clutch disc 41 at the other end of the mandrel assembly. These drives are synchronized with the horizontal movement of the die during the printing cycle. The drive means engaging the forward end of the mandrel clutch 40 is coupled thereto by means of the chain drive illustrated at 42, 43 and 44. The center drive wheel 33 is driven by an independent drive means engagable on the forward side with the shaft 50 (FIG. 1) which drive means is intermittent and synchronized with the drive means for the rotary table 10.
The operation of the machine is such that the vertical printing dies are moved toward the article 9 to be decorated at each of the decorating stations 15 and 16. Just prior to the printing die making contact with the article to be decorated, the front drive 40 is engaged with the mandrel and rear drive is engaged with the rear clutch disc 41 (FIG. 6). At the same time, the locking bar 30 is withdrawn from the hexagonal cam 14 by the connecting linkage 32 which is attached to the center wheel 33. In this manner, the mandrel 11 upon which is mounted the article to be decorated, is free to rotate during the printing cycle.
The dies then are moved vertically upward and removed from the article with the front drive 40 and rear drive being released and returned to the inactive position. The locking bar 30 is also released and urged into engagement with the hexagonal cam 14 by the tension spring 35. With the printing dies out of engagement with the article, the rotary table 10 advances the mandrels 11 one station. During movement between the decorating stations, 15 and 16 respectively, gear 24 engages the teeth 21 of the registration or selector means 20 and the movement of the mandrel 11 and article 9 is thereby controlled. The engagement of the locking bar 30 with the hexagonal cam 14 restricts the movement of the mandrel such that between the first decorating station 15 and the second decorating station 16, the article is positively driven by the engagement of the registration means 20 and the gear 24. As previously discussed, the ratio between the teeth of the registration or selector means 20 and the gear 24 is such that the mandrel 11 is rotated 420° and arrives at the second decorating station 16 with the same orientation as that which it arrived at the first decorating station 15. In this manner, the resultant printing is imparted on the article 9 at each decorating station in a manner precisely related to that applied at the other station.
Thus there has been described a means for accurately maintaining registration between various decorating stations. By the method and means disclosed herein, the positioning of the article is maintained under control during the entire rotational movement so that the design imparted at one station may be regulated with respect to that imparted at another station.
Although the above description is directed to a preferred embodiment of the invention, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit and scope of the present disclosure.
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A method and apparatus for decorating the outer surface of an article or ware at a plurality of decorating stations wherein registration between the decoration applied at each of the plurality of stations is maintained. The article is advanced to each of the decorating stations at which a predetermined decoration is applied. The movement of the article as it is advanced to the subsequent station is controlled with the article being rotated a predetermined amount such that the orientation of the article at each of the decorating stations is appropriate for the particular decoration being applied.
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RELATED APPLICATIONS
[0001] The present patent application is based upon Provisional Patent Application Ser. No. 61/281,487 filed Nov. 18, 2009 and the priority to that prior Provisional patent application is hereby claimed.
BACKGROUND OF THE INVENTION
[0002] It is widely known that babies born prematurely with extremely low birth weights (ELBW) are at particular risk for intraventricular hemorrhage (IVH) during their early neonatal period due to both the vulnerability of the germinal matrix and the protective cerebral autoregulation which is present in older babies has not yet developed. Any event that results in disruption of vascular autoregulation can cause IVH making the higher in ELBW infants who are transported after birth.
[0003] Preliminary data for 2006 estimates 4,265,996 births occurred in the United States during the year, an increase of 3 percent from 2005, the largest single-year increase in the number of births since 1989, and the largest number of births since 1961. Preterm births (as defined before 37 weeks of gestation) have risen 21 percent since 1990 to 12.8 percent of the births during 2006. Infants born with Low Birth Weight (as defined as less than 2,500 grams) have risen 19 percent over this same period to 8.3 percent of births. The reviewed literature suggests the most vulnerable cohort of this population to be the very pre-term (less than 32 wks) and very low birth weight (less than 1,500 gms.) This suggests, at a minimum, between 63,136 and 85,319 births during 2006 in the United States were at risk for perinatal brain injury and was increased whenever they were required to be transported.
[0004] The current pathway for the care of a High Risk Premature Neonate generally requires the neonate to be moved into a minimum of three separate devices. Immediately upon birth, the newborn neonate is typically placed on an open bed radiant warmer (device number one) located in the birthing area and is assessed, possibly receiving some type of intervention such as resuscitation. The neonate is then moved into a transport incubator (device number two) and transported within the same hospital to a neonatal intensive care unit (NICU) where the infant is place in another thermal regulation device (device number three) where they are admitted for care.
[0005] Depending on the state of the facility, the infant may remain in this device for most of its care during the period of vulnerability. However, the infant may need to be transported again to another care facility using a transport incubator if the hospital in which they were born cannot provide the level of care required. They may also be moved to another thermal device during their care for another reason such as access or to have some procedure outside of the NICU.
[0006] During the past five years advances have been made in understanding perinatal brain injury and have led to an increased desire and need to monitor and image the neonate's brain. Imaging techniques include conducting Cranial Ultrasound and Magnetic Resonance Imaging (MRI) of the premature infant's brain. New thermal transport devices which are MRI compatible have also made it easier to transport the infant to and conduct the MRI by providing life support. However, clinicians are now forced to make difficult trade-offs between the value of an MRI and the added risk involved in moving a high risk premature infant. Clinicians are now challenged by how to access the neonate's head for examination, monitoring and imaging purposes with minimal disruption to the neonate.
[0007] Hospital's also have significant investments in existing patient support apparatus for the care of neonates. The goal of this invention is to provide a platform which allows clinicians to examine and, if necessary, move the high risk neonate between these apparatus in a stable method thereby reducing the disruption of vascular autoregulation. However, the invention may have use in other patient populations and is not to be limited to neonatal use.
SUMMARY OF THE INVENTION
[0008] According to the present disclosure, a patient care apparatus comprises a patient support platform with a mattress and a means to allow clinicians to examine and, if necessary, move the patient support platform and mattress from one patient care apparatus to another patient care apparatus in a stable method reducing the disruption of vascular autoregulation. The patient care apparatus furthermore comprises of base in which the patient support platform and mattress will fit allowing it to be used in any patient care apparatus. The support base may be either custom tailored to a specific patient care apparatus or it may be adjustable allowing it to be used in multiple types of patient care apparatuses.
[0009] The patient care apparatus includes a mechanism to allow the patient support platform and mattress to be raised and, if required, lifted from the support base and moved in a level fashion from one patient care apparatus to another thereby causing minimal disruption to the patient.
[0010] As further features, the patient care apparatus may include support capabilities for such items as ventilator, feeding, and I.V. tubing, as well as other cables such as electrodes and sensors so they can easily move with the patient.
[0011] Further, the patient care apparatus may include the ability to transmit video and physiological data to clinicians who may be involved in the care of the high risk patient but are remotely situated to the patient.
[0012] Still further, the patient care apparatus may include a mechanism to allow its use during any type of imagining including the use of X-Ray cassettes and head coils for conducing MRIs.
[0013] As another feature of the present invention, the patient care apparatus can include a means to provide thermal support to the patient.
[0014] The drawings supplied in this disclosure represent one or more embodiments of the invention and are not meant to limit other embodiments of the inventions disclosed herein. These and other features and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic view illustrating the possible movement of an infant within a health care facility using existing patient care apparatus;
[0016] FIG. 2 is an exploded view of an exemplary embodiment of the present invention and FIG. 2A is a perspective view of a generic support base;
[0017] FIG. 3 is a side view of a patient support platform of the present invention with the handles of the lifting mechanism in the upper, usable position;
[0018] FIG. 4 is a side view of the patient support platform of the present invention with the handles of the lifting mechanism in the lower, at rest, position;
[0019] FIG. 5 is a perspective view illustrating the use of the present invention to transfer an infant from one infant care apparatus to another infant care apparatus;
[0020] FIG. 6 is an enlarged, perspective view illustrating support capabilities of the lifting mechanism of the present invention;
[0021] FIG. 7 is a perspective view of an exemplary embodiment of the present invention illustrating one end of the patient support platform in a raised position;
[0022] FIG. 8 is a perspective view of an alternative exemplary embodiment of the present invention; and
[0023] FIG. 9 is a perspective view of the FIG. 8 embodiment illustrating the patient support platform in a raised, flat and level position and a removable head section.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to FIG. 1 , there is shown a perspective view illustrating the possible movements of an infant within a patient care facility. The movements of the infant are initially shown in the direction of the arrows A. As can be seen, the infant, immediately after birth, is typically placed on an open bed radiant warmer 10 located in the birthing area where the infant is assessed, possibly receiving some type of intervention such as resuscitation. The infant may then be moved into a transport incubator 12 and transported within the same health care facility to a neonatal intensive care unit where the infant is placed in another thermal regulation device, such as a NICU warmer 14 where the infant is admitted for care. Alternatively, or in addition, the infant may be placed into a NICU incubator 16 .
[0025] Depending on the state of the facility, the infant may remain in the NICU incubator 16 for most of its care during the period of vulnerability. However, the infant may need to be transported again to another care facility using a transport incubator 18 if the hospital in which they were born cannot provide the level of care required. The infant may also be moved to another thermal patient care apparatus during its care for another reason such as access or to have some procedure outside of the NICU. It is also possible that the infant may be moved by means of the transport incubator 18 to a MRI apparatus 20 for further diagnostic testing. As can be seen by the arrows B, the infant may then be returned to a prior infant care apparatus such as the NICU incubator 16 or the NICU warmer 14 by means of the transport incubator 18 .
[0026] As can therefore be seen, the infant potentially can be moved in a series of moves and be contained with a plurality of infant care apparatuses during its stay in the health care facility. As stated, each move is tedious to the infant and it would be desirable to make each move with as little trauma to the infant as possible.
[0027] Turning then to FIG. 2 , there is shown an exploded view of the present invention that is designed to be used with a specific patient support system, such as an incubator or infant warmer. As such, there is a support base 22 that is dimensioned so as to fit within an existing infant care apparatus, and, in particular, any of the various infant care apparatuses illustrated in FIG. 1 . Within the support base 22 are locating features 24 that will be explained later but, it will be seen that the locating features 24 are, in the exemplary embodiment, indentations or projections in the support base 22 .
[0028] As also can be seen in FIG. 2 , there is a patient support platform 26 that fits into a similarly shaped indented area 28 in the support base 22 such that the patient support platform 26 can be firmly located within the indented area 28 in an immovable manner, that is, the patient support platform 26 does not move laterally once fitted into the indented area 28 . As shown, the indented area 28 has diagonal corners, however, the indented area 28 can be any shape that can interfit with a conforming shaped patient support platform 26 .
[0029] An infant mattress 30 is fitted within the patient support platform 26 for the comfort in supporting an infant thereon. In addition, there may be receptacles 32 located at the sides of the patient support platform 26 for securing straps (not shown) that retain the infant in position atop of the mattress 30 . The securing straps may be joinable together by some affixing system such as the loop and hook system marketed under the mark Velcro. Other fastening systems can, however, be used, such as buckles, snap fasteners or the like.
[0030] There is also a supply system support 34 that is used to retain the various tubes or wires that are used to support the care being given to the patient when located atop of the mattress 30 . Such tubes and wires may include wires for physiological electrodes as well as wires for sensors, IV lines, ventilation tubing, and feeding tubes.
[0031] Also, there is a lifting mechanism that is used to physically lift the patient support platform 26 off of the support base 22 when it is desired to relocate the infant from one infant care apparatus to another, as illustrated in FIG. 1 . The lifting mechanism can comprise a pair of fixed handles 36 located at both ends of the patient support platform 26 or can comprise a pair of pivotable handles 38 that can be moved between an at rest, lower position to an upper, usable position by the user. The pivotable handles 38 will be later explained with reference to FIGS. 3 and 4 .
[0032] Turning now to FIG. 2A , there can be seen an exemplary embodiment of a generic support base 40 that can be used for any infant care apparatus since it is variable in dimensions. With this embodiment, the generic support base 40 has lateral sides 42 that are variable so as to vary the width of the generic support base 40 so as to interfit in any infant care apparatus. There are straps 43 that can be used to secure the lateral sides 42 to a center section 45 and be slidingly fitted beneath that center section 45 . As such, the width of the generic support base 40 can be varied in accordance with the particular patient care apparatus and that same type of sliding adjustment may also be used to adjust the ends of the generic support base 40 .
[0033] There are also locating features 44 at the ends of the generic support base 40 for guiding the generic support 26 when using the generic patient base 40 . In addition, as can be seen, there are support location features 46 that interfit with the locating features 24 on the support base 22 so as to locate the generic support base 40 in the proper position.
[0034] Turning then to FIGS. 3 and 4 , there are shown, side views of the patient support platform 26 illustrating the use of the pivotable handles 38 . As can be seen, the pivotable handles 38 are pivotally mounted at pivot points 48 such that the pivotable handles 38 are shown in their upper, usable positions in FIG. 3 and in their lower, at rest positions of FIG. 4 . In the upper, usable position, the pivotable handles 38 can, of course, be used to lift and carry the patient support platform 26 and mattress 30 to relocate the infant from one infant care apparatus to another infant care apparatus. In this position, the pivotable handles 38 can also be used for a supply system support which will be later described in FIG. 6 .
[0035] Next, referring to FIG. 5 , there is shown a perspective view illustrating the relocation of the patient support platform 60 in order to relocate an infant from an infant warmer 50 to a transport incubator 52 . As can be seen, the infant warmer 50 has a pedestal 54 with a support base 56 having an indented area 58 that is specially shaped to receiver the profile of the patient support platform 60 . The same is true of the transport incubator 52 where there is a support base 62 having an indented area 64 that is of the same shape, that is, the indented area 64 also conforms to the bottom of the patient support platform 60 .
[0036] Accordingly, as can be seen, the caregiver 66 can simply lift the patient support platform 60 upwardly to remove it from the indented area 58 of the infant warmer 60 to transport the infant to the indented area 64 of the transport incubator 52 easily and securely since the infant is retained in its position on the mattress 68 and secured therein by the straps 70 . The transfer of the infant from one infant care apparatus to another infant care apparatus is thus is carried out with a minimum of disruption and trauma to the infant.
[0037] Turning next to FIG. 6 , there is shown a perspective view of a portion of the present invention to illustrate a typical supply system support 72 that is incorporated into a handle 74 of the patient support platform 76 . With the present supply system support 72 , there are a plurality of U-shaped openings 78 in the handle 74 such that a supply device 80 and associate or other tubing 82 can be removable connected thereto such that as the patient support platform 76 is moved from one infant care apparatus to another infant care apparatus, the supply device 80 will be carried therealong and there is no need to disconnect many of the supply devices and tubing and then reconnect the devices when the infant has been relocated.
[0038] Turning then to FIG. 7 , there is shown a perspective view of an exemplary embodiment which is adapted to be emplaced into an infant care apparatus as previously described. In this embodiment, the support base 84 can be seen and which has an indented area 86 that, again, conforms to the outer shape of the patient support platform 88 . In this embodiment, however, the upper surface has a plurality of stops 90 formed thereon. The stops 90 can be molded into the indented area 86 and be depressions or protrusions that interact with the handle 92 so as to secure the distal end of the handle 92 according to a selected stop 90 .
[0039] As can thus be seen, therefore, an end of the patient support platform 88 can be raised or lowered by selecting the particular stop 90 to retain the handle 92 at the desired location for the particular tilt angle. While the stops 90 are shown in FIG. 7 at one end of the support base 84 , they are normally located at both ends such that the infant can be raised to a head up orientation (Fowler) or a head down orientation (Trendelenberg) while resting on the contoured infant mattress 94 . The stops 90 can also be used to raise both ends of the support base 84 to a fully, level raised position to facilitate access to an infant.
[0040] In FIG. 7 , there can be seen the safety strap receptacle or tie down 96 used to secure the safety straps to retain the infant safely in place on the patient support platform 88 . The corresponding safety strap tie down oppositely located along the other lateral side of the patient support platform is not shown in FIG. 7 .
[0041] As such, therefore, the handle 92 or handles 92 can be used both for lifting the patient support platform 88 from the infant care apparatus as well as to position the infant in a plurality of tilt angles or raised levels desired by the caregiver for a number of reasons such as Trendelenberg or Fowler positions or for easier access in conducting examination of the infant.
[0042] Turning then to FIGS. 8 and 9 , there is shown perspective views of a further exemplary embodiment of the present invention and wherein the patient support platform 98 has a removable head section 100 that can be removed for better access to the infant's head for cranial ultrasound imaging and other neurological procedures. The removable head section 100 has a V-shape facing the head of the infant and has an outer contour complementary to the normal shape of the patient support platform 98 so as to fit within the indented area of the support base 84 . Furthermore, FIG. 9 illustrates the patient support platform 98 raised and level and with the head section 100 removed allowing better access to the patient's head.
[0043] The materials for construction of the patient support platform of the present invention can be those that are non-magnetic or compatible with all imaging devices such as MRI and X-ray apparatus and the patient support platform can accommodate a coil for a MRI apparatus. Types of compatibility include combined EM fields (static magnetic, gradient magnetic, and/or radio frequency) and attachment of head coils or use of X-ray trays.
[0044] Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the infant care apparatus of the present invention which will result in an improved infant carrying structure and infant care apparatus utilizing the same, yet all of which will fall within the scope and spirit of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the following claims and their equivalents.
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A patient care apparatus comprises a platform carrying a mattress configured to allow the care of and facilitate the transfer of a patient from one support platform to another support platform with minimal stimulation or disruption to the patient. The patient care apparatus further comprises of a base designed to allow the platform to be used on any stationary or mobile patient support platform including a mechanism for lifting the patient.
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BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates to copolymeric materials which are useful as adhesives, as binders for explosive compositions, propellants and pyrotechnic articles and as binders for gas producing substances.
2. Description of the Prior Art.
In the recent past, several disastrous explosions have occurred both on shipboard and during rail transit when explosive compositions were inadvertantly subjected to heat or fires. Various explosive compositions, both plastic bonded and non-plastic bonded, too numerous to describe in detail here have detonated in such situations. Obviously, if explosive compositions will detonate under accidental, unexpected heat, it is undesirable to transport them in situations where they may be subjected to such heat. Because of these explosions, considerable research is now being carried out in attempts to develop explosive compositions which will burn rather than detonate if they are subjected to intense heat.
Under combat conditions as well as during shipping and storage, weapons such as warheads which contain explosive compositions are also subjected to mechanical shock and impact forces. It is desirable to have available explosives which will withstand such forces without detonating.
SUMMARY OF THE INVENTION
It has now been found that copolymers made by reacting from 40 to 90 weight percent 2-ethylhexyl acrylate with from 60 to 10 weight percent N-vinyl-2-pyrrolidone have a desensitizing effect on commonly used explosive fillers such as cyclotetramethylenetetranitramine (HMX) and cyclotrimethylenetrinitramine (RDX) or these explosives combined with aluminum powder and oxidizer powders such as sodium, ammonium or potassium perchlorates. When explosive compositions containing from 3 to 30 weight percent of such a copolymer as binders are subjected to impact, fast cookoff conditions or slow cookoff conditions, inadvertant explosions are significantly less likely to occur. The copolymers of this invention are also useful as adhesives; as binders for solid propellant compositions and as binders for gas producing substances. The binder is effective in desensitizing the composition from mechanical shock such as bullet or fragment impact. Thus, under enemy fire, bombs contacting it are less likely to detonate and destroy the aircraft or carrier and in large scale explosions in ammunition dumps, detonation of one item is less likely to set off the others.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
When the copolymers of this invention are utilized as binders for cast explosive compositions, it is preferable to precoat sensitive filler ingredients with a water insoluble, low-volatility termonomer before preparing the cast composition. A cast explosive composition may be conveniently prepared according to Example 1.
EXAMPLE 1
First, an aqueous suspension of the non-soluble (in water) fillers (such as, for example, HMX or RDX) is prepared. Next, a solution of either di-2-ethylhexyl maleate or di-n-butyl maleate in a suitable organic solvent (such as, for example, dichloromethane) is added to the aqueous suspension. When this second step is carried out, the maleate derivative coats the fillers and coated filler particles settle to the bottom of the container. Next the water and all possible organic solvent are decanted. Next, residual organic solvent and water are removed by evaporation. This leaves dry, maleate coated filler particles. Next, the two monomers, 2-ethylhexyl acrylate and N-vinyl-2-pyrrolidone (40 to 90 weight percent acrylate and 60 to 10 weight percent pyrrolidone), a small amount (0.1 to 015 weight percent) of a crosslinker such as triethylene glycol dimethacrylate, tetramethylene diacrylate or their homologues and whatever special derivatives one wishes to add (such as p-tertiary butyl catechol to prolong shelf life, colloidal silica to control viscosity or an oxidizer powder such as sodium, potassium or ammonium perchlorate) or aluminum are combined and thoroughly mixed in a mixer. The coated explosive is then added to and mixed with the binder. After mixing until homogeneous, from 0.5 to 1 weight percent of a curative is added to the contents of the mixer. A suitable curative may be a peroxide such as t-butyl hydroperoxide with prior addition of cobalt acetylacetonate to serve as an accelerator. After the curative has been added, the contents of the mixer are stirred again for several minutes then the contents of the mixer are cast and allowed to cure. Explosive compositions containing from as little as 7.0 weight percent binder (with a balance of explosive fillers to make a total of 100 weight percent) to as much as 30 weight percent binder may be prepared this way. In the process the three monomers, 2-ehtylhexyl acrylate, N-vinyl-2-pyrrolidone and the maleate derivative react to form a terpolymer.
Explosive compositions prepared according to the foregoing procedure exhibit excellent qualities insofar as resistance to cracking under stress and resistance to cracking when undergoing temperature cycling are concerned. They may be readily detonated by means of ordinary detonating procedures commonly used with other plastic bonded explosives.
In addition to being useful as binders for explosive compositions, the copolymers of this invention are useful alone as adhesives and are useful as binders for propellant compositions. They may also be used as binders for pyrotechnic compositions and as binders for gas producing substances. A brief discussion of their preparation for such uses appears in Examples 2 and 3.
EXAMPLE 2
To prepare an adhesive one simply reacts 2-ethylhexyl acrylate and N-vinyl-2-pyrrolidone in the optimal presence of a crosslinker such as triethylene glycol dimethacrylate, tetramethylene diacrylate or a homologue. As in the case of the binder of Example 1, from 40 to 90 weight percent of the 2-ethylhexyl acrylate and from 60 to 10 weight percent of N-vinyl-2-pyrrolidone is used. Also, as in the case of the binder of Example 1, from 0.1 to 0.5 weight percent of the crosslinker is used. The resulting copolymer is very tacky and forms an excellent adhesive. The crosslinker is omitted if the cured adhesive is to be applied from solution in a solvent but it may be included if the adhesive is to be cured in situ from a monomeric mixture.
EXAMPLE 3
To prepare a binder for a propellant, pyrotechnic article or gas producing substance, the procedure of Example 1 may be used substituting, of course, propellant, pyrotechnic, or gas producing ingredients for the explosive fillers and the like of Example 1.
Example 4 below describes, in some detail, one explosive composition that was made and subjected to various impact and cookoff tests. The example also gives the results of the tests. While the Example specifies certain weight percentages for the ingredients, it is to be realized that the inventors do not wish to limit themselves to those percentages. Other tests with other compositions (in different weight percentage ranges) have been conducted with results similar to those described in the Example. That is, cast explosive compositions containing from 70 to 93 weight percent explosive fillers made up (1) entirely of explosive such as HMX; (2) partially of explosive such as HMX and partially of aluminum powder; and (3) partially of explosive, partially of aluminum and partially of perchlorates bound in from 30 to 7 weight percent of the copolymeric binder of this invention all will give results similar to those described in Example 4 if subjected to similar test conditions.
EXAMPLE 4
An explosive composition (made according to Example 1) containing about 86 weight percent RDX powder, as explosive filler and 14 weight percent of copolymeric binder made up by reacting 42 parts by weight 2-ethylhexyl acrylate 28 parts N-vinyl-2-pyrrolidone and 30 parts di-2-ethylhexyl maleate (precoated on the RDX) in the presence of triethylene glycol dimethacrylate crosslinker (0.1 weight percent) and cobalt acetylacetonate (0.1 weight percent) cured by adding 1.0 weight percent peroxide was prepared and then subjected to impact tests, slow cookoff tests and fast cookoff tests.
The impact tests consisted of firing 50 caliber projectiles at the composition. Seventy shots were fired with no detonations resulting.
The fast cookoff tests consisted of suspending bombs containing the cast explosive composition over a burning pool of jet fuel. In these tests, the bomb casings ruptured and the explosive composition burned but no detonations occurred. Bomblets and bombs containing from 2 pounds up to 100 pounds of the explosive were tested in fast cookoff studies.
The slow cookoff tests consisted of placing bombs containing 100 pounds of the explosive on combustable platforms and igniting the platforms so they would burn slowly. In a series of tests, some bomb casings ruptured and some did not. When a bomb casing ruptured, the explosive would ooze out and slowly burn. No detonations occurred in any case. No deterious effects on the explosive could be detected upon opening the unruptured bombs after tests. In these cases, the bombs were closed and reused in subsequent tests.
Example 1, Example 3, and Example 4 relate to cast explosive compositions. 2-Ethylhexyl acrylate and N-vinyl-2-pyrrolidone may also be polymerized and utilized to make pressed explosive compositions. In pressed compositions as little as 3 weight percent binder and as much as 30 weight percent binder may be used. A pressed composition may be prepared by following the procedure set forth in Example 5.
EXAMPLE 5
First, prepare and cure a copolymer from 2-ethylhexyl acrylate (40 to 90 weight percent) and N-vinyl-2-pyrrolidone (60 to 10 weight percent) by mixing the two liquids, adding cobalt acetylacetonate (0.1 weight percent) and then adding a peroxide (1 weight percent). (Any peroxide such as t-butyl hydroperoxide or the like may be used. Also, there are other acceptible methods for preparing the copolymer.) Next, the solid copolymer is dissolved in a suitable solvent such as a mixture of dichloromethane and acetone. The explosive filler is then slurried in water and the solution of copolymer is slowly added to the slurry. The copolymer is thus precipitated onto the explosive particles in the sulrry. The organic solvent is periodically removed by evacuation. It has been found that removing the organic solvent two or three times during the addition step is helpful. After the addition is complete, decant the liquid, filter, dry and press at 80° to 90° C. for up to 2 minutes under a pressure of 20,000 to 30,000 psi.
HMX, RDX, Al and other solid additives may be readily incorporated into pressed solid billets based on the binder described herein by following the method of this example.
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Adhesives and binders for cast explosive compositions, pressed explosive compositions, propellants and pyrotechnic articles. The adhesives are prepared by reacting 2-ethylhexyl acrylate and N-vinyl-2-pyrrolidone in a copolymerization reaction with the aid of a suitable crosslinker. Binders are prepared by reacting the above-named monomers in a copolymerization reaction with the aid of a crosslinker and a curative. Copolymers prepared by reacting from 40 to 90 weight percent of the acrylate and from 60 to 10 weight percent of the pyrrolidone are preferred.
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BACKGROUND OF THE INVENTION
This invention relates to the use of chelating molecules to deactivate iron species to prevent fouling in hydrocarbon fluids.
In a hydrocarbonn stream, saturated and unsaturated organic molecules, oxygen, peroxides, and metal compounds are found, albeit the latter three in trace quantities. Of these materials, peroxides can be the most unstable, decomposing at temperatures from below room temperature and above depending on the molecular structure of the peroxide (G. Scott, "Atmospheric Oxidation and Antioxidants", published by Elsevier Publishing Co., NY, 1965).
Decomposition of peroxides will lead to free radicals, which then can start a chain reaction resulting in polymerization of unsaturated organic molecules. Antioxidants can terminate free radicals that are already formed.
Metal compounds and, in particular, transition metal compounds such as copper and iron can initiate free radical formation in three ways. First, they can lower the energy of activation required to decompose peroxides, thus leading to a more favorable path for free radical formation. Second, metal species can complex oxygen and catalyze the formation of peroxides. Last, metal compounds can react directly with organic molecules to yield free radicals.
The first row transition metal species manganese, iron, cobalt, nickel, and copper are already found in trace quantities (0.01 to 100 ppm) in crude oils, in hydrocarbon streams that are being refined, and in refined products. C. J. Pedersen (Ind. Eng. Chem., 41, 924-928, 1949) showed that these transition metalspecies reduce the induction time for gasoline, an indication of free radical initiation. Copper compounds are more likely to initiate free radicals than the other first row transition elements under these conditions.
To counteract the free radical initiating tendencies of the transition metal species so called metal deactivators are added to hydrocarbons with transition metal species already in the hydrocarbon. These materials are organic chelators that tie up the orbitals on the metal rendering the metal inactive. When metal species are deactivated, fewer free radicals are initiated and smaller amounts of antioxidants would be needed to inhibit polymerization.
Not all chelators will function as metal deactivators. In fact, some chelators will act as metal activators. Pedersen showed that while copper is deactivated by many chelators, other transition metals are only deactivated by selected chelators.
Prior Art
Schiff Bases such as N,N'-salicylidene-1,2-diaminopropane are the most commonly used metal deactivators. In U.S. Pat. Nos. 3,034,876 and 3,068,083, the use of this Schiff Base with esters were claimed as synergistic blends for the thermal stabilization of jet fuels.
Gonzalez, in U.S. Pat. No. 3,437,583 and 3,442,791, claimed the use of N,N'-disalicylidene-1,2-diaminopropane in combination with the product from the reaction of a phenol, an amine, and an aldehyde as a synergistic antifoulant. Alone the product of reaction of the phenol, amine, and aldehyde had little, if any, antifoulant activity.
Products from the reaction of a phenol, an amine, and an aldehyde (known as Mannich-type products) have been prepared in many ways with differing results due to the method of preparation and due to the exact ratio of reactants and the structure of the reactants.
Metal chelators were prepared by a Mannich reaction in U.S. Pat. No. 3,355,270. Such chelators were reacted with copper to form a metal chelate complex. The metallic complex was then added to the furnace oil as a catalyst to enhance combustion.
Mannich-type products were used as dispersants in U.S. Pat. No. 3,235,484 and U.S. Pat. No. Re. 26,330 and 4,032,304 and 4,200,545. A Mannich-type product in combination with a polyalkylene amine was used to provide stability in preventing thermal degradation of fuels in U.S. Pat. No. 4,166,726.
Copper, but not iron, is effectively deactivated by metal chelators such as N,N'-disalicylidene-1,2-diaminopropane. Mannichtype products, while acting as chelators for the preparation of catalysts or as dispersants, have not been shown to be transition metal ion deactivators.
DESCRIPTION OF THE INVENTION
Accordingly, it is an object of the inventors to provide an effective iron deactivator for use in hydrocarbon mediums so as to inhibit free radical formation during the high temperature (e.g., 100°-1000° F., commonly 600°-1000° F.) processing of the hydrocarbon fluid. It is an even more specific object to provide an effective iron deactivator that is capable of performing efficiently even when used at low dosages.
We have found that iron is effectively deactivated by the use of certain Mannich-type products formed via reaction of the reactants (A), (B), and (C); wherein (A) is an alkyl substituted phenol of the structure ##STR1## wherein R is selected from alkyl, aryl, alkaryl, or arylalkyl of from about 1 to 20 carbon atoms; wherein (B) is a polyoxyalkylenediamine selected from the group consisting of ##STR2## where the sum of x and z is from 1 to 6 and ##STR3## where y is from 1 to 6; and wherein (C) is an aldehyde of the structure ##STR4## wherein R 1 is selected from hydrogen and an alkyl having from 1 to 6 carbon atoms.
As to exemplary compounds falling within the scope of Formula I supra, p-cresol, 4-ethylphenol, 4-t-butylphenol, 4-t-amylphenol, 4-t-octylphenol, 4-dodecylphenol, and 4-nonylphenol may be mentioned. At present, it is preferred to use 4-nonylphenol as the formula I component.
Exemplary polyoxyalkylenediamines which can be used in accordance with Formula II include dipropylene glycol diamine, tripropylene glycol diamine, tetrapropylene glycol diamine, diethylene glycol diamine, triethylene glycol diamine, tetraethylene glycol diamine and mixtures thereof.
The aldehyde component can comprise, for example, formaldehyde, acetaldehyde, propanaldehyde, butrylaldehyde, hexaldehyde, heptaldehyde, etc. with the most preferred being formaldehyde which may be used in its monomeric form, or, more conveniently, in its polymeric form (i.e., paraformaldehyde).
As is conventional in the art, the condensation reaction may proceed at temperatures from about 50° to 200° C. with a preferred temperature range being about 75°-175° C. As is stated in U.S. Pat. No. 4,166,726, the time required for completion of the reaction usually varies from about 1-8 hours, varying of course with the specific reactants chosen and the reaction temperature.
As to the molar range of components (A):(B):(C) which may be used, this may fall within 0.5-5:1:0.5-5.
The iron deactivator of the invention may be dispersed within the hydrocarbon medium within the range of about 0.05 to 50,000 ppm based upon one million parts of the hydrocarbon medium. Preferably, the iron deactivator is added in an amount from about 1 to 10,000 ppm. A Mannich product-metal complex is formed in situ upon Mannich product addition to the hydrocarbon medium. The complex deactivates the metal so as to inhibit free radical formation.
EXAMPLES
The invention will now be further described with reference to a number of specific examples which are to be regarded solely as illustrative and not as restricting the scope of the invention.
Testing Method
The peroxide test was employed to determine the deactivating ability of the chelators. The peroxide test involves the reaction of a metal compound, hydrogen peroxide, a base, and a metal chelator. In the presence of a base, the metal species will react with the hydrogen peroxide yielding oxygen. When a metal chelator is added, the metal can be tied up resulting in the inhibition of the peroxide decomposition or the metal can be activated resulting in the acceleration of the rate of decomposition. The less oxygen generated in a given amount of time, the better the metal deactivator.
A typical peroxide test is carried out as follows: In a 250 mL two-necked, round-bottomed flask equipped with an equilibrating dropping funnel, a gas outlet tube, and a magnetic stirrer, was placed 10 mL of 3% (0.001 mol) hydrogen peroxide in water, 10 mL of a 0.01 M (0.0001 mol) metal naphthenate in xylene solution, and metal deactivator. To the gas outlet tube was attached a water-filled filled trap. The stirrer was started and stirring kept at a constant rate to give good mixing of the water and organic phases. Ammonium hydroxide (25 mL of a 6% aqueous solution) was placed in the dropping funnel, the system was closed, and the ammonium hydroxide added to the flask. As oxygen was evolved, water was displaced, with the amount being recorded as a factor of time. A maximum oxygen evolution was 105 mL. With metal species absent, oxygen was evolved over 10 minutes.
Example 1
A 2:1:2 mole ratio of 4-nonylphenol:triethylene glycol diamine:paraformaldehyde was prepared as follows. In a three-necked, round-bottomed flask equipped with a mechanical stirrer, a reflux condenser, and a thermometer was placed 55 g (0.25 mole) of nonylphenol, 7.88 g (0.25 mole) of paraformaldehyde, and 76.9 g of xylene. On addition of the 18.5 g (0.125 mole) of triethylene glycol diamine, the temperature rose to 63° C. The mixture was held at about 70° C. for 1 hour. A Dean Stark trap was inserted between the condenser and the flask and the temperature was increased to 150° C., by which the time water of formation was azeotroped off --4.5 mL was collected (approximately the theoretical amount). The mixture was cooled to room temperature, the xylene returned to the mixture, and the mixture used as is at 50% actives.
When 100 mg of the solution in the above mixture was used in the peroxide test, only 37 mL of oxygen was evolved in 5 minutes. In contrast, when the product was not used in the peroxide test, 72 mL of oxygen was evolved.
The example shows that the product reduced the iron activity by 49%.
Example 2
A 2:1:2 mole ratio of p-cresol:triethylene glycol diamine: paraformaldehyde was prepared as follows. In a three-necked, roundbottomed flask equipped with a mechanical stirrer, a reflux condenser, and a thermometer was placed 43.26 g (0.4 mole) of p-cresol, 12.61 (0.4 mole) of paraformaldehyde, and 78.4 g of xylene. On addition of the 29.6 g (0.2 mole) of triethylene glycol diamine, the temperature rose to 66° C. The mixture was held at 70° C. for 1 hour. A Dean Stark trap was inserted between the condenser and the flask and the temperature was increased to 150° C., by which time water of formation was azeotroped off --7.4 mL was collected (approximately the theoretical amount). The mixture was cooled to room temperature, the xylene returned to the mixture, and the mixture used as is at 50% actives.
When 100 mg of the actives in the mixture was used in the peroxide test, 39 mL of oxygen was evolved in 5 minutes. In contrast, when the product was not used in the peroxide test, 72 mL of oxygen was evolved.
This example shows that the product reduced the iron activity by 46%.
Example 3
A 2:1:2 mole ratio of 4-nonylphenol:mixture of tripropylene glycol diamine and tetrapropylene glycol diamine:paraformaldehyde was prepared as follows. In a three-necked, round-bottomed flask equipped with a mechanical stirrer, a reflux condenser, and a thermometer was placed 44 g (0.2 mole) of 4-nonylphenol, 6.30 g (0.2 mole) of paraformaldehyde, and 23.5 g of xylene. On addition of the 23 g (0.1 mole) of the mixture of tripropylene glycol diamine and tetrapropylene glycol diamine, the temperature rose to 63° C. The mixture was held at 70° C. for 1 hour. A Dean Stark trap was inserted between the condenser and the flask and the temperature was increased in 151° C., by which time water of formation was azeotroped off --3.6 mL (approximately the theoretical amount). The mixture was cooled to room temperature, the xylene returned to the mixture, and the mixture used as is at 75% actives.
When 100 mg of the actives in the above mixture was used in the peroxide test, 24 mL of oxygen was evolved in 5 minutes. In contrast, when the product was not used in the peroxide test, 52 mL of oxygen was evolved.
This example shows that the product reduced the iron activity by 54%.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
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Certain Mannich reaction products (i.e., alkylated phenol, polyoxyalkylenediamine, and an aldehyde) are used to deactivate iron species already present in hydrocarbon fluids. Left untreated, such iron species lead to decomposition resulting in the formation of gummy, polymer masses in the hydrocarbon liquid.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to humidifying devices, and more specifically, to an ultraviolet (UV) sterilization chamber suited for use in an evaporative humidifier.
BACKGROUND OF THE INVENTION
[0002] Humidifying devices, or humidifiers, are used to moisturize the ambient air in a room, most commonly, a single room of a home. Evaporative (or wick) humidifiers, for example, utilize a reservoir of water, from which the wick draws moisture, and a fan forces air through and/or past the wick, thereby picking up moisture in the air as it is directed through a spout or vent into the room.
[0003] It is well known that ultraviolet (UV) irradiation may be used to reduce or eliminate the various minerals, microorganisms, and other contaminants in water. In particular, UV irradiation has been provided in an evaporative humidifier to sterilize the water supply to the wick. See, for example, the evaporative humidifier as described in the commonly-owned U.S. Pat. No. 7,513,486, (“the '486 Patent”), the entire contents of which are incorporated by reference herein.
[0004] In order for sterilization to be achieved, the water being provided to the wick must be exposed to UV irradiation for a sufficiently long period of time. In the '486 Patent, a UV lamp is provided in a disinfection unit and the lamp is surrounded with a helical ramp around which the supplied water travels prior to reaching the wick. By traveling along the extended path provided by the helical ramp as it is irradiated by the UV lamp, the supplied water receives sufficient irradiation for effective sterilization. However, this unit is relatively complex to fabricate, and subjects the quartz tube to the risk of being directly contacted by the water as a result a failure of the unit.
SUMMARY OF THE INVENTION
[0005] According to an embodiment of the present invention, a novel UV sterilization chamber is disclosed for use in a humidifier having a fellable water reservoir, a humidifying element and a pathway for directing water provided by the fillable water reservoir to the humidifying element of the humidifier. The pathway is provided in a base of the humidifier, over which an enclosure of the humidifier is removably placed. The sterilization chamber includes a portion of the pathway and a UV radiation source that is provided in the enclosure and positioned over the portion of the path way for illuminating the portion of the pathway with UV light. Upwardly-directed projections are provided in the base that border a perimeter of the pathway; and a downwardly-directed projection of a housing for the UV radiation source is configured to extend between the upwardly-directed projections when the enclosure is mated with the base in order to locate the UV radiation over the portion of the pathway to be illuminated. The downwardly-directed projection of the housing includes a radiation window for emitting the UV radiation. The housing also includes a switch configured to disable the UV radiation source when the enclosure is removed from the base
[0006] The housing further preferably includes a reflector for reflecting UV light emitted from a UV lamp downwardly through the radiation window. In addition, the illuminated portion of the pathway preferably comprises a serpentine pathway, which increases the time of travel of the water through the pathway and thereby the time of exposure to the UV radiation as a sterilant.
[0007] By configuring the humidifier to include a base with a removable enclosure in which the water pathways are primarily confined to the base unit, and in which the UV radiation source is easily and readily separated and removed from these water pathways, fabrication and cleaning of the humidifier are simplified over prior art systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention in which:
[0009] FIG. 1 is a perspective cutaway view of a humidifier including a UV sterilization chamber in accordance with a preferred embodiment of the present invention;
[0010] FIGS. 2A-2D are exploded perspective views of component sections of the humidifier of FIG. 1 ;
[0011] FIG. 3 is a top view of a base of the humidifier of FIG. 1 ;
[0012] FIG. 4 is bottom view of the humidifier of FIG. 1 , with the base of FIG. 3 having been removed;
[0013] FIG. 5 is a front exploded view of the humidifier of FIG. 1 , with cutaway portions showing elements of the UV sterilization chamber in a separated state; and
[0014] FIG. 6 is a front exploded view of the humidifier of FIG. 1 , with cutaway portions showing elements of the UV sterilization chamber in an engaged state.
[0015] Like reference numerals are used in the drawing figures to connote like components of the humidifier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] A preferred embodiment of an ultraviolet (UV) sterilization chamber for a humidifier according to the present invention is described below. This embodiment is provided for the purpose only of illustrating principles of the present invention, and should not be interpreted as limiting the invention in any way beyond the scope of the claims and their equivalents.
[0017] Referring to FIG. 1 , a humidifier 100 includes a body 1 carried on a base 20 . The base 20 has a molded ring 20 a (see, e.g., FIG. 3 ) for carrying a water reservoir 50 , as well as a molded ring 20 b for carrying a wicking filter 21 . The filter 21 is preferably formed from several layers of “expanded” cellulose (paper), each layer of cellulose being slit and stretched into a non-raveling open mesh and then mechanically or adhesively adhered to the other layers. This filter design enables water to be fully absorbed while maintaining air flow through the cellulose layers in order to achieve a maximum evaporation rate. Expanded cellulose filters of this type may be obtained, for example, from Columbus Industries, Inc. of Columbus, Ohio.
[0018] Water exiting the water reservoir 50 is directed from a compartment 20 f defined by molded ring 20 a along a series of molded paths 20 c, 20 d and 20 e to a compartment 20 g defined by the molded ring 20 b and a molded insert 20 i (see, e.g., FIG. 3 ). The filter 21 rests within the compartment 21 , and absorbs water by capillary action (“wicking”) to moisten a substantial volume of the filter. The moisture is evaporated from the filter with the assistance of a fan and control unit 60 , which draws air through vents 20 h of the base 20 and around the filter 21 to be exhausted through a grill 4 positioned in an opening 1 a in the upper surface of the body 1 .
[0019] With reference to FIGS. 2B and 2C , a UV lamp 41 is positioned within a quartz glass tube 27 in a lower cavity of a motor cavity 2 of the fan and control unit 60 . The UV lamp 41 may preferably be a filament-type, 4-watt UV lamp that produces UV radiation having wavelengths in the UV-C (or shortwave) range of 200 to 280 nanometers, which may be obtained for example from Osram Sylvania of Danvers, Mass. Radiation in the UV-C range has been proven effective as a mutagen in the destruction of the DNA of micro-organisms such as pathogens, viruses, bacteria and molds, thereby preventing their reproduction. See, e.g., Philip W. Brickner, MD et al., “The Application of Ultraviolet Germicidal Irradiation to Control Transmission of Airborne Disease: Bioterroism Countermeasure,” Public Health Reports, Vol. 118, March- April 2003, pp. 99-119, which is incorporated by reference herein.
[0020] A UV bracket 9 is fastened at a bottom surface of the cavity to retain the UV lamp 41 and quartz glass tube 27 within the cavity, and includes an aperture 9 b (see, e.g., FIG. 4 ) permitting UV light from the UV lamp 41 to be downwardly directed toward the molded path 20 d to irradiate water in the molded path 20 d, through which water provided by the water reservoir 50 is directed to the filter 21 .
[0021] With reference to FIG. 2A , an exploded diagram further illustrates the body 1 , the grill 4 and a knob 5 . The body 1 may be formed in any number of shapes, and as shown is preferably formed as a substantially rectangular box made of molded plastic. The knob 5 attaches to a switch 40 of the fan and control unit 60 (see FIG. 2B ) at an aperture 1 d in a ring 1 e located at the upper surface of the body 1 . In addition, an aperture 1 g is provided in the ring 1 e adjacent to the aperture 1 d. The ring 1 e is integrally formed with a vertical rib 1 f of the body 1 .
[0022] The body 1 further includes a cavity 1 b for receiving the water reservoir 50 , and a slot 1 c through which an indicator portion 22 c of the tank member 22 of the reservoir 50 protrudes in order to provide a visual indication of the water level in the reservoir 50 .
[0023] With reference to FIG. 2B , the fan and control unit 60 includes a fan blade 3 which is installed on a drive shaft 33 a of motor 33 and retained by a circlip 33 b or other suitable fastener. The fan blade 3 may preferably be a five-bladed, seven-inch axial blade design, or any other suitable design.
[0024] The fan motor 33 a is mounted in a motor bracket 2 f that is mounted to base member 2 g within a bowl 2 b of the motor bracket 2 (see, e.g., FIG. 4 ), and is controlled by conventional control circuitry that is mounted on a printed circuit board (PCB) 30 via a rotary switch 40 . The fan motor 33 a may preferably be a 1380 RPM, single-phase shaded-pole 120 VAC motor (conventionally referred to as a “universal” motor), or a motor of other suitable design. Alternatively, the fan motor 33 a may be a 1380 RPM, single-phase shaded-pole motor operating at 220-240 VAC. Motors of these types may be obtained, for example, from Wolong Electric Group, Ltd. Of Shangyu (Zhejiang province), China.
[0025] The rotary switch 40 is preferably a multiple position switch that, in combination with the control circuitry, enables a user to operate the fan at several selectable fan speeds.
[0026] The base member 2 g may preferably include a rim 2 h which is configured to locate the upper surface of the cylindrical filter 21 against the base member 2 h. Similarly, molded ring 2 b locates a bottom surface of the cylindrical filter 21 against a bottom surface of the compartment 20 g. In this configuration, the fan operates to draw air through vents 20 h in the base 20 toward an external surface of the cylindrical filter 21 through to an interior of the filter 21 to be exhausted through the grill 4 positioned in the opening 1 a in the upper surface of the body 1 .
[0027] With reference to FIG. 2B , the PCB 30 is housed in a PCB box 7 having a PCB box cover 8 , which is housed within a control compartment 2 c of the motor bracket 2 . The PCB 30 also controls the operation of the UV lamp 41 , as will be further described herein, and a light emitting diode (LED) 32 , which is housed in a lamp shade 6 . The rotary switch 40 and the LED 32 in its lamp shade 6 are mounted to a rotary switch cover 17 , which is fastened to one or more of the body 1 and motor bracket 2 so that the rotary switch 40 protrudes through the aperture 1 d and the lamp shade 6 extends through the aperture 1 g . The lamp shade 6 is firmly fitted within the aperture 1 g by means of an O-ring 16 . The LED 32 , in combination with the control circuitry, is preferably configured to indicate one or more of “power on” condition and/or a “maintenance needed” condition (for example, filter or UV lamp replacement) for the humidifier 100 . The LED 32 may preferably be configured to emit several colors of light under the control of the PCB 30 in order to indicate different operating conditions of the humidifier 100 .
[0028] A conduit 2 e of the motor bracket 2 reaches to the base 20 and provides a path for a conventional power cord 38 (see, e.g., FIG. 2C ) to extend externally from the humidifier 100 .
[0029] With reference to FIG. 2C , the base 20 is shown with reference to the filter 21 and a UV lamp unit including the UV lamp 41 and the quartz glass tube 27 . As shown, the base 20 is preferably provided with rubber feet 31 at each corner of the base 20 for stable placement of the base 20 on an operating surface.
[0030] The lamp 41 and the quartz glass tube 27 are housed in a UV box 18 . A UV lamp holder electrically interconnected to the PCB 30 (see FIG. 2B ), is inserted through an aperture of a UV box cover and receives the UV lamp 41 . In order to guard against the ingress of moisture to the vicinity of UV lamp 41 , seal pads 29 are provided at either end of the quartz glass tube 27 to seal the quartz glass tube 27 against end faces of the UV box 18 and UV cover 19 . The assembled UV box 18 and UV box cover 19 are enclosed by a cap 14 and the UV bracket 9 , and the entire assembly is inserted into a UV lamp unit compartment 2 a. The UV bracket 9 is sealed to the UV lamp unit compartment 2 a by means of an O-ring 15 . As illustrated, the UV box 18 includes an upper member 18 a that is arced (preferably along a parabolic profile). An inner surface of the upper member 18 a is preferably provided with a reflective material, such that the inner surface of the upper member 18 a is effective to direct UV light radiated by the UV lamp 41 downwardly to irradiate water in the molded path 20 d of FIG. 3 . When a filament-type, 4-watt UV-C lamp is provided in the UV box 18 , the upper member 18 a is provided with the reflective material and the UV lamp 41 is positioned less than one inch above a surface of the water in the molded path 20 d, it is possible to achieve a germ-killing effectiveness of 99.99%.
[0031] The cap 14 and UV bracket 9 further mount a microswitch 39 , fixed chip 12 and push rod 13 to the UV lamp unit. The microswitch 39 is also electrically interconnected to the PCB 30 . The push rod 13 is preferably fabricated from silicone rubber, and a rod portion 13 a extends through an aperture in the fixed chip 12 . The rod portion 13 a of the push rod 13 is positioned for actuating the microswitch 39 , and a base portion 13 b of the push rod 13 is placed in contact with the UV bracket 9 over an aperture 9 a (see, e.g., FIG. 4 ) positioned to be flexibly displaced by a pin 20 j of the base 20 (see, e.g., FIG. 3 ). When the body 1 of the humidifier 100 is placed onto the base 20 , the pin 20 j extends through the aperture 9 a to flexibly displace the base portion 13 b of the push rod 13 , such that the rod portion 13 a engages the microswitch 39 to switch the microswitch 39 to an electrically closed position. In this position, the UV lamp is powered when the rotary switch 41 is switched to an operating position. When the body 1 is removed from the base 20 , the pin 20 j exits the aperture 9 a and the rod portion 13 a of the push rod 13 retracts to switch the microswitch 39 to an electrically open position. In this position, one or more of the UV lamp and or the fan unit are inoperative regardless of the position of the rotary switch 41 .
[0032] With reference to FIG. 2D , the water reservoir 50 includes a tank member 22 which may be formed in any of a variety of volumetric shapes that may be suitable for coupling the water tank 100 to the humidifier. A principal portion of the tank member 22 has an approximately trapezoidal lower face 22 a with rounded vertices, and extends upwardly along a longitudinal direction of the portion with a continuously expanding cross-section that reaches its maximum cross-sectional area at an upper face 22 b. Respective perimeter edges 22 f, 22 g of the lower face 22 a and upper face 22 b are also rounded, and join side walls 22 h, a rear wall 22 j and a front wall (not shown) of the principal portion to the lower face 22 a and upper face 22 b, respectively.
[0033] The tank member 22 further includes a handle portion 22 d that extends upwardly from a rear portion of the upper face 22 b and forward from this portion, but not completely across the upper face 22 b. Over the portion of the upper face 22 b that the handle portion 22 d extends, it has essentially the same cross-section as this portion of the upper face 22 b.
[0034] A front region 22 i of the handle portion 22 d is slightly inset to receive a tank cover 25 . The tank cover 25 preferably includes a gripping portion 25 a for gripping by a human hand, and recesses 25 e which mate with projections 22 e on the tank member 22 in order to positively locate the tank cover 25 over the front region 22 i of the handle portion 22 d. The tank cover 25 in addition may be optionally bonded to the handle portion 22 d with a conventional adhesive.
[0035] An indicator portion 22 c of the tank member 22 extends rearwardly from the rear face 22 k of the tank member 22 and handle portion 22 d As illustrated in FIG. 1 , a depth of the indicator portion 22 c increases in a downward vertical direction, while a width of the indicator portion 22 c decreases in the downward vertical direction. The indicator portion 22 c of the water tank 100 is configured for example to extend through a wall of the humidifier to provide a visual indication to the user regarding the fluid level in the tank member 22 ,
[0036] At the lower face 22 a, a round, externally threaded opening 22 j is provided for receiving a cap 23 , which has an inner thread for mating with an outer thread of the threaded opening 22 j. The cap 23 is provided with an O-ring 23 for sealably securing the cap 23 to the threaded opening 22 j of the tank member 22 .
[0037] A valve bar 34 is positioned within a central aperture 23 a of the cap 23 . A downward force is exerted on the valve bar 34 by a spring 36 , which is fitted over the valve bar 34 and between a flange 34 b of the valve bar 34 and the upper surface of a spring cup (not shown) of the cap 23 . A rubber valve member 35 is lockably fitted to a groove 34 a of the valve bar 34 , and serves to restrict further downward movement of the valve bar 24 when the valve member 35 is interferingly pulled by the force of the spring 36 against the central aperture 23 a. When inserted into the compartment 20 g of the base 20 , a post 20 j (see, e.g., FIG. 3 ) positioned at the center of the compartment 20 g is pressed against a bottom surface of the flange 34 b of the valve bar 34 , thereby raising the valve member 35 above the central aperture 23 a and permitting fluid in the water tank 100 to flow around the valve 34 a and through the central aperture 23 a for delivery to the wick of the humidifier.
[0038] With reference to FIG. 3 , the base 20 as previously described includes the compartment 20 f defined by the molded ring 20 a, the compartment 20 g defined by the molded ring 20 b and the molded insert 20 i, and the molded paths 20 c, 20 d and 20 e which interconnect and enable water to flow from the compartment 20 f to the compartment 20 g . Molded path 20 d is positioned near the center of the base 20 , and has a serpentine shape defined by vanes 20 k and 20 l . The serpentine path carries water supplied by the path 20 c near a front side of the base 20 to the path 20 d near the rear side of the base 20 . Each of paths 20 c and 20 e carry water across the base 20 to the serpentine path 20 d.
[0039] In FIG. 3 , the serpentine path 2 d is shown with a region 20 n, With reference to FIG, 4 , the region 20 n corresponds to a position occupied by a first rectangular projection 9 c of the bracket 9 when the body 1 of the humidifier 100 is placed onto the base 20 . As the first rectangular projection 9 c includes the aperture 9 b through which UV light from the UV lamp 41 is emitted, water carried within the serpentine path 2 d is thereby irradiated. By following the serpentine path defined by the molded path 2 d, the amount of time required for water to be carried along the path is increased, thereby increasing the time that the water is exposed to the UV light and increasing the effectiveness of the UV sterilization.
[0040] With reference to FIG. 4 , the bracket 9 includes the first rectangular projection 9 c and a second rectangular projection 9 d that extend downwardly from a base bottom surface 9 e of the bracket 9 . When the body 1 of the humidifier 100 is placed on the body 20 , the first rectangular projection is positioned over the region 20 n of FIG, 3 , and the second rectangular projection is positioned over a region 20 m of FIG. 3 . As further shown in FIG. 3 , the perimeter of regions 20 m, 20 n is bordered by molded projections 20 o and 20 q. The region 20 m further includes a pad 20 p, which also defines a portion of the serpentine path 20 d.
[0041] Upper surfaces of each of the vanes 20 k, 20 l and the pad 20 p lie below the upper surfaces of the molded projections 20 o, 20 q. As a result, when the body 1 of the humidifier 100 is placed on the body 20 , the first and second projections 9 c, 9 d extend below the upper surfaces of the molded projections 20 o, 20 q into the regions 20 n, 20 m, respectively. In this manner, the molded projections 20 o, 20 q operate to properly locate the first and second projections 9 c, 9 d (and the UV lamp 41 positioned above the aperture 9 b ) with respect to the serpentine path 20 d, and thereby assist in confining the emitted UV light to the serpentine path.
[0042] These features can be further illustrated as follows. FIGS. 5 and 6 each show the body 1 and the base 20 of the humidifier 100 in partially broken views that make visible elements of the disclosed UV sterilization chamber. FIG. 5 illustrates the humidifier 100 in a state in which the body 1 has been separated from the base, and FIG. 6 illustrates the humidifier 100 in a state in which the body 1 has been placed onto the base 20 . With reference to FIG. 6 , it can be seen that, when the body 1 is placed onto the base 20 , the first projection 9 c is directed between the molded projections 20 o, 20 q until portions of the base bottom surface 9 e rest on the upper surfaces of the molded projections 20 o, 20 q. In this position, a bottom surface of the first projection 9 c extends below the top surfaces of the molded projections 20 o, 20 q and the top surface of the pad 20 p, in proximity to the top surfaces of the vanes 20 k and 20 l . Side surfaces of the first projection 9 c substantially abut side surfaces of the molded projections 20 o, 20 q , thereby locating the first projection 9 c over the serpentine path 2 d in a substantially fixed position.
[0043] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. For example, the first and second rectangular projections of the UV bracket may be made in any of a variety of shapes determined as a function of the humidifier design (in particular, as a function of the corresponding molded projections of the base. In addition, the serpentine path may include any of a variety of configurations of folded paths, and the serpentine path and lamp unit may be positioned at any of a variety of positions relative to a footprint of the base.
[0044] Accordingly, the invention is to be limited only by the scope of the claims and their equivalents.
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A UV sterilization chamber is provided to a humidifier having a water reservoir, a humidifying element and a pathway for directing water provided by the water reservoir to the humidifying element of the humidifier. The pathway is provided in a humidifier base, over which a humidifier enclosure is removably placed. The UV sterilization chamber includes a serpentine portion of the pathway and a UV radiation source positioned for illuminating the portion of the pathway with UV light. Upwardly-directed projections in the base border a perimeter of the pathway; and a downwardly-directed projection of the UV radiation source extends between the upwardly-directed projections when the enclosure is mated with the base, thereby locating the UV radiation source over the portion of the pathway. A switch disables the UV radiation source when the enclosure is removed from the base.
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CROSS-REFERENCE
[0001] This is a United States national phase application of PCT/GB2015/050019 filed Jan. 8, 2015 entitled “Instrument Articulation,” which claims priority from United Kingdom Application No. 1400569.8 filed Jan. 14, 2014 entitled “Instrument Articulation” and United Kingdom Application No. 1418255.4 filed Oct. 15, 2014 entitled “Instrument Articulation,” the entire disclosures of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to articulations, for example for surgical robots.
BACKGROUND
[0003] A typical robot arm comprises a series of rigid links, each of which is connected to the next by a respective articulation. Each articulation is designed to have appropriate characteristics of strength, range of motion, size etc. for the purpose the arm is to perform.
[0004] One particular application of robots is for performing or assisting in surgery. FIG. 1 illustrates a typical surgical robot arm. A patient 1 is lying on a bed 2 . The robot arm 3 extends from a base 4 towards the patient. The arm has a series of rigid links 5 , 6 , 7 , which are connected to each other and to the base by articulations 8 , 9 , 10 . The articulations provide a sufficient range of motion that the arm can approach the patient in different ways so as to perform a range of surgical procedures. The links can be made to move about the articulations by motors 11 which are under the control of a surgeon. The final link 7 of the arm terminates in a wrist articulation 12 to which a surgical instrument 13 is attached. The surgical instrument is designed for insertion into the patient and, for example, could be an endoscope or could terminate in a cutting or pinching tool.
[0005] It is desirable for the tip of the surgical instrument to be articulated and hence mobile, so that it can be placed in a wide range of orientations relative to the remainder of the surgical instrument. That assists in allowing the surgical instrument to perform a wide range of surgical procedures, and in allowing a surgeon to place multiple arms close to a surgical site. It is also desirable for the surgical instrument articulation to be kinematically well-functioning, without there being any attitudes in the core of its range of motion that are difficult to reach or where there could be poor control over the motion of the end effector.
[0006] U.S. Pat. No. 4,257,243 describes a constant velocity joint for coupling a tractor drive shaft to an agricultural machine. U.S. Pat. No. 3,470,712 describes a similar arrangement for serving as a constant velocity coupling.
SUMMARY
[0007] According to the present invention there is provided a robot, robot arm or articulation as set out in the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will now be described by way of example with reference to the accompanying drawings. In the drawings:
[0009] FIG. 1 shows a surgical robot arm.
[0010] FIG. 2 shows various views of a first wrist joint for a surgical instrument.
[0011] FIG. 3 shows various views of a second wrist joint for a surgical instrument.
[0012] FIG. 4 shows various views of the second wrist joint for a surgical instrument.
[0013] FIG. 5 shows various views of a third wrist joint for a surgical instrument.
[0014] FIG. 6 shows a fourth wrist joint for a surgical instrument.
[0015] FIG. 7 shows a fifth wrist joint for a surgical instrument.
[0016] FIG. 8 shows example slaving arrangements for two links of a surgical instrument.
DETAILED DESCRIPTION
[0017] FIG. 2 shows the terminal part of a surgical instrument. The surgical instrument is attached to a robot arm which is generally of the type shown in FIG. 1 , with a base and a number of inter-articulated rigid links. The end-most part of the terminal link of the surgical instrument is shown at 20 in FIG. 2 . The terminal link of the surgical instrument ends in a wrist joint 21 which carries an attachment 22 to which a surgical end effector can be attached, for example a cutting or pinching tool. The joint 21 articulates the attachment 22 relative to the terminal link 20 of the surgical instrument.
[0018] The terminal link of the surgical instrument is a rigid shaft, defined by a stiff outer tube 23 . At the distal end of the tube is a spherical joint 21 . Spherical joint 21 comprises a part-ball 24 which is captive in a part-cup 25 . The part-cup is fast with the terminal link 20 of the surgical instrument. The part-ball is fast with the attachment 22 . The spherical joint allows the attachment to move with three degrees of rotational freedom, but no translational freedom, relative to the terminal link of the surgical instrument.
[0019] On the interior of the part-ball 24 is a Hooke's or universal joint 35 . The Hooke's joint is offset from the centre of rotation of the spherical joint 21 and connects the part-ball 24 to a control rod 26 . The control rod runs through the interior of the tube 23 towards the proximal end of the terminal link 20 of the surgical instrument. The universal joint 35 connects the control rod to the tube so that it has two degrees of rotational freedom relative to the part-ball.
[0020] A pantograph mechanism 27 couples the control rod 26 to the tube 23 . The pantograph comprises a pair of hinged two-part links 28 , 29 which terminate in collars 30 , 31 through which the control rod 26 runs. The pantograph permits the control rod to have three degrees of translational freedom relative to the tube 23 , and to rotate relative to the tube about its longitudinal axis by spinning in the collars, but prevents the control rod from yawing about its transverse axes. The control rod is preferably rigid.
[0021] With this mechanism, when the control rod translates laterally relative to the tube, as indicated by axes 32 and 33 in FIG. 2 , this causes the centre of the Hooke's joint 35 to move laterally. That in turn causes rotation of the spherical joint 21 , which alters the direction of the attachment 22 relative to the terminal link 20 of the surgical instrument. In this way, when an end effector is coupled to the attachment the attitude of the end effector can be altered.
[0022] The motion of the control rod relative to the tube can be driven by any suitable means, for example electric motors or hydraulic or pneumatic rams. The control rod can be elongated so that it runs from the distal end of the terminal link 20 to near the proximal end of the terminal link, with the result that those drive means can be located near the proximal end of the terminal link. That is convenient because it reduces the weight that is suspended near the distal end of the terminal link, making the terminal link easier to control.
[0023] A further advantage of the mechanism described above is that the spherical joint 21 is relatively compact, meaning that when the attachment 22 is deflected at a significant angle to the terminal link 20 the terminal end of the surgical instrument can be brought relatively close to a patient on whom the robot is operating. The compactness of the joint also allows multiple similar robot arms to work in close proximity.
[0024] The pantograph mechanism for maintaining the direction of the control rod could be replaced with another mechanism for achieving the same purpose, for example a set of interlinked rockers running between the inner wall of the tube and the control rod and terminating in slip rings in which the control rod runs. Alternatively, the control rod could be permitted to yaw relative to the tube. For example the control rod could run through a spherical joint mid-way along the tube.
[0025] FIG. 3 shows an alternative design of joint for a surgical instrument. In FIG. 3 the end-most part of the terminal link of the surgical instrument is shown at 50 . The terminal link of the surgical instrument ends in a wrist joint 51 which carries an attachment 52 to which a surgical end effector can be attached. The joint 51 articulates the attachment 52 relative to the terminal link 50 of the surgical instrument. A control rod 53 runs inside the terminal link of the surgical instrument for controlling motion of the joint 51 .
[0026] The joint 51 comprises a can 54 , which is shown in more detail in FIG. 4 . An inner end of the can is attached to the distal end of the control rod 53 . The attachment 52 is provided at the outer end of the can. The can is mounted relative to the terminal end of the surgical instrument in a joint 55 . The joint 55 provides the can with freedom to rotate about axes orthogonal to the terminal link of the surgical instrument. In the example illustrated in the figures the spherical joint is provided by a gimbal ring, but it could be provided in other ways, for example it could be a spherical joint provided by a part-cup fast with the terminal end of the surgical instrument in which a part-ball formation of the can 54 is captive.
[0027] Referring to FIG. 4 , the can comprises an outer shell 60 . At each end of the shell is a spherical joint 61 , 62 defined by a part-cup 63 , 64 that is attached to the shell and a part-ball 65 , 66 that is captive in the cup. The outer side of one part-ball 65 is coupled to the control rod 53 . The outer side of the other part-ball 66 is coupled to the attachment 52 . The inner side of each part-ball is provided with a universal joint 67 , 68 whose centre is offset from the rotation centre of the respective part-ball. The universal joints 67 , 68 are linked by a connecting rod 69 . The connecting rod 69 is equipped with a mechanism 70 whose purpose is to prevent the connecting rod from rotating about axes transverse to its length. In the example of FIG. 4 , that mechanism is provided by a flat slipper washer 71 which is attached to and extends transversely to the connecting rod 69 . The slipper washer can slide snugly in an annular passageway 72 which also runs transversely to the connecting rod. The fact that the slipper washer is located in the annular passageway prevents the connecting rod from yawing.
[0028] FIG. 5 shows a similar can to that of FIG. 4 . Like parts are designated the same in FIG. 5 as in FIG. 4 . In FIG. 5 the mechanism for preventing the connecting rod from yawing is a pantograph having two links 73 , 74 which are hinged relative to each other. One of the links, 73 , is also hinged relative to the interior of the can. The other of the links, 74 , carries a slip ring in which the connecting rod runs snugly.
[0029] As the part-balls 65 , 66 rotate relative to the can the distance between the universal joints 67 , 68 will change. To accommodate that the connecting rod could be made in two parts, one sliding snugly over the other. Alternatively, the attachment 52 and the control rod 53 could run slidably through the part-balls 65 , 66 and terminate within the can in the universal joints. Then the connecting rod could be of fixed length.
[0030] When part-ball 65 , which is connected to the control rod 53 , is rotated relative to the can about an axis other than the can's longitudinal axis, that rotation causes the connecting rod 69 to translate laterally within the can. That in turn causes the part-ball 66 to rotate relative to the can in a way that mirrors the rotation of the part-ball 65 .
[0031] Referring again to FIG. 3 , the can is mounted in a spherical joint 55 relative to the terminal link of the surgical instrument. The control rod runs through a guide tube 75 that is mounted in a spherical joint 76 in the mid-part of the terminal link of the surgical instrument. That arrangement permits the control rod to rotate about that spherical joint and also to slide along its axis relative to that joint. When the control rod is moved so that its distal end moves transverse to the terminal link of the surgical instrument, that motion is transmitted to the inner part-ball 65 of the can. The can reacts against the spherical joint 55 , resulting in rotation of the inner part-ball 65 relative to the can about an axis transverse to the terminal link of the instrument and also in rotation of the can relative to the instrument about an axis transverse to the terminal link of the instrument. The action of the connecting rod 69 means that the rotation of the inner part-ball is transmitted to the outer part-ball 66 , causing it also to rotate relative to the can about an axis transverse to the terminal link of the instrument.
[0032] The terminal link of the surgical instrument of FIG. 3 is a rigid shaft, defined by a stiff outer tube 53 . At the distal end of the tube is a spherical joint 21 . Spherical joint 21 comprises a part-ball 24 which is captive in a part-cup 25 . The part-cup is fast with the terminal link 20 of the surgical instrument. The part-ball is fast with the attachment 22 . The spherical joint allows the attachment to move with three degrees of rotational freedom, but no translational freedom, relative to the terminal link of the surgical instrument.
[0033] As can be seen in FIG. 3 , this arrangement allows the attachment 52 for the end effector to be deflected to relatively large angles relative to the terminal link of the surgical instrument. In a typical embodiment it may be expected that the attachment can be deflected through a cone approaching 180°.
[0034] It can also be seen from FIG. 3 that the joint 51 at the terminal end of the surgical instrument is relatively compact. This is illustrated at 70 . The compactness of the joint also allows multiple similar surgical instruments to work in close proximity.
[0035] A further advantage of the joint of FIGS. 3 to 5 is that rotation of the control rod 53 about its longitudinal axis can be conveyed to the end effector with constant velocity. This may be useful if, for example, the end effector is a drill. It may also simplify the strategy needed to manage the motion of the control rod. To permit this behaviour it is preferable that the joint 55 in which the can 54 is mounted relative to the terminal link of the surgical instrument does not permit rotation of the can about the longitudinal axis of the terminal link of the surgical instrument. The joint 55 could be a gimbal joint.
[0036] The motion of the control rod 53 relative to the tube can be driven by any suitable means, for example electric motors 71 or hydraulic or pneumatic rams. The control rod can be elongated so that it runs from the distal end of the terminal link 50 to near the proximal end of the terminal link, with the result that those drive means can be located near the proximal end of the terminal link. That is convenient because it reduces the weight that is suspended near the distal end of the terminal link, making the terminal link easier to control.
[0037] The joints described above can be used in other applications. For example, the joints could be used for joints in robots other than surgical robots; and for joints other than wrist joints, whether in surgical robots or for other purposes. The joints could be used in non-robotic applications, for example in vehicles (e.g. in drive shafts or steering columns) or in other machinery.
[0038] The end effector could be engaged in the attachment 22 , 52 by any suitable mechanism, for example by a screw, bayonet or snap fitting.
[0039] The can 54 need not enclose the connecting rod 69 .
[0040] FIG. 6 shows a further way in which the can 54 could be controlled. In this mechanism three push rods 80 , 81 , 82 are attached to the inner end of the can, at locations spaced around the can. The push rods can be moved axially relative to the terminal link of the surgical instrument, e.g. by screw drives, to cause the can to adopt a desired location. The control rod 53 is mounted to a universal joint 83 within the terminal link of the surgical instrument, and is made in two parts, with one surrounding and being splined to the other in order to accommodate changes of distance between the universal joint 83 and its point of attachment to the inner part-ball 65 . This arrangement is convenient in that the control rod 53 can readily be rotated by way of the universal joint 83 independently of the mechanism for setting the attitude of the end effector.
[0041] FIGS. 3 to 6 illustrate using a spherical joint to couple the control rod to the can and another spherical joint to couple the attachment to the can. Other joints may be used in these instances instead of a spherical joint. For example, a gimble joint may be used. As another example, a universal joint may be used. FIG. 7 illustrates an example in which two universal joints 90 and 91 are used to couple control rod 53 to attachment 52 via intermediate shaft 96 . Control rod 53 terminates in U-joint 92 which rotates about axes A 1 and A 2 . Intermediate shaft 96 comprises U-joint 93 which is arranged perpendicular to U-joint 92 and is coupled to U-joint 92 via cross-piece 97 . U-joint 93 rotates about axes A 1 and A 2 . Attachment 52 terminates in U-joint 94 which rotates about axes A 3 and A 4 . Intermediate shaft 96 comprises U-joint 95 which is arranged perpendicular to U-joint 94 and perpendicular to U-joint 92 and is coupled to U-joint 94 via cross-piece 98 . U-joint 95 rotates about axes A 3 and A 4 .
[0042] Intermediate shaft 96 may house the components interior to the can shown in FIGS. 3 to 6 . In this case the attachment 52 is mechanically slaved to the control rod 53 via the mechanisms described with respect to FIGS. 3 to 6 except that the universal joints 90 and 91 provide the articulation provided by the spherical joints in FIGS. 3 to 6 . In other words, the rotation of universal joint 90 about axes A 1 and A 2 mirrors the rotation of universal joint 91 about axes A 3 and A 4 . In an alternative implementation, the rotation of universal joint 90 about axes A 1 and A 2 is asymmetric to the rotation of universal joint 91 about axes A 3 and A 4 . For example, the double universal joint may be constructed such that universal joint 90 has ˜±90° of travel about axis A 1 and ˜±30° of travel about axis A 2 , and universal joint 91 has ˜±30° of travel about axis A 4 and ˜±90° of travel about axis A 3 .
[0043] In this alternative implementation, the slaving may be accomplished mechanically by driving both joints from a common drive but with different gear ratios in the joint mechanisms. In the example given, a common drive input causes universal joint 90 to rotate around axis A 1 and universal joint 91 to rotate around axis A 4 . However different gear ratios are used in the joint mechanisms, such that when driven, universal joint 90 rotates three times as far as universal joint 91 . This would lead to both joints reaching the limit of their range at the same time. Another common drive input causes universal joint 90 to rotate about axis A 2 and universal joint 91 to rotate about axis A 3 . Different gear ratios are used in the joint mechanisms, such that when driven, universal joint 91 rotates three times as far as universal joint 90 . This would lead to both joints reaching the limit of their range at the same time. Alternatively the joints may be slaved electronically. In this case, each axis is independently controlled and software implemented to ensure the correct relationship between all the joint movements.
[0044] The attachment 52 and control rod 53 may be mechanically slaved together as illustrated in FIGS. 3 to 6 . Alternatively, the attachment 52 and control rod 53 may be partially or fully electronically slaved to one another in order to provide the same range of motion described with respect to FIGS. 3 to 6 .
[0045] FIG. 8 illustrates some exemplary slaving arrangements for a first joint J 1 which is the terminal joint of control rod 53 and a second joint J 2 which is the terminal joint of attachment 52 . Joints J 1 and J 2 may be spherical joints, universal joints, gimble joints or any other joints which enable the same articulation between the control rod 53 and the intermediate shaft 96 /can 54 and the intermediate shaft 96 /can 54 and the attachment 52 as described above.
[0046] In one implementation of FIG. 8( a ) , J 1 and J 2 are wholly electronically slaved together. In this case, control shaft 101 driven by motor 103 controls part of the motion of J 1 and J 2 . The other part of the motion of J 1 and J 2 is controlled by control shaft 102 driven by motor 104 . Control shaft 101 is coupled to J 1 and terminates at J 2 . Control shaft 102 is coupled to J 1 and terminates at J 2 . Motor 103 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Motor 104 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. In the case of a double universal joint as shown in FIG. 7 , rotation of the universal joint 90 about axis A 1 is controlled by motor 103 via control shaft 101 . Similarly, rotation of the universal joint 91 about axis A 4 is controlled by motor 103 via control shaft 101 . Rotation of the universal joint 90 about axis A 2 is controlled by motor 104 via control shaft 102 . Rotation of the universal joint 91 about axis A 3 is controlled by motor 104 via control shaft 102 . Motors 103 and 104 drive their respective control shafts to cause J 1 and J 2 to articulate in the same manner as if J 1 and J 2 were mechanically slaved together as described above.
[0047] In an alternative implementation of FIG. 8( a ) , J 1 and J 2 are mechanically slaved together by intermediate shaft 96 /can 54 , for example as discussed above with reference to FIGS. 3 to 7 . Control shaft 101 driven by motor 103 terminates at J 2 . Motor 103 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Control shaft 102 driven by motor 104 also terminates at J 2 . Motor 104 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. In the case of a double universal joint as shown in FIG. 7 , rotation of the universal joint 91 about one axis A 3 or A 4 is controlled by motor 103 via control shaft 101 . Similarly, rotation of the universal joint 91 about the other axis A 3 or A 4 is controlled by motor 104 via control shaft 102 . J 1 is mechanically slaved to J 2 , thus when J 2 is driven by motors 103 and 104 , J 1 also moves in a manner determined by the manner in which J 1 and J 2 are mechanically slaved. In FIG. 8( a ) the joint J 2 which is the most distal of joints J 1 and J 2 from the control rod 53 is driven by motors 103 and 104 . Alternatively, the control shafts 101 and 102 may be attached to and drive joint J 1 , and joint J 2 moves in a manner determined by the mechanical slaving between J 1 and J 2 .
[0048] In one implementation of FIG. 8( b ) , J 1 and J 2 are wholly electronically slaved together. In this case, control shaft 105 driven by motor 106 controls part of the motion of J 1 and J 2 . The other part of the motion of J 1 and J 2 is controlled by control shaft 107 driven by motor 108 . Control shaft 105 is coupled to J 1 and terminates at J 2 . Control shaft 107 driven by motor 108 terminates at one end at J 1 and at the other end at J 2 . Motor 108 is located in intermediate shaft 96 between J 1 and J 2 . Motor 106 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. In the case of a double universal joint as shown in FIG. 7 , rotation of the universal joint 90 about axis A 1 is controlled by motor 106 via control shaft 105 . Similarly, rotation of the universal joint 91 about axis A 4 is controlled by motor 106 via control shaft 105 . Rotation of the universal joint 90 about axis A 2 is controlled by motor 108 via control shaft 107 . Rotation of the universal joint 91 about axis A 3 is controlled by motor 108 via control shaft 107 . Motors 103 and 104 drive their respective control shafts to cause J 1 and J 2 to articulate in the same manner as if J 1 and J 2 were mechanically slaved together as described above.
[0049] In one implementation of FIG. 8( d ) , J 1 and J 2 are wholly electronically slaved together. In this case, control shaft 117 driven by motor 118 controls part of the motion of J 1 and J 2 . Control shaft 117 is coupled to J 1 and terminates at J 2 . The other part of the motion of J 1 is controlled by control shaft 119 driven by motor 120 . The other part of the motion of J 2 is controlled by control shaft 121 driven by motor 122 . Motor 122 is located in intermediate shaft 96 between J 1 and J 2 . Motor 118 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Motor 120 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. In the case of a double universal joint as shown in FIG. 7 , rotation of the universal joint 90 about axis A 1 is controlled by motor 118 via control shaft 117 . Similarly, rotation of the universal joint 91 about axis A 4 is controlled by motor 118 via control shaft 117 . Rotation of the universal joint 90 about axis A 2 is controlled by motor 120 via control shaft 119 . Rotation of the universal joint 91 about axis A 3 is controlled by motor 122 via control shaft 121 . Motors 118 , 120 and 122 drive their respective control shafts to cause J 1 and J 2 to articulate in the same manner as if J 1 and J 2 were mechanically slaved together as described above.
[0050] FIG. 8( c ) illustrates an arrangement in which J 1 and J 2 are wholly electronically slaved together. Control shaft 109 driven by motor 110 terminates at J 1 . Motor 110 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Control shaft 111 driven by motor 112 terminates at J 1 . Motor 112 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Control shaft 113 driven by motor 114 terminates at one end in intermediate shaft 96 between J 1 and J 2 and at the other end at J 2 . Motor 114 is located in intermediate shaft 96 between J 1 and J 2 . Control shaft 115 driven by motor 116 terminates at one end in intermediate shaft 96 between J 1 and J 2 and at the other end at J 2 . Motor 116 is located in intermediate shaft 96 . Motor 110 drives J 1 to articulate about one of its axes. Motor 112 drives J 1 to articulate about the other of its axes. Motor 114 drives J 2 to articulate about one of its axes. Motor 116 drives J 2 to articulate about the other of its axes. Motors 110 , 112 , 114 and 116 drive their respective control shafts to cause J 1 and J 2 to articulate in the same manner as if J 1 and J 2 were mechanically slaved together as described above.
[0051] FIG. 8( e ) illustrates an arrangement in which J 1 and J 2 are wholly electronically slaved together. Control shaft 123 driven by motor 124 terminates at J 1 . Motor 124 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Control shaft 125 driven by motor 126 terminates at J 1 . Motor 126 is located either in control rod 53 or further towards the base of the surgical instrument or robot arm. Control shaft 127 driven by motor 128 terminates at one end in attachment 52 and at the other end at J 2 . Motor 128 is located in attachment 52 . Control shaft 129 driven by motor 130 terminates at one end in attachment 52 at the other end at J 2 . Motor 130 is located in attachment 52 . Motor 124 drives J 1 to articulate about one of its axes. Motor 126 drives J 1 to articulate about the other of its axes. Motor 128 drives J 2 to articulate about one of its axes. Motor 130 drives J 2 to articulate about the other of its axes. Motors 128 , 130 , 124 and 126 drive their respective control shafts to cause J 1 and J 2 to articulate in the same manner as if J 1 and J 2 were mechanically slaved together as described above
[0052] The control shafts of FIG. 8 may drive the respective joints about their axes using, for example, a worm and spur gear or a worm and face gear. The control shafts may be coaxial. For example, control shafts 117 and 119 in FIG. 8( d ) may be coaxial shafts where the inner shaft 117 drives J 2 and the outer shaft 119 drives J 1 . Alternatively, the joints may be driven from an off-axis control shaft which drives the joints via a bevel gear, worm gear or offset hypoid gear. Suitably, the control shafts are hollow in order to allow for control cables to pass through them.
[0053] Suitably, the motors and drive elements are located towards the base of the robot arm. This reduces the weight suspended near the distal end of the attachment, making the attachment easier to control. It also reduces the required strength of the other arm joints and surgical instrument joints, enabling the arm and surgical instrument to be lighter and hence easier to control.
[0054] The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.
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A robotic instrument comprising an arm extending between a robot arm connection and an attachment for an end effector, the arm comprising: a first arm part; a second arm part distal of the first arm part; and a joint whereby the first and second arm parts are coupled together, the joint permitting the first and second arm parts to rotate relative to each other about at least two mutually offset axes; a control rod attached to the second part of the arm at a location spaced from the first and second axes, the control rod extending distally of that location along the first arm part; and a drive mechanism for driving the control rod to move relative to the first arm part and thereby alter the attitude of the second arm part relative to the first arm part.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 09/878,802 entitled AQUEOUS SUSPENSIONS OF PENTABROMOBENZYL ACRYLATE, filed Jun. 11, 2001, which claims foreign priority on Israeli Application No. 136725, filed on Jun. 12, 2000, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to novel compositions of matter that are aqueous suspensions of pentabromobenzyl acrylate (PBBMA) and to a process for making them.
BACKGROUND OF THE INVENTION
[0003] Pentabromobenzyl acrylate (PBBMA) is an acrylic monomer, which is useful in many applications, especially but not exclusively, in the field of fire retardants for plastic compositions. It can be polymerized easily by known techniques such as bulk polymerization, solution polymerization etc., or by mechanical compounding or extrusion. In mechanical compounding or extrusion, it may be grafted onto existing polymer backbones, or added to unsaturated loci on polymers.
[0004] All these properties render PBBMA a particularly useful tool in the hands of experienced compounders. However, it has been impossible, so far, to carry out aqueous manipulations with PBBMA, in spite of their desirability, because, on the one hand, PBBMA is insoluble in water, and on the other hand, because of its high bromine content, it has a high specific gravity, about 2.7,—and therefore does not lend itself to the preparation and use of aqueous suspensions.
[0005] It is a purpose of this invention to provide stable dispersions or suspensions of PBBMA, which are new compositions of matter. Dispersions and suspensions are to be considered synonyms, as used herein.
[0006] It is another purpose of this invention to provide such dispersions or suspensions that are aqueous dispersions or suspensions.
[0007] It is a further purpose of this invention to provide a process for preparing such suspensions.
[0008] It is a further purpose of this invention to provide suspensions of PBBMA for particular applications in industry.
[0009] It is a still further purpose of this invention to provide suspensions of PBBMA together with additional compounds, such as synergists for increasing the fire-retarding efficiency of compositions obtained from PBBMA.
[0010] It is a still further purpose of this invention to provide processes comprising the polymerization and/or copolymerization of PBBMA for the production of particular products.
[0011] Other purposes and advantages of the invention will appear as the description proceeds.
SUMMARY OF THE INVENTION
[0012] The suspension of PBBMA, according to the invention, is characterized in that it comprises PBBMA in the form of finely ground particles, having a size smaller than 50 μm and preferably smaller than 10 □m and more preferably from 0.3 □m to 10 μm, and contains suspending agents chosen from among xanthene gums, anionic or nonionic purified, sodium modified montmorilonite, naphthalene sulfonic acid-formaldehyde condensate sodium salt, sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, and wetting agents chosen from among alkyl ether, alkylaryl ether, fatty acid diester and sorbitan monoester types, polyoxyethylene (POE) compounds. The POE compounds are preferably chosen from among:
POE allyl ethers N-5; 10; 20; POE lauryl ethers N-5; 10; 20; POE acetylphenyl ethers N-3; 5; 10; 20; POE nonylphenyl ethers N-3; 4; 5; 6; 7; 10; 12; 15; 20; POE dinonylphenyl ethers N-5; 10; 20; POE oleate-N-9, 18, 36; Sorbitan monooleate N-3; 5; 10; 20.
[0020] Alkyl naphthalene sulfonates or their sodium salts.
[0021] N is the number of ethylene oxide units.
[0022] Said suspension is typically, though not necessarily, an aqueous one.
[0023] The suspension according to the invention may also include nonionic or anionic surface active agents or wetting agents, which can be chosen by persons skilled in the art. For example, nonionic agents may be polyoxyethylene (POE) alkyl ether type, preferably NP-6 (Nonylphenol ethoxylate, 6 ethyleneoxide units) Anionic agents may be free acids or organic phosphate esters or the dioctyl ester of sodium sulfosuccinic acid. It may, also, include other additives which function both as dispersing agents and suspending agents commonly used by skilled persons like sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, preferably naphthalene sulfonic acid-formaldehyde condensate sodium salt. The suspension according to the invention may also include defoaming or antifoaming agents, which can be chosen by persons skilled in the art. For example, emulsion of mineral oils or emulsion of natural oils or preferably emulsion of silicon oils like AF-52™.
[0024] The invention further comprises a method of preparing a suspension of PBBMA, which comprises grinding the PBBMA together with wetting agent and preferably also dispersing agent to the desired particle size adding it to the suspending medium, consisting of water containing suspension stabilizing agents, with slow stirring, preferably at 40 to 400 rpm. Grinding is preferably carried out with simultaneous cooling. The order of the addition of the wetting agents, the dispersing agents and the suspending agents is important.
[0025] Preserving or stabilizing agents such as Formaldehyde, and preferably a mixture of methyl and propyl hydroxy benzoates, can also be added to the suspension.
[0026] Typical size distributions of PBBMA both before grinding and as they are when present in suspensions according to the invention, are listed hereinafter. “D” indicates the diameter of the particles in μm and S.A. indicates the surface area in square meters per gram. “v” designates volume and 0.25 means 25% by volume.
D (v, 0.1) D (v, 0.5) D (v, 0.9) Specific S.A. PBBMA before 2.40 19.34 58.20 0.3623 grinding PBBMA in 0.36 1.54 6.62 2.2554 suspension
[0027] In an embodiment of the process of the invention, wherein suspensions of PBBMA and additional compounds—such as fire-retardant synergists, e.g. fire-retardant antimony oxide (AO), the process comprises preparing a suspension of the additional compound in a way similar to the preparation of the PBBMA suspension, and then mixing the two suspensions, preferably by adding the suspension of the additional compound to a slowly stirred suspension of PBBMA, and continuing stirring until a homogeneous, mixed suspension is obtained.
[0028] The suspensions, in particular the aqueous suspensions, of the invention are stable. When stored at room temperature, they are stable for at least two weeks and preferably at least one month. Their stability may be higher, e.g. three months or more. If they have to be stored at high temperature, they should pass the “Tropical Storage Test”, at 54° C., viz. be stable under such Test for at least one week.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] The following examples are intended to illustrate the invention, but are not binding or limitative.
EXAMPLE 1
Preparation of a Suspension of PBBMA
[0030] A glass bead wet mill equipped with cooling jacket and continuous feed by a peristaltic pump, was utilized for grinding. PBBMA (750 gr) was mixed with water (240 ml), NP-6 (Nonylphenol ethoxylate) (1 ml) and Darvan#l (Naphtalenesulfonic acid formaldehyde condensate, sodium salt) (30 gr). The mixture was fed into the grinding beads mill over a period of 25 min. The resulting slurry was stirred gently, mechanical blade stirrer, 40-60 rpm, and 10 ml of 1.5% Rhodopol 23, Xanthan Gum (CAS No 11138-66-2) in water with preserving agents, 1% Methyl Paraben, methyl-4-hydroxybenzoate, CAS No 99-76-3 and 0.5% Propyl Paraben, propyl-4-hydroxybenzoate, CAS No 94-13-3, were added.
EXAMPLE 2
Preparation of a PBBMA-AO Suspension
[0031] A suspension of Antimony Oxide was prepared as follows. To a 3-liter round bottom flask, fitted with a mechanical stirrer, were added water (240 ml), NP-6 (1 ml) (Nonylphenol ethoxylate), and Darvan #1 (Naphtalenesulfonic acid formaldehyde condensate, sodium salt) (30 g). Finely ground antimony oxide, Ultrafine grade with typical average particle size of 0.2 μm-0.4 μm. (AO, 750 g) was slowly added under fast stirring, 400-600 rpm. The stirrer was slowed, 50-150 rpm and a 1.5% solution of Rhodopol 23 Xanthan Gum (CAS No 11138-66-2) with preserving agents—1% Methyl Paraben, methyl-4-hydroxybenzoate, (CAS No 99-76-3) and 0.5% Propyl Paraben, propyl-4-hydroxybenzoate, (CAS No 94-13-3) were added (115 ml).
[0032] The mixed PBBMA-AO suspension was prepared as follows. To a slowly stirred, 40 rpm, suspension of PBBMA (750 ml) at 25° C.-30° C., obtained as described in Example 1, was added the AO suspension (250 ml) as described above. After five minutes, stirring was stopped, yielding a homogeneous mixture.
EXAMPLE 3
Preparation of a PBBMA-Styrene-Butylacrylate Terpolymer Latex
[0033] In a 0.5 L 4 necked round bottom flask fitted with mechanical stirrer, reflux condenser, thermometer, dropping funnel and Nitrogen inlet were charged 1.4 gr SDS (Sodium Dodecyl Sulfate) and 100 mL of water. The flask was immersed in an oil bath and heated to 70° C. with continuous stirring, 250 rpm, Nitrogen was introduced under the surface of the liquid. After 1 hr. the nitrogen inlet was raised above the surface of the liquid and 0.15 gr of K 2 S 2 O 8 were added. Five minutes later a solution of 15 gr Styrene and 15 gr Butylacrylate was added dropwise over 30 min. The emulsion pre-polymerization was continued for another 90 min. after which 6 gr of a PBBMA suspension (˜60% solids) were added dropwise over 70 min. The polymerization was continued overnight.
[0034] A stable latex (stable for more than two month) was obtained.
[0035] The terpolymer isolated from this emulsion was characterized. The bromine content was 7% and the glass transition temperature was 18.8° C.
EXAMPLE 4
Preparation of a PBBMA-Styrene-Acrylonitrile Terpolymer
[0036] In a 0.5 L 4 necked round bottom flask fitted with mechanical stirrer, reflux condenser, thermometer, dropping funnel and Nitrogen inlet were charged 1.4 gr SDS (Sodium Dodecyl Sulfate) and 100 mL of water. The flask was immersed in an oil bath and heated to 70° C. with continous stirring, 250 rpm, Nitrogen was introduced under the surface of the liquid. After 1 hr. the nitrogen inlet was raised above the surface of the liquid and 0.15 gr of K 2 S 2 O 8 were added. Five minutes later a solution of 18.2 gr Styrene and 5.8 gr Acylonitrile was added dropwise over 30 min. The emulsion pre-polymerization was continued for another 20 min. after which 8.5 gr of a PBBMA suspension (˜60% solids) were added dropwise over 40 min. A second portion of 0.15 gr of K 2 S 2 O 8 was added 3 hr. after the addition of the suspension was finished. The polymerization was continued overnight.
[0037] A stable latex (stable for at least one month) was obtained.
[0038] The terpolymer isolated from this emulsion was characterized. The bromine content was 12.5%, the nitrogen content was 5% and the glass transition temperature was 107° C. The molecular weight depends on the polymerization conditions. In this particular case a Weight Average Molecular Weight, Mw, of 1.2*106 and Number Average Molecular Weight, Mn, of 422,000, was determined (in Dimethylformamide solution, calibrated with Polystyrene standards).
[0039] The suspensions of the invention are useful for a number of applications, and the way in which they are used and the resulting products, are also part of the invention.
[0040] Fire Retardants are commonly used in carpet-backings. However, the fire retardants of the prior art are not bound to the carpet, and are susceptible to removal by dry cleaning. According to the invention, the aqueous suspension of PBBMA is applied to the reverse side of the carpets and is polymerized by heating at temperatures above 130° C. This results in a coating of PBBMA polymer, which is bound to the carpet.
[0041] In the prior art, fire retardants are used in the textile industry. However, they generally produce light scattering, because they are used in powder form. According to the invention, the aqueous solution of PBBMA, optionally with complementary components, is applied to textile materials and penetrates into the fibers, and then polymerization is effected by heating at temperatures above 130° C., thus polymerizing PBBMA and binding the resulting polymers to the fibers. Addition of free radical initiating catalysts, the conventional polymerization catalysts such as organic peroxides, e.g., benzoylperoxide, or other free radical producing catalysts, e.g., azobisisobutyronitrile, will shorten polymerization time.
[0042] The PBBMA suspensions of the invention can be used to copolymerize PBBMA with other monomers or grafted to polymers, in order to produce adhesives, which are also fire-retardants or other types of surface modifiers and binding promoters.
[0043] Likewise, the suspensions of the invention can be used to copolymerize PBBMA with other (meth)acrylate derivatives, such as butyl acrylate, methyl methacrylate or other monomers, to produce transparent plastics of predetermined refraction indices.
[0044] Double layered particles can also be produced, according to the invention, by adding another monomer, e.g. another (meth)acrylic derivative, to the PBBMA suspensions under polymerization conditions, to produce very stable latexes. An example of such other monomers can be, for instance, aliphatic (meth)acrylates or hydroxyethyl acrylate.
[0045] The novel products obtained according to the invention, and the processes for their production, are also part of the invention.
[0046] While examples of the invention have been described for purposes of illustration, it will be apparent that many modifications, variations and adaptations can be carried out by persons skilled in the art, without exceeding the scope of the claims.
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Suspensions of PBBMA, characterized in that they comprise PBBMA in the form of finely ground particles and contain suspending agents chosen from among xanthene gums, anionic or nonionic purified, sodium modified montmorilonite, naphthalene sulfonic acid-formaldehyde condensate sodium salt, sodium or calcium or ammonium salts of sulfonated lignin, acrylic acids/acrylic acids ester copolymer neutralized-sodium polycarboxyl, and wetting agents chosen from among alkyl ether, alkylaryl ether, fatty acid diester and sorbitan monoester types, polyoxyethylene (POE) compounds.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an access control circuit for use in an optical disk unit.
The term "optical disk unit" herein includes a magneto-optic disk unit.
2. Description of the Related Art
Recently, there have been developed not only an optical disk unit in which recorded ROM data is reproduced by irradiating a laser beam thereon but also a magneto-optic disk unit in which the user can write desired data into the disk. Such optical disk units are required to have an access control mechanism being small in size and yet capable of seeking out desired data quickly.
The control to locate a particular track in an optical disk unit consists of a slide mode in which the laser beam spot is shifted at a high speed in the radial direction to the target track on the optical disk and a tracking mode in which the beam spot, after being shifted, is kept to follow the target track. When irradiating the beam spot on the track of the optical disk, a laser beam from a light source is focused on the optical disk by means of an objective lens. The slide mode for shifting the beam spot to the target track is generally performed by linearly moving the optical head having the objective lens using a voice coil motor.
The voice coil motor is a linear motor which, when supplied with a drive current, operates such that its moving portion, or slider, makes a linear sliding motion. As the slider is moved, the head coupled with the slider is moved and, as a result, the beam spot is shifted in the radial direction of the optical disk. The number of tracks to be traversed is calculated from the difference between the target track number to be accessed and the current track number and, thereupon, the slider of the voice coil motor is moved such that the beam spot travels the distance corresponding to the calculated number of tracks. At this time, the voice coil motor makes the slide motion in a target speed according to target speeds preprogrammed for numbers of tracks to be traversed.
While the voice coil motor is making a sliding motion, the current sliding speed is detected, and a drive current in accordance with the difference between the detected current sliding speed and the target speed is supplied to the voice coil motor and, thereby, the voice coil motor makes the sliding motion in the target speed. Thus, the speed control in the accessing of the voice coil motor is basically executed such that the voice coil motor is decelerated when it is moving faster than the target speed and accelerated when it is moving slower than the target speed. The conventional access speed control methods include the following three methods.
A first method is such that the driving current supplied to the voice coil motor is changed according to the difference in speed between the current moving speed of the voice coil motor and the target speed. This method will be described below with reference to FIG. 1A and FIG. 1B.
For example, when it is assumed that the current speed of the voice coil motor is faster than the target speed by a speed difference of +s3 in the interval between the times t0 and t1 shown in FIG. 1A, the voice coil motor must be decelerated correspondingly. Therefore, a negative current of -i3 corresponding to the speed difference +s3 is supplied as the driving current to the voice coil motor as shown in FIG. 1B. Thereby, the voice coil motor is decelerated.
On the other hand, when it is assumed that the current speed of the voice coil motor is slower than the target speed by a speed difference of -s2 as indicated in the interval between the times t3 and t4 in FIG. 1A, the voice coil motor must be accelerated correspondingly. Therefore, a positive current of +i2 corresponding to the speed difference -s2 is supplied as the driving current to the voice coil motor as shown in FIG. 1B. Thereby, the voice coil motor is accelerated.
Further, when the current speed of the voice coil motor is equal to the target speed and the speed difference between them is zero as indicated in the interval between the times t4 and t5 in FIG. 1A, the driving current is set to zero as shown in FIG. 1B.
A second method is such that, while the value of the current supplied to the voice coil motor is kept constant, the time period during which the current is supplied is varied according to the speed difference. This method will be described below with reference to FIG. 2A and FIG. 2B.
For example, when the speed difference in the interval between the times t0 and t1 is +s3 as shown in FIG. 2A, the voice coil motor must be decelerated correspondingly. Therefore, a constant negative current of -i3 is supplied to the voice coil motor for a period of time corresponding to the speed difference +s3 as shown in FIG. 2B.
When the speed difference is +s2 smaller than +s3, the time period during which the constant negative current value -i3 is supplied is made shorter, as shown in FIG. 2B, than the time period during which the current was passed when the speed difference was +s3. Namely, control is made such that the time period during which the negative current -i3 is passed through the voice coil motor is made longer the greater the difference in speed for each unit time is. Also, when the speed difference is on the negative side, control is made such that the time period during which a positive current +i3 is passed through the voice coil motor is made longer the larger the speed difference on the negative side for each unit time is.
A third method is that called the BANG-BANG control. In this method, as shown in FIG. 3A and FIG. 3B, a maximum negative current -i3 is supplied to the voice coil motor when its speed is higher than the target speed, while a maximum positive current +i3 is supplied when the speed is lower than the target speed.
Recently, downsizing has come into fashion also in the field of optical disk units and the optical disk unit is tending to become smaller, thinner, and less power consuming. In the conventional voice coil motor, as shown in FIG. 4A and 4B, its moving portion (slider) 2 was supported by roller bearings 8 slidably contacting a pair of guide rails 6. The slider 2 is structured to be integral with an optical head having an objective lens 4. However, as the optical disk unit becomes smaller and thinner, the roller bearings supporting the slider becomes relatively thick. In order to advance the design for a smaller and thinner type, it becomes necessary not to employ a voice coil motor using roller bearings but to employ a voice coil motor, for example, of a slide-along-shaft type.
An optical head employing a voice coil motor of a slide-along-shaft type is schematically shown in FIG. 5A and FIG. 5B. A slider 10 of the voice coil motor is directly and slidably supported by a pair of guide rails 14. The slider 10 is structured to be integral with an optical head having an objective lens 12. As shown in FIG. 5B, the slider 10 is provided with yokes 16 and coils 18, while there is provided magnets 22 in the stator 20 in confronting relationship with the coils 18. The sliding speed and direction of the slider 10 is controlled by the value and direction of the current passed through the coils 18.
When such a slide-along-shaft type voice coil motor is employed, and if the access speed control method described with reference to FIG. 1A and FIG. 1B is used, the voice coil motor becomes suddenly slow or stopped by friction between the shaft and the slider when the drive current becomes small. Thus, there has been a problem that the voice coil motor is difficult to control when it is at a low speed.
Further, in order to realize a drive consuming low power, there is a tendency toward the use of a 5-volt single power source. In this case, since the voltage applied to a current amplifier for supplying the driving current to the voice coil motor is low, the current amplifier operates not in the current mode but in the voltage mode. For example, if the maximum voltage applicable to the current amplifier is 12 V as shown in FIG. 6B, the driving current output from the current amplifier immediately after the application of the voltage 12 V instantly rises to a preset current value capable of driving the voice coil motor as shown in FIG. 6A.
However, when the maximum voltage value applicable to the current amplifier is 5 V as shown in FIG. 7B, the preset current value cannot be reached unless a certain time has elapsed after the voltage 5 V has been applied as shown in FIG. 7A and, hence, the voice coil motor is held inoperative during this time.
Such trouble occurs immediately after the polarity of the driving current has been changed and also occurs when the method of control described with reference to FIG. 2A and FIG. 2B in which a constant current value is supplied for a period of time corresponding to the speed difference or the method of the BANG-BANG control described with reference to FIG. 3A and FIG. 3B is used. When such trouble occurs, it becomes unable to control the voice coil motor to provide a motion at the target speed, and hence quick access control of the beam spot becomes unachievable.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an access control circuit for use in an optical disk unit in which a beam spot is quickly shifted to a target track on an optical disk even if a linear drive mechanism of a small-sized and low-voltage driven type is employed.
In accordance with an aspect of the present invention, there is provided an access control circuit for use in an optical disk unit including an optical disk having a plurality of circular tracks and an optical head for forming a beam spot on the optical disk comprising: linear drive means operatively connected with the optical head for linearly sliding the optical head so that the beam spot is shifted to a target track on the optical disk; speed detection means for detecting the sliding speed of the linear drive means; target speed calculation means for calculating a target speed of the linear drive means on the basis of a difference between a distance from a position of the beam spot at the start of the access to said target track and a number of tracks the beam spot has traversed; speed difference detection means operatively connected with the speed detection means and the target speed calculation means for detecting the difference between the sliding speed of the linear drive means detected by the speed detection means and the target speed to thereby output a speed difference signal; oscillation means for outputting a high-frequency signal at a predetermined period; adding means operatively connected with the oscillation means and the speed difference detection means for adding up the high-frequency signal and the speed difference signal; and driving current supply means operatively connected with the adding means and the linear drive means for supplying the linear drive means with a driving current for accelerating or decelerating the sliding speed of the linear drive means according to the output of the adding means.
Preferably, the linear drive means is a voice coil motor of a slide-along-shaft type and the optical head and the slider of the voice coil motor are integrally structured.
The target speed calculation means obtains a distance for the beam spot to travel from a difference between a distance from a position of the beam spot at the start of the access to said target track and a number of tracks the beam spot has traversed and calculates the target speed of the linear drive means by referring to a table according to the obtained distance.
In accordance with another aspect of the present invention, there is provided an access control circuit for use in an optical disk unit including an optical disk having a plurality of circular tracks and an optical head for forming a beam spot on the optical disk comprising: linear drive means operatively connected with the optical head for linearly sliding the optical head so that the beam spot is shifted to a target track on the optical disk; speed detection means for detecting the sliding speed of the linear drive means; target speed calculation means for calculating a target speed of the linear drive means on the basis of a difference between a distance from a position of the beam spot at the start of the access to said target track and a number of tracks the beam spot has traversed; speed difference detection means operatively connected with the speed detection means and the target speed calculation means for detecting the difference between the sliding speed of the linear drive means detected by the speed detection means and the target speed to thereby output a speed difference signal; oscillation means for outputting a high-frequency rectangular-wave signal at a predetermined period; duty ratio control means operatively connected with the oscillation means and the speed difference detection means for controlling the duty ratio of the high-frequency rectangular-wave signal according to the speed difference signal and alternately outputting accelerating pulse and decelerating pulse; and driving current supply means operatively connected with the duty ratio control means and the linear drive means for supplying the linear drive means with a driving current for accelerating or decelerating the sliding speed of the linear drive means according to the output of the duty ratio control means.
The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description and appended claims with reference to the attached drawings showing some preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A and FIG. 1B are diagrams explanatory of a conventional access speed control method;
FIG. 2A and FIG. 2B are diagrams explanatory of another conventional access speed control method;
FIG. 3A and FIG. 3B are diagrams explanatory of a further conventional access speed control method;
FIG. 4A is a perspective view schematically showing a voice coil motor of a bearing-supported type;
FIG. 4B is a view as viewed in the direction of the arrow IV in FIG. 4A;
FIG. 5A is a perspective view schematically showing a voice coil motor of a slide-along-shaft type;
FIG. 5B is a cross-sectional view taken along the line V--V in FIG. 5A schematically showing a relationship between coils and magnets;
FIG. 6A and FIG. 6B are diagrams explanatory of a current amplifier operating in a current mode;
FIG. 7A and FIG. 7B are diagrams explanatory of a current amplifier operating in a voltage mode;
FIG. 8 is a schematic diagram showing a relationship between an optical disk and an optical head;
FIG. 9 is a block diagram showing an access control circuit for use in an optical disk unit according to a first embodiment of the present invention;
FIG. 10A is a diagram showing voltage waveforms of an output signal from a D/A converter and an output signal from an oscillator in the first embodiment;
FIG. 10B is a diagram showing a voltage waveform of an output signal from an operational amplifier in the first embodiment;
FIG. 11 is a block diagram of an access control circuit for use in an optical disk unit according to a second embodiment of the present invention;
FIG. 12 is a flow chart showing operations of an MPU in the second embodiment;
FIG. 13A is a diagram showing voltage waveforms of a speed difference signal and a clock signal generated within the MPU in the second embodiment;
FIG. 13B is a diagram showing a voltage waveform of an output signal from a D/A converter in the second embodiment; and
FIG. 14 is a block diagram of an access control circuit for use in an optical disk unit according to a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 8, an optical disk or magneto-optic disk 24 is rotated by a motor 26. On the optical disk 24, there are formed a plurality of circular tracks for example spirally. A beam spot is focused on a selected track by an objective lens 30 mounted on an optical head 28 so that data writing or reading is performed. A collimated beam from a collimated laser beam generator 34 having a laser diode and a collimator lens is reflected by a mirror 32 and focused on the selected track on the optical disk 24 by the objective lens 30. The optical head 28 is structured to be integral with the slider of a voice coil motor of a slide-along-shaft type shown in FIG. 5A and FIG. 5B and shifted in the radial direction of the optical disk 24, i.e., in the direction of the arrow R. The access of the optical head 28 to the target track is controlled by an access controller 36 which will be described later in detail.
Referring now to FIG. 9, an access control circuit of a first embodiment of the present invention will be described. Reference numeral 40 denotes a voice coil motor of a slide-along-shaft type shown in FIG. 5A and FIG. 5B, of which the slider is moved depending on a drive current I supplied from a current amplifier 54, so that a beam spot is irradiated on a target track of the optical disk 24 by the optical head 28 structured to be integral with the slider.
Reference numeral 42 denotes a microprocessing unit (MPU) which outputs speed difference data D1 for controlling the traveling distance and traveling speed of the voice coil motor 40 so that the beam spot is shifted to a target track. The MPU 42 calculates the number of tracks to be traversed from a difference between the target track number N1 to which the beam spot is to be shifted and the number N2 of the track on which the beam spot is being currently irradiated and thereby obtains the distance the slider of the voice coil motor 40 has to travel. In other words, a difference between the target track number N1 and the track number on which the beam spot is formed at the start of the access is set to a counter. The counter is decremented whenever the beam spot moves across each track and therefore counter value represents the number of tracks or distance to be traversed for the beam spot. It further obtains the target speed of the voice coil motor 40 corresponding to the distance to be traveled by retrieving it from a preprogrammed target speed table. Further, the MPU 42 detects the current traveling speed V of the voice coil motor 40, and obtains a difference between the detected traveling speed V and the earlier obtained target speed, and thus obtains and outputs the speed difference data D1. The speed difference data D1 is converted into an analog signal in a D/A converter 44 and output therefrom as a speed difference signal S1.
Reference numeral 46 denotes an oscillator which outputs a high-frequency rectangular-wave signal S2 for example at a frequency of 30 KHz. Switches 48 and 50 are brought into on/off states by on/off signals S3 and S3' output from the MPU 42. When the MPU 42 executes control to move the voice coil motor 40, the MPU 42 outputs the on signal S3 to turn on the switches 48 and 50, and in the case to the contrary, it outputs the off signal S3' to turn off the switches.
Reference numeral 52 denotes an operational amplifier supplied with +2.5 V as the positive power supply voltage and -2.5 V as the negative power supply voltage, and its inverting input "-" is connected with its output terminal through a resistor R3 and its non-inverting input "+" is grounded through a resistor R4. Namely, the operational amplifier 52 functions as an inverting amplifier. When a sum signal S4 obtained by adding up the output signal S2 of the oscillator 46 sent over through a resistor R1 and the switch 48 and the output signal S1 of the D/A converter 44 sent over through a resistor R2 and the switch 50 is supplied to the inverting input "-" of the operational amplifier 52, an inverted-amplified signal S5 of the sum signal S4 is output from the operational amplifier 52.
Referring to FIG. 10A, there are shown the waveform of the output signal S2 of the oscillator 46 in solid line and the waveform of the output signal S1 of the D/A converter 44 in broken line. The output signal S1 corresponds to the speed difference data D1 output from the MPU 42 as described above. The signal S2 is a rectangular wave oscillating to positive voltage side/negative voltage side with 0 V taken as a reference at a constant period and it is so set for example that the maximum positive voltage value is +2.5 V and the maximum negative voltage value is -2.5 V. Since the signal S1 corresponds to the speed difference data D1, it varies with time t. Here, it is assumed that the voltage is +2.1 V in the interval between times t0 and t6, +1.3 V in the interval between times t6 and t12, and -0.6 V in the interval between times t12 and t17.
Such signals S2 and S1 are added up on the output side of the switches 48 and 50 and the sum signal S4 is inverted-amplified in the operational amplifier 52 so that a signal waveform S5 as shown in FIG. 10B is obtained. For easiness of comparison between signal waveforms before amplification and after amplification here, the amplification factor of the operational amplifier 52 is assumed to be "1". More specifically, in the interval between the times t0 and t1, the signal S2 with the voltage value +2.5 V and the signal S1 with the voltage value +2.1 V shown in FIG. 10A are added but the sum becomes +2.5 V because the maximum value is +2.5 V. As a result, the voltage value of the output signal S5 of the operational amplifier 52 becomes -2.5 V, the inverted value of +2.5 V, as shown in FIG. 10B. In the interval between the times t1 and t2, the voltage value -2.5 V and voltage value +2.1 V are added and, hence, the voltage value of the output voltage S5 becomes +0.4 V, the inverted value of the sum of -2.5 V and +2.1 V. For each of the time intervals that follow, the signal S2 and signal S1 are added and inverted so that the signal S5 of the waveform as shown in FIG. 10B is output from the operational amplifier 52.
Referring back to FIG. 9, the output signal S5 of the operational amplifier 52 is supplied to the current amplifier 54 and the current amplifier 54 supplies a driving current I corresponding to the output signal S5 to the voice coil motor 40. The voice coil motor 40 moves at the target speed in accordance with the driving current I. More specifically, since the driving current I flows correspondingly to the waveform shown in FIG. 10B, if it is seen macroscopically, the driving current I corresponds to the speed difference signal D1, output from the MPU 42, as the control signal for accelerating/decelerating the speed of the voice coil motor 40. Accordingly, the voice coil motor 40 moves at the target speed.
On the other hand, if it is seen microscopically, when the voice coil motor 40 is to be decelerated, a maximum decelerating current is passed through the voice coil motor 40 in the period corresponding to 1/2 period of the high-frequency signal S2 to cause the motor to be decelerated in a maximum degree, and when the voice coil motor 40 is to be accelerated, a maximum accelerating current is passed through the voice coil motor 40 in the period corresponding to 1/2 period of the high-frequency signal S2 to cause the motor to be accelerated in a maximum degree. Therefore, such a difficulty encountered in the conventional art that the voice coil motor 40 comes to be stopped because a small positive or negative driving current is continuously supplied to it for a certain period of time can be overcome.
Further, the effect to slow down the rise of the driving current at a switchover between accelerating current/decelerating current is lessened the shorter the period of time, during which the current in the direction before the switchover is passed, is. Therefore, also from this reason, it is advantageous to alternate acceleration/deceleration at a short period. According to the first embodiment described above, even if the voice coil motor 40 is of a slide-along-shaft type and it is of the type driven by a low voltage using a single power source of 5 V, such a difficulty encountered in the conventional art that the voice coil motor comes to be suddenly slowed down or stopped due to friction between the shaft and the slider can be overcome, and hence proper speed control can be achieved even when the speed of the voice coil motor is low. Accordingly, the beam spot can be quickly shifted to the target track on the optical disk.
Although it was described in the above description of the first embodiment such that the signal waveform oscillates between +2.5 V and -2.5 V with 0 V taken as a reference, it was described so just for convenience of explanation. In reality, when a single power supply of 5 V is used, each signal wave oscillates between 0 V and 5 V with 2.5 V taken as a reference. The same rule correspondingly applies to below described second and third embodiments.
Referring now to FIG. 11, there is shown a block diagram of an access control circuit of a second embodiment of the present invention. In the description of the present embodiment, component parts thereof substantially the same as those in the first embodiment shown in FIG. 9 will be denoted by like reference numerals and description thereof will be omitted to avoid duplication. The MPU 56 in the present embodiment outputs a speed control data D2 for controlling the sliding distance and sliding speed of the voice coil motor 40 to shift the beam spot to the target track on the optical disk. The operation of the MPU 56 will be described with reference to a flow chart of FIG. 12.
First in step S1, the sliding distance of the voice coil motor 40 is obtained by calculating the number of tracks to be traversed from the difference between the target track number N1 and the current track number N2. In step S2, the target speed of the voice coil motor 40 corresponding to the sliding distance is obtained by retrieving it from a preprogrammed target speed table.
In step S3, the current sliding speed V of the voice coil motor 40 is detected and, in step S4, the speed difference is obtained by taking the difference between the detected sliding speed V and the earlier obtained target speed. Then, in step S5, the duty ratio of the clock signal which is oscillated at 30 KHz by an oscillator provided within the MPU 56 is changed in accordance with the earlier obtained speed difference, and this signal is output as speed control data D2.
Referring now to FIG. 13A, there are shown a voltage waveform of the clock signal in solid line and a waveform of the speed difference expressed in voltage in broken line. In changing, in the MPU 56, the duty ratio of the clock signal in accordance with the speed difference, the duty ratio of the deceleration pulse for decelerating the voice coil motor 40 is made greater when the current speed is higher than the target speed. Conversely, the duty ratio of the acceleration pulse for accelerating the voice coil motor 40 is made greater when the current speed is lower than the target speed.
The voltage waveform of an analog signal S6 obtained by conversion of the speed control data D2 formed of the accelerating pulses and decelerating pulses in the D/A converter 44 is shown in FIG. 13B. As apparent from the relationship between FIG. 13A and FIG. 13B, the sliding speed V of the voice coil motor 40 in the interval between the times t0 and t6 is higher than the target speed and the voltage value corresponding to the speed difference is +2.1 V as indicated by the broken line. In this case, the duty ratio of the decelerating pulse within one period of the clock signal is increased to the duty ratio to decelerate the voice coil motor 40 to the target speed. As a result, the duty ratio of a negative voltage -2.5 V of the analog signal S6 as the decelerating pulse for one period of the clock signal is increased as shown in FIG. 13B.
Also in the interval between the times t6 and t12, the sliding speed V of the voice coil motor 40 is higher than the target speed and the voltage value corresponding to the speed difference is at +1.3 V. Hence, as shown in FIG. 13B, the duty ratio of the negative voltage -2.5 V of the analog signal S6 is increased. However, since the speed difference in the interval between the times t6 and t12 is smaller than the speed difference in the interval between the times t0 and t6, the duty ratio of the negative voltage -2.5 V of the analog signal S6 is made smaller than the duty ratio in the interval between the times t0 and t6.
The sliding speed V of the voice coil motor 40 in the interval between the times t12 and t17 is lower than the target speed and the voltage value corresponding to the speed difference is -0.6 V. Hence, the duty ratio of the acceleration pulse within one period of the clock signal is increased to a suitable duty ratio for accelerating the voice coil motor 40 to the target speed. Accordingly, as shown in FIG. 13B, the duty ratio of a positive voltage +2.5 V of the analog signal S6 as the acceleration pulse for each period of the clock signal is increased. By application of the analog signal S6 as shown in FIG. 13B to the current amplifier 54, a driving current I' corresponding to the analog signal S6 is supplied to the voice coil motor 40 and thereby the voice coil motor 40 is controlled so that its sliding speed V is brought to the target speed.
More specifically, when the voice coil motor 40 is to be decelerated, a maximum decelerating current corresponding to the high-frequency clock signal with the duty ratio of the decelerating pulse increased is supplied to the voice coil motor 40 and thereby the voice coil motor 40 is decelerated. When the voice coil motor 40 is to be accelerated, a maximum accelerating current corresponding to the high-frequency clock signal with the duty ratio of the accelerating pulse increased is supplied to the voice coil motor 40 and thereby the voice coil motor 40 is accelerated. Accordingly, such a difficulty encountered in the conventional art that the voice coil motor is suddenly slowed down or stopped due to friction between the shaft and the slider can be overcome and hence proper speed control is achieved even when the voice coil motor is operated at a low speed. Accordingly, the beam spot can be quickly shifted to the target track on the optical disk.
Referring now to FIG. 14, there is shown a block diagram of an access control circuit of a third embodiment of the present invention. In the description of the present embodiment, component parts substantially the same as those in the second embodiment shown in FIG. 11 will be denoted by like reference numerals and description of the same will be omitted to avoid duplication.
In this third embodiment, the same as in the second embodiment, it is adapted such that the sliding speed of the voice coil motor 40 is controlled by supplying the maximum accelerating current and the maximum decelerating current to the voice coil motor 40. However, it is different from the second embodiment in that the voltage of the waveform as shown in FIG. 13B is applied to the current amplifier 54 by on/off control of a first and a second switch 60 and 62 by the MPU 58.
The MPU 58 obtains the sliding distance of the voice coil motor 40 by calculating the number of tracks to be traversed from the difference between the target track number N1 and the current track number N2. It obtains the target speed of the voice coil motor 40 corresponding to the sliding distance by retrieving it from a preprogrammed speed table. Then, it detects the current sliding speed V of the voice coil motor 40 and obtains the speed difference by taking the difference between the detected sliding speed V and the earlier obtained target speed. Then, the duty ratio of the accelerating pulse or the decelerating pulse of the clock signal which is oscillated at 30 KHz by an oscillator provided within the MPU 58 is changed in accordance with the earlier obtained speed difference.
The MPU 58 outputs first on/off signals S7 and S7' according to the accelerating pulse with its duty ratio controlled and also outputs second on/off signals S8 and S8' according to the decelerating pulse with its duty ratio controlled. Since the accelerating pulse and the decelerating pulse are arranged to be generated alternately, the second off signal S8' is output while the first on signal S7 as the accelerating pulse is output, and the first off signal S7' is output while the second on signal S8 as the decelerating pulse is output.
Accordingly, by such operation that the second switch 62 is turned off while the first switch 60 is turned on and the first switch 60 is turned off while the second switch 62 is turned on, the voltage of the waveform as shown in FIG. 13B is applied to the current amplifier 54. Thus, a driving current I" corresponding to the applied voltage is supplied to the voice coil motor 40 so that the sliding speed V of the voice coil motor 40 is controlled to become the target speed.
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An access control circuit for use in an optical disk unit including a linear drive mechanism for linearly sliding an optical head to thereby shift a beam spot to a target track on an optical disk. The slider of the linear drive mechanism and the optical head are integrally structured. The sliding speed of the linear drive mechanism is detected by a speed detection unit and the target speed of the linear drive mechanism is calculated by a target speed calculation unit. The difference between the sliding speed and the target speed is detected by a speed difference detection unit and thereby a speed difference signal is obtained. Then, the speed difference signal and a high-frequency signal from an oscillation unit are added together and the sum signal is output to a current supply unit, and thereby a drive current in accordance with the sum signal is supplied from the current supply unit to the linear drive mechanism to drive the same.
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RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application No. 61/807,532 filed on Apr. 2, 2013, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to a ball transfer unit configured to be mounted on a floor of a cargo hold.
BACKGROUND OF THE INVENTION
Various systems for movably supporting cargo on the floor of cargo holds, such as those found in aircraft, sea-going cargo ships and other cargo-carrying vehicles, have been previously proposed. Typically, such systems include a plurality of roller ball elements mounted on the floor of the cargo hold, thereby providing a low friction support surface over which cargo may be moved. In a typical cargo hold, the floor, and sometimes the walls, are provided with a plurality of elongated trays that are permanently or semi-permanently attached to the floor or other interior surface of the cargo hold. Each tray accommodates one or more ball transfer units, which are removably secured to the trays, thereby permitting the ball transfer units to be replaced when worn or damaged.
While prior systems may have certain functional and useful features, many of the prior system suffer from common shortcomings. For example, it is not uncommon for cargo holds in vehicles to be subject to the periodic ingress of water, dirt or other contaminants. As a result, many prior designs are prone to contamination and may act as receptacles for unwanted water. As dirt, dust and other debris find their way into cargo holds, prior designs have a tendency to allow, or even facilitate, the entry of such contaminants into the ball transfer units. At some point, oxidation of the internal components of ball transfer units may occur, and the collection and concentration of debris in the interior of the units may significantly increase the internal friction occurring within the units, which may render them inefficient and make it difficult for cargo to be easily moved over the ball transfer assemblies. In addition, many prior devices have seams on their upper surfaces that may provide opportunities for cargo to get caught and immobilized during the loading and unloading processes of the cargo bay.
Additionally, currently known products are typically manufactured from metal castings. The loads imposed on ball transfer units by movement of cargo over such units are substantial, sometimes concentrating hundreds of pounds per square inch of load to an individual ball transfer unit. It is not uncommon for cast units to fracture under these loads, rendering the damaged ball transfer unit useless.
There is a need, therefore, for an improved ball transfer unit which restricts the ingress of water, contaminating fluids, dirt, dust and other debris, which present a smooth and unobstructed surface to minimize unintentional interference between the ball transfer unit and cargo being moved there over, and for a ball transfer unit design being constructed from machined versus cast materials to enhance the overall strength of the unit, thereby increasing its durability and useful life.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a ball transfer unit for use in association with installed trays in vehicle cargo bays. The ball transfer units are modular units that comprise a large or main roller ball element, a semi-spherical housing for holding that element, a plurality of smaller ball elements interposed between the housing and the main ball element and a unitary cover affixed to the housing for securing the various ball elements in relation to the housing and cover, whereby the large ball element protrudes partially through said cover and where the cover is designed to discourage the ingress of water and contaminants into the housing.
The cover is manufactured without seams, and includes a transitional elevated portion of sufficient height to prevent most ingress of water or contaminants. The housing and cover may be machined, rather than cast, from high strength steel stock, such as, for example, stainless steel, which imparts substantial strength to the unit, reduces deterioration resulting from elemental exposure and provides the necessary strength to support a significant distributed and undistributed loads.
The preferred embodiments of the invention will be described by way of example with reference to the accompanying drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features, advantages and other uses of the present apparatus will become more apparent by referring to the following detailed description and drawings in which:
FIG. 1 is a schematic illustration of a typical cargo hold employing an exemplary roller unit;
FIG. 2 is a perspective view of the roller unit of FIG. 1 including an exemplary ball transfer unit attached to a roller tray and a second ball transfer unit shown removed from the roller tray;
FIG. 3 is top plan view of the roller tray with the ball transfer unit removed;
FIG. 4 is cross-sectional view of the roller tray taken along section line 4 - 4 of FIG. 2 ;
FIG. 5 is partial cross-sectional view of the roller unit taken along section line 5 - 5 of FIG. 2 ;
FIG. 6 is a top a plan view of the roller unit;
FIG. 7 is partial cross-sectional view of the roller unit taken along section line 7 - 7 of FIG. 6 ;
FIG. 8 is partial cross-sectional view of the roller unit taken along section line 8 - 8 of FIG. 6 ;
FIG. 9 is a bottom view of the ball transfer unit mounted to the roller tray;
FIG. 10 is a top plan view of the ball transfer unit; and
FIG. 11 is a top plan view of a bearing housing of the ball transfer unit.
DETAILED DESCRIPTION OF THE EMBODIMENTS
A typical cargo hold 20 , such as may be found, for example, in an aircraft, is illustrated in FIG. 1 . The cargo hold 20 may include a cargo hold floor 22 , opposing cargo hold walls 24 and a cargo hold ceiling 26 , which serve to define a generally confined compartment 28 in which a wide range of cargo 30 may be positioned, secured and transported. Attached to the cargo hold floor 22 are multiple elongated roller unit 31 that include a roller tray 32 configured to support a ball transfer unit 33 . The roller unit 31 may also be mounted to the cargo hold walls 24 . The number of roller units 31 disposed within the cargo hold 20 may depend, at least in part, upon the size of the cargo hold 20 and the configuration and weight of the cargo 30 to be distributed along the roller unit 31 . The roller unit 31 may be permanently or semi-permanently mounted to the cargo hold floor 22 .
With reference to FIGS. 2-5 , the roller tray 32 may be generally configured in the shape of a rectangular tube. In one exemplary configuration, the roller tray 32 may have an overall height “H” of approximately two to three inches. Each roller tray 32 may include a top wall 34 , a bottom wall 36 and opposing side walls 38 , surrounding an approximately rectangular roller tray cavity 40 . The top wall 34 of each roller tray 32 is provided with a plurality of tray openings 42 configured to receive the ball transfer unit 33 . Each tray opening 42 has a diameter 44 which generally corresponds to an outer diameter 46 of a retainer cover 48 of the ball transfer unit 33 . The outer diameter 46 of the retainer cover 48 may be sized slightly smaller than the diameter 44 of the tray opening 42 to enable the ball transfer unit 33 to be positioned within the tray opening 42 .
Each tray opening 42 may include a lip 50 for supporting the ball transfer unit 33 within the tray opening 42 . The lip 50 extends generally inward from a circumferential edge 52 of the tray opening 42 . The retainer cover 48 of the ball transfer unit 33 engages a top surface 51 of the lip 50 when the ball transfer unit 33 is positioned within the tray opening 42 . The outer diameter 46 of the retainer cover 48 may be sized larger than an inner diameter 62 as measured between diametrically opposed points on lip 50 (see for example FIG. 3 ). This enables the retainer cover 48 of the ball transfer unit 33 to rest on the lip 50 .
To provide a generally smooth transition between an outside surface 56 of the retainer cover 48 of the ball transfer unit 33 and an outside surface 58 of the roller tray 32 , the lip 50 may be displaced downward from the top wall 34 of the roller tray 32 by an offset 54 (see for example FIG. 5 ). The offset 54 may generally correspond to a thickness “T” (see for example FIG. 5 ) of the retainer cover 48 to enable the outside surface 56 of the ball transfer unit 33 align approximately flush with the outside surface 58 of the roller tray 32 .
The lip 50 may include one or more lip cutouts 64 to provide clearance for locking features on the ball transfer unit 33 used for connecting the ball transfer unit 33 to the roller tray 32 . The locking features are discussed in more detail subsequently.
With reference to FIGS. 7-11 , each ball transfer unit 33 includes a bearing housing 66 having an upper lip or housing annulus 68 . The housing annulus 68 may be sized to have an outer circumferential diameter 71 less than the inner diameter 62 of the lip 50 of roller tray 32 . The bearing housing 68 is preferably seamlessly machined of stainless steel, rather than cast, inasmuch as the machining process may impart substantially higher strength and resiliency to the housing, in comparison to cast housings. The bearing housing 66 may include a bearing cup 70 having a semi-spherical interior 72 . The bearing cup 70 includes a wall 74 having an outer surface 76 and an opposing inner surface 78 defining the interior region 72 of the bearing cup 70 . The housing annulus 68 extends generally radially outward from the wall 74 of the bearing cup 70 .
The housing annulus 70 is provided with a pair of retaining tabs 80 spaced approximately 80° apart around the housing annulus 70 . The retaining tabs 80 engage the cutouts 64 in the lip 50 of the roller tray 32 when the ball transfer unit 33 is attached to the roller tray 32 . Diametrically opposed from a midpoint of the housing annulus 68 between the two retaining tabs 80 is a cutout 82 that is dimensioned and configured to accommodate passage of a clamp 84 (see FIGS. 6 , 7 , 9 and 10 ) used to secure the ball transfer unit 33 to the roller tray 32 . A drain hole 86 may be provided at a bottom 88 of the bearing cup 70 to facilitate drainage of fluids.
With particular reference to FIGS. 5 , 7 and 8 , the bearing housing 66 is provided with a plurality of small roller balls 90 and a single large roller ball 92 . The small roller balls 90 are arranged within the bearing cup interior 72 along the inner surface 78 of the bearing cup 70 . The large roller ball 92 is also positioned within the bearing cup interior 72 and is supported by the small roller balls 90 . The large roller ball 92 disperses the small roller balls 90 along the bottom and side walls of the bearing cup 70 . The small roller balls 90 form a movable generally low friction layer between the inner surface 78 of the bearing cup 70 and an exterior 94 of the large roller ball 92 . This configuration helps to evenly transmit forces associated with the weight of the cargo 30 (see FIG. 1 ) positioned on the large roller ball 92 to the small roller balls 90 and to the bearing housing 66 .
With reference to FIGS. 5-8 , the retainer cover 48 may be formed as a one-piece unitary annular machined component that attaches to the housing annulus 68 of the bearing housing 66 . The diameter 46 of retainer cover 48 is larger than a diameter 71 of housing annulus 68 and inner diameter 62 of lip 50 . The retainer cover 48 includes a center opening 96 through which the large roller ball 92 extends. A tapered lip 98 extends generally upward and inward from the center opening 96 to form a generally cone-shaped configuration. The tapered lip 98 surrounds and guides the large roller ball 92 into a generally centralized relationship with a central axis of the bearing housing 66 . The tapered lip 98 terminates at a distal circumferential edge defining a circular opening 100 having a diameter 102 smaller than a diameter 104 of the large roller ball 92 . The tapered lip 98 may extend above a surface 106 of the retainer cover 48 a distance of at least one-half of the segment 108 of the large roller ball extending above the surface 106 . The height and generally cone-shaped configuration of the tapered lip 98 of the retainer cover 48 helps prevent ingress of water and contaminants from entering the interior 72 of the bearing housing 66 .
With particular reference to FIGS. 10-11 , the retainer cover 48 may be secured to the bearing housing annulus 68 using threaded fasteners 110 . The housing annulus 68 may be provided with a plurality of tapped and threaded holes 112 for engagement the fasteners 110 . A plurality of corresponding counter-sunk fastener holes 114 may be provided in the retainer cover 48 that align with the tapped holes 112 in the housing annulus 68 of the bearing housing 66 . In this fashion, when the retainer cover 48 is secured to the bearing housing 66 , the large roller ball 92 is generally centered in the bearing housing 66 , and a portion of the larger roller ball 92 protrudes through the circular opening 100 in the tapered lip 98 .
Referring to FIGS. 7 and 10 , retainer cover 48 may be provided with the pivoting clamp 84 for releasably attaching the ball transfer unit 33 to the roller tray 32 . The clamp 84 may be pivotally secured to an outer rim 116 of the retainer cover 48 using a threaded fastener 118 . The clamp 84 may be selectively moved between an unlatched position and a latched position. For example, the clamp unlatched position is illustrated in phantom in the FIGS. 9-10 , and the latched position is illustrated in solid line.
With reference to FIGS. 6-9 , the ball transfer unit 33 may be attached to the roller tray 32 by inserting the retaining tabs 80 of the housing annulus 68 through the lip cutout 64 in the roller tray 32 and sliding the retaining tabs 80 under the top wall 34 of the roller tray 32 . With the clamp 84 rotated to an unlatched position (illustrated in phantom in FIG. 9 ) generally tangential to an outer circumference of the retainer cover 48 , the retainer cover 48 may be positioned within the tray opening 42 , thereby permitting the entire ball transfer unit 33 to come to rest on the tray opening lip 50 . With the ball transfer unit 33 positioned within the tray opening 42 the retaining tabs 80 on the bearing housing 66 engage an underside 120 of the top wall 34 of the roller tray 32 , and the retainer cover 48 rests on the lip 50 of the tray opening 42 .
The clamp 84 may be pivotally secured to the retainer cover 48 using the threaded fastener 118 . The clamp 84 may be positioned in the unlatched position so as to clear the tray opening 42 , and engages the underside surface 120 of the top wall 34 when rotated 90° from the unlatched position to the latched position and secured with the threaded fastener 118 . The ball transfer unit 33 may be secured to the roller tray 32 by rotating the clamp 84 approximately 90° from unlatched position to bring the clamp 84 into engagement with the underside surface 120 of the roller tray top wall 34 , thereby preventing removal of the ball transfer unit 33 from the roller tray cavity 40 . By this operation, the ball transfer unit 33 will be removably secured within the tray opening 42 .
While recited characteristics and conditions of the invention have been described in connection with certain embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
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A ball transfer unit for use in association with installed trays in vehicle cargo bays. Ball transfer unit is a modular unit that includes a larger main roller ball, a semi-spherical housing for holding the larger main roller ball, a plurality of smaller roller balls interposed between the housing and the main roller ball and a unitary cover affixed to the housing for securing the various ball elements in relation to the housing and cover. The large roller ball protrudes partially through the cover, and the cover is designed to discourage the ingress of water and contaminants from entering the housing.
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This application is a continuation of U.S. application Ser. No. 08/365,751, filed Dec. 29, 1994, now U.S. Pat. No. 5,659,489, which is a continuation-in-part of U.S. application Ser. No. 07/705,122, filed May 24, 1991, now U.S. Pat. No. 5,390,108.
TECHNICAL FIELD
The invention relates to a system for the analysis and comparison of surfaces of fired bullets. The invention also relates to a method of analyzing and comparing the surfaces of fired bullets using the inventive system.
DESCRIPTION OF PRIOR ART
Forensic firearm examiners have to match bullets in order to determine if they have been fired from the same gun. Under present procedures, two bullets are placed under a comparison microscope, and the bullets are viewed at the same time by the examiner who compares the characteristics of their outer surfaces to determine if there is a match between them. As the reason for determining whether there is or is not a match is to present evidence in legal proceedings, the final step in the determination is normally performed by a human being who can subsequently appear as a witness in the legal proceeding. Nevertheless, the burden of the examiner could be greatly alleviated by an automated system for providing degree of match between pairs of bullets. Such system would preferably be an optoelectronic system.
Optoelectronic systems for comparing bullets are known in the prior art as at, for example, U.S. Pat. No. 3,680,966, Cofek et al, Aug. 1, 1972. However, the Cofek et al apparatus examines the flash hole of cartridge cases after manufacture but before firing.
U.S. Pat. No. 3,780,614, Maier, Dec. 25, 1973, teaches a multiple bullet and cartridge holder for forensic microscopes which provide improved indexing and manipulation.
The problem is also addressed in COMPUTER IDENTIFICATION AND CLASSIFICATION OF BULLETS, a Dissertation Submitted in Partial Fulfillment of the Requirement for the Degree of Doctor of Philosophy (Electrical Engineering) at the Polytechnic Institute of New York by Geoffrey Y. Gardner, June 1976.
SUMMARY OF INVENTION
It is therefore an object of the invention to provide a method for obtaining a signature from a fired bullet, comprising the steps of: a) mounting the bullet to turn substantially about a longitudinal axis thereof; b) illuminating a surface portion of said bullet; c) obtaining and storing a frame image at a given position of said surface portion using microscope optics, said frame image having a transverse extent substantially transverse to said longitudinal axis; d) advancing said position by an amount less than a transverse extent of the frame image; e) repeating the steps (c) and (d) a plurality of times to obtain a plurality of overlapping frame images; f) combining the frame images to form a continuous composite image having a transverse extent much greater than said transverse extent of said frame images; and g) computing a signature of the composite image along a line extending in said transverse extent of the composite image, wherein points of the signature are determined from image data along a direction of striations in said composite image, The direction is at an angle with respect to the transverse line and the longitudinal axis.
Preferably, step (f) comprises positioning each additional one of the frame images in at least one direction, the one direction being along the transverse extent, until overlapping portions of the additional frame image and the composite image match, and adding to the composite image a non-overlapping portion of the additional frame image.
The invention also provides an apparatus for obtaining a signature from a fired bullet, comprising: means for rotatably mounting the bullet to turn substantially about a longitudinal axis of the bullet; means for illuminating a surface portion of the bullet; means for obtaining and storing a frame image at a given position of the surface portion using microscope optics, the frame image having a transverse extent substantially transverse to the longitudinal axis; motor means for advancing the position by an amount less than a transverse extent of the frame image; means for combining a plurality of the frame images to form a continuous composite image having a transverse extent much greater than the transverse extent of the frame images; and means for computing a signature of the composite image along a line extending in the transverse extent of the composite image, wherein points of the signature are determined from image data along a direction of striations in the composite image, the direction being at an angle with respect to the line and the longitudinal axis.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
FIG. 1 is a block diagram of the inventive system;
FIG. 2 illustrates a particular embodiment of a bullet carrier used in the invention;
FIG. 3A is a schematic representation of a fired bullet showing striations inscribed by the gun barrel as the bullet is fired from the gun barrel;
FIG. 3B illustrates a frame modified so that the striations extend horizontally in the frame;
FIGS. 4A and 4B illustrate a flow chart for a computer program which aligns the striations parallel to the longitudinal axis of the bullet, and which eliminates the overlap between frames; and
FIGS. 5A and 5B illustrate a flow chart for a computer program for comparing the characteristics of a reference bullet with the characteristics of a bullet under examination.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, the system includes a bullet carrier 1 for rotatably maintaining a bullet 3 under examination in a position to be examined by the remainder of the system. One end of the bullet 3 is detachably attached to a rotating rod 5 which is rotated by a motor 7 . The other end of the bullet is detachably attached to a supporting rod 9 .
Disposed above the bullet is a microscope 11 . A light source 13 is provided to direct light 15 at the surface of the bullet 3 . In the illustrated embodiment the light source directs the light 15 to the surface of the bullet 3 through the microscope. Obviously, other arrangements are possible.
The light 15 is reflected from the surface of the bullet and reflected light 17 is directed to the light receiving (objective) lens 19 of the microscope. In the illustrated embodiment, light 15 is also emitted through the light receiving (objective) lens 19 .
The microscope 11 also includes an output 21 which is connected to be in optical communication with an input 23 of a video camera 25 . As is well known, the video camera converts the optical signal to an electrical signal. The optical signal is an analog representation of the characteristics of the outer surface of the bullet, and the video camera converts the optical signal to an electrical analog of the optical analog at the output terminal 26 of the video camera.
The output terminal 26 of the video camera 25 is connected to an input terminal of ANALOG/DIGITAL converter ADC 29 . The ADC 29 converts the electrical analog signal to electrical coded digital representations of the electrical analog signal and, thereby, the optical analog signal and, thereby, the characteristics of the outer surface of the bullet.
The coded digital signal is then fed, from an output terminal of ADC 29 , to an input terminal of processor means 31 .
Instructions, or other information, can be fed to the processor means 31 using an input device, such as a keyboard 33 , which is connected to a further input terminal of the processor means 31 .
The processor means 31 can contain within it a mass storage means for storing the coded digital representations. Alternatively, the processor means 31 can be connected to an external mass storage means 35 in an input/output relationship so that the coded digital representations will be forwarded by the processor means 31 for storage in the mass storage means 35 , and such that the processor means 31 can access the coded digital representations from the mass storage means 35 , as is well known in the art.
Other output terminals of the processor means 31 can be connected to a printer 37 , a video monitor 39 , or, for communications to other locations, a MODEM 41 . As usual, a system monitor 43 is also connected to the processor means 31 for monitoring the performance of the entire system.
Automatic focusing means 27 is provided to maintain the microscope in focus. As is well known, this can be accomplished by either moving the bullet to address the position between the top surface of the bullet and the lens, or by moving the lens for the same purpose. Automatic focusing means 27 receives a signal from the microscope camera or an external device to determine if the microscope is in focus. If it is not, it will receive a signal from the processor 31 to appropriately cause either the bullet or the microscope lens to be moved.
It is also noted that there is a connection between the processor 31 and the motor 7 as well as the video camera 25 . In accordance with the invention, the processor 31 is preferably programmed to synchronize the rotation of the bullet with the recording of video frame images. Specifically, the processor would cause the bullet to rotate by rotating motor 7 through a predetermined angle. It will then activate video camera 25 to record the image at the top surface of the bullet with the bullet in this first position. It will then again cause the bullet to be rotated through the same predetermined angle, and it will then turn on the video camera for recording of an overlapping frame image of the top surface at the second position. This will continue until a continuous band around the surface of the bullet has been recorded as will be described below.
Turning now to FIG. 2, there is illustrated a bullet carrier 1 wherein the motor 7 is replaced with a manual rotator 45 . Mounting adaptors 47 are affixed to each end of the bullet and are connected to the inner ends of rotating rod 5 and support rod 9 . The rods 5 and 9 are supported by arches 49 , and the arches are disposed on a base 51 . The end pieces permit the bullet to rotate in such a manner as to produce minimum variations of the distance between the surface being investigated and the microscope lens.
In operation, the base 51 is disposed underneath the microscope such that an imaginary line extending along and beyond the direction of light 15 intersects the axis of rotation (the longitudinal axis) of the bullet 3 . The bullet is then rotated and sectors of the bullet are illuminated by the light 15 . Light 15 illuminates a plurality of sectors such that, the plurality of sectors, when connected end-to-end, form a continuous band or composite image around the peripheral surface of the bullet. The video camera then records a plurality of frame images such that each frame records a complete sector plus overlap between that sector and an adjacent sector, so that each frame will include a sector and overlap, at one end thereof, between that sector and a following sector. The plurality of frames will consist of the complete band of sectors plus the overlap between adjacent ones of each of the sectors.
The optical representations of the surface of the bullet, as reflected back to the microscope by light 17 , is first magnified by the microscope and then converted to an electrical analog signal in video camera 25 . It is subsequently converted to an electric coded digital signal in ADC 29 .
In a preferred embodiment of the invention, the signature of the bullet for each frame is computed and recorded along with the frame as will be discussed below. As is known in the art, and as is explained in the Gardner reference, the signature comprises some set of striation features quantified for use in verification and classification of bullets. As is also known in the art, and as is also explained in the Gardner reference, striations 55 (see FIG. 3A) are engraved on the surface of the bullet by irregularities in the barrel of the gun. Other lines and scratches 56 are also engraved on the surface of the bullet. Because the bullet rotates as it passes through the barrel, the striations 55 will be at an angle to the longitudinal axis 57 of the bullet as shown in FIG. 3 A. Lines and scratches 56 are of a less significant and random nature.
In accordance with the invention, the data in each frame is rotated by software using a special purpose algorithm which determines the predominant slope of the significant lines so that, if the data were converted to visual signals and displayed, the striations 55 would be in a horizontal attitude in frame 58 as shown in FIG. 3 B.
In the preferred embodiment, the consecutive frame images are placed side-by-side and moved until their overlap matches. The overlap is then removed and the remaining portion of the new frame image is added to the composite image.
To compute the signature, the light intensity magnitudes of each row across the width of the band, i.e. along a line extending in a transverse extent of the composite image, are subjected to mathematical computations whereby to obtain a number representative of each row of pixels. These numbers constitute the signature, and, when signatures are compared, it is, of course, these numbers which are compared. The signature is computed using data which is from the striations 55 direction for each point along the transverse direction of the signature. When the image is rotated, the striation direction is horizontal, with the transverse extent being vertical. In the preferred embodiment, the signature is computed using the composite image.
Alternatively, the signature of the first frame is placed in side-by-side arrangement with the signature of the second frame such that the bottom of the signature of the first frame is disposed adjacent the top of the second frame, and there is overlap of at least one segment between frames. A segment can be several pixels high but is, preferably, only a single pixel high. The signatures are then compared to obtain a correlation value. The signature of the second frame is then moved upwardly one segment, and the adjacent signatures are again compared to obtain a second correlation value.
It is noted that, initially, the overlap of a few pixels will give a poor correlation. As the amount of manipulated overlap reaches the actual overlap, the correlation will increase to a maximum, when the actual overlap is reached, and will begin to fall again as soon as the manipulated overlap exceeds the actual overlap.
The manipulated overlap can then be returned to the position of maximum correlation and, at this point, the actual overlap between the two adjacent frames has been determined. The overlapping portion will then be deleted from the bottom end of the first frame so that the bottom end of the first frame corresponds exactly with the end of a corresponding first sector. The top of the second frame already corresponds exactly with the adjacent end of a corresponding second sector. Accordingly, with the overlap removed from the first frame, and with the first and second frames being joined together bottom end to top end respectively, they will represent the first and second sectors of the surface of the bullet in a continuous fashion and without gaps or overlap. (Of course, the bottom end of the second frame will include overlap between the second sector and the third sector. However, this will also be deleted further on in the process.)
Although the foregoing has described a process wherein the entire overlap is deleted from one frame, it is also possible to obtain the same effect by deleting the overlap only partially from each adjoining frame, i.e., part of the overlap is deleted from one frame and the remainder from an adjoining frame.
This procedure is continued until all of the overlap has been deleted. The remaining frames will then form a continuous band, without overlap, and without gaps, around the peripheral surface of the bullet which has been examined.
Although the foregoing has described a process wherein signature correlation is used to line up consecutive frames, other features of the consecutive frames could be used for this purpose.
It is of course understood that the above procedures are carried out in the microprocessor which is driven by appropriate software as will be discussed below. In determining the correlation between segments, the adjacent numbers of the signatures are mathematically compared to each other. For example, if the numbers are subtracted from each other, then a small magnitude remainder will indicate a high correlation and vice-versa.
In order to compare a bullet under investigation with a reference bullet, a continuous band is prepared for each bullet as per the above-described procedure and stored in the memory.
The signatures of the reference bullet and the bullet under investigation are then accessed by the processor and electronically placed in side-by-side arrangement. Two adjacent frames are then compared, one segment at a time, and the correlation value is mathematically calculated and stored.
The second band is then advanced relative to the first band by one segment so that the first frame of the first band is now adjacent the second frame of the second band. Once again, the frames are compared on a segment-by-segment basis to obtain a correlation value. This is continued until the first frame of the first band has been compared with each frame of the second band.
The first band is then advanced to another frame and the second frame of the first band is then compared with each frame of the second band. This process is continued until several frames of the first band have been compared with each frame of the second band. The two bands are then aligned along their best correlation point.
The two bands will then be compared on a segment-by-segment basis to obtain a correlation value for each pair of segments of the two bands. This creates a list of correlation values for the complete length of the two bands, and this list is then subjected to a mathematical calculation whereby to obtain a global correlation factor.
It is also known that when a bullet is fired into an object, the bullet may be distorted so that it is no longer cylindrical in shape. Because different bullets will be differently distorted depending on the object into which they have been fired, the surface characteristics of two bullets fired from the same gun will not necessarily be identical. In order to take this into account, the length of each signature is preferably expanded and contracted, and the expanded signature of the frame of one band is compared with the signature of the frame of the other band, as is also the contracted signature. Thus, the frames are compared so that one frame of one band remains as is throughout the comparison process and the other frame is compared with each signature, expanded and contracted. The best correlation point of the three comparisons is selected both for the purpose of aligning the bands and for the purpose of obtaining a global correlation factor.
Flow charts for the software to drive the processor in the above processes are illustrated in FIGS. 4A, 4 B, 5 A and 5 B which are self-explanatory.
As can be seen, with the inventive apparatus and method, one can obtain a reasonable first estimate degree of match between two bullets. As above-mentioned, the two bullets will normally have to be viewed by a forensic expert both for the purpose of making a final decision and also so that the forensic expert can testify in judicial proceedings. In spite of this mandatory participation by the forensic expert, his load is greatly reduced by the first estimate approximation.
Although the above describes a method in which a single band is obtained, it is within the scope of the invention to obtain two or more bands.
Although a particular embodiment has been described, this was for the purpose of illustrating, but not limiting, the invention. Various modifications, which will come readily to the mind of one skilled in the art, are within the scope of the invention as defined by the appended claims.
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A method for obtaining a signature from a fired bullet by mounting the bullet to turn substantially about a longitudinal axis of the bullet, illuminating a surface of the bullet, obtaining and storing a frame image at a given position of the surface portion using microscope optics, the frame image having a transverse extent substantially transverse to the longitudinal axis, advancing the frame image position by an amount less than a transverse extent of the frame image, repeating the last two steps a plurality of times to obtain a plurality of overlapping frame images, combining the frame images to form a continuous composite image having a transverse extent much greater than the transverse extent of the frame images, and computing a signature of the composite image along a line extending in the transverse extent of the composite image. The points of the signature are determined from image data along a direction of striations in the composite image which is at an angle with respect to the transverse line and the longitudinal axis.
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BACKGROUND
[0001] This disclosure relates generally to toys for children and more particularly to blowguns and peak flow meters.
[0002] A projectile, a small spherical object, is loaded into one end of a blowgun or peashooter and blown forcefully through by the user. This is a competitive sport especially for children and it would be useful to develop an improved version of the device.
SUMMARY
[0003] One embodiment is an apparatus comprising an elongated tubular component, a mouth piece connected to the tubular component for application of air pressure, a generally spherical projectile concentric to the tubular component, at least one sensor attached to the tubular component, and a visual indicator connected to the sensor(s) providing a visual indication of speed of the projectile travelling through the tubular component.
[0004] Another embodiment is a method comprising obtaining an apparatus comprising an elongated tubular component, a mouth piece, a generally spherical projectile, and a velocity sensor configured to sense the velocity of the projectile traveling through the tubular component. The method also includes blowing through and ejecting the projectile and reading the projectile velocity output on a display.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a side view of a first embodiment of the present invention;
[0006] FIG. 2 is a perspective view of an apparatus with a form of indicators;
[0007] FIG. 3 is a cutaway view along the length of the apparatus depicted in FIG. 2 ;
[0008] FIG. 4 is a perspective view of a second embodiment of an indicator;
[0009] FIG. 5 is a cutaway view along the length of the apparatus depicted in FIG. 4 ;
[0010] FIG. 6 is a front view of a generic schematic version of the apparatus;
[0011] FIG. 7 is a side view of a generic schematic version of the apparatus;
[0012] FIG. 8 is a perspective view of a third embodiment of an indicator;
[0013] FIG. 9 is a perspective view of a fourth embodiment of an indicator;
[0014] FIG. 10 is a cutaway view along the length of another embodiment of the apparatus;
[0015] FIG. 11 is a view of a gripping portion of another embodiment of the apparatus;
[0016] FIG. 12 is a block diagram of electronic components in the apparatus;
DETAILED DESCRIPTION
[0017] One embodiment described herein is a blowgun and projectile combination wherein a sensor and display combination tracks the speed of an impelled object. In embodiments, the blowgun is primarily made of a plastic safe for children to interact and play with. In embodiments, the projectile is primarily a sphere created from any range of materials including plastic, foam, rubber, or wood. The combination is low cost and offers use as either a children's toy or a fun alternative form of a peak flow meter for young children.
[0018] The embodiments of a blowgun described here are configured to display the speed of projectiles impelled through the tube by the force of breath. The speed may be displayed in a variety of forms in order to give the user a way to quantitatively measure their skill. In embodiments, the user can directly measure and display the velocity of projectile going through the blowgun, allowing data to be acquired from use. This can be used as a toy by children in a competitive nature. Another use is in order to measure breathing for asthmatic children who need to measure out medication accordingly.
[0019] Referring to the drawings, FIG. 1 shows apparatus 110 . The rendering is not to scale. For clarity, a cutaway of the front portion of the apparatus is shown. The tube 12 has a thin wall with a hollow inside surface 16 . A flanged opening 40 may facilitate use as a mouth opening. Indicator display 20 may be placed upon tube 12 .
[0020] Projectile 30 has a diameter slightly smaller than the inside wall 12 to allow easy movement. Projectile 30 is preferably not much smaller than inside wall 12 to prevent blown air from escaping. The tube and projectile can be packaged as a kit.
[0021] Now referring to FIGS. 2 and 3 , apparatus 210 incorporates a device configured to sense velocity for the indicator display 20 . On one side of tube 12 break beam emitters 52 and 62 are mounted. The emitters 52 and 62 emit a form of light or laser 54 and 64 . The receivers 50 and 60 are mounted on the other side of tube 12 and detect emitted waves. An electronic timing device in receivers 50 and 60 relays information to through wires 70 and 80 . Processed information is displayed through display 20 . As shown in FIG. 3 , the break beams 54 emit through the middle of tube 20 in order for projectile 30 to pass through and break beams 54 and 64 .
[0022] Now referring to FIGS. 4 and 5 , apparatus 310 shows an alternate method of sensing and indication. A protrusion 90 in tube 12 allows for movement of a moveable vane 120 , and optionally at least one additional moveable vane 115 , connected to a rotating axle 100 . As air is impelled through tube 12 , the vanes 120 and 115 rotate axle 100 thereby rotating indicator arrow 22 . Axle 100 runs entirely through tube 12 to the outer side. Indicator arrow 22 moves along indicator display 24 displaying the speed corresponding to the force used to blow and rotate vane 115 .
[0023] Now referring to FIGS. 6 and 7 , the generic schematic 410 shows inside diameter 16 of tube 412 and length 14 with dimensions optimized for allowing a projectile to propel through by use of breath. Length 14 and diameter 16 may vary accordingly to projectile type and use case. In embodiments, a length 14 to diameter 16 ratio can be in the range of about 5:1 to about 20:1, or about 10:1 to about 15:1. In embodiments, the length to diameter ratio is about 12:1.
[0024] Various features and embodiments that can be incorporated into the embodiments shown in FIGS. 1-5 are illustrated in FIGS. 8-11 . FIG. 8 shows an alternate form of indicating for apparatus 510 . Tube 12 holds the LED 26 on display 20 according to markings 24 placed linearly to correspond to speed output. In FIG. 9 , apparatus 610 is used to show tube 12 in a configuration utilizing frustoconical mouthpiece 40 . The mouthpiece 40 can refer to a built-in feature as part of tube 12 or as a separate piece attached to the tube by other means. In FIG. 10 apparatus 710 is shown in a cutaway view to illustrate the use of integrating a safety stopper 130 into tube 12 . Stopper 130 is a way to prevent a projectile from falling back in towards the user. In FIG. 11 , apparatus 810 has molded gripping features 140 built into tube 12 to allow easy grasp and use while impelling breath.
[0025] FIG. 12 illustrates a block diagram 910 of components that may be present in the apparatus. The components in diagram 910 may be embodied by hardware and/or software components in the system. Components may include a processor or processors 930 , input structure 920 , power source 940 , memory 950 , display 960 , and I/O ports 970 . Input structure 920 includes a sensor array to detect the projectile's travel. The power source 940 can be a small battery that can provide the required power to the rest of the system. The memory 950 can the electronic component that allows for the temporary or permanent storage of data about the projectile's speed. The display 960 correlates to forms of display as mentioned in other embodiments. I/O ports 970 embody the communication methods between the computing components.
[0026] In embodiments, a method of using the apparatus includes using the force of breath through the mouthpiece to propel the projectile and determining the velocity of the projectile by looking at the indicator.
[0027] In embodiments, the tube has a length in the range of about 4 inches to about 18 inches. In embodiments, the tube has an inner diameter of the range of about ¼ inch to about 2 inches. The tube typically has a thickness of about ⅛ inch to about ¼ inch. In embodiments, the apparatus is typically made of a thermoplastic material, a thermoset material, or wood. In embodiments, the projectile is typically made of a thermoplastic material, a thermoset material, foam, or wood. In embodiments, the projectile is in a weight range allowing human breath to impel the projectile a sufficient distance.
[0028] Although the present apparatus has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the versions contained herein. A number of alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
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A combined blow gun and projectile wherein the blowgun includes an elongated tubular component, a mouth piece, at least one sensor, and a visual indicator for projectile speed. The kit is simple and provides a method of qualitatively evaluating breath force whether for sport or for medical purposes.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 08/048,287 filed Apr. 14, 1993 which is now abandoned which is a continuation-in-part of Ser. No. 08/046,237 filed Apr. 13, 1993 which is now abandoned, the entire contents of which is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to systems for delivering prostheses into the body.
BACKGROUND OF THE INVENTION
Prostheses, such as stents, grafts, and the like, are placed within the body to improve the function of a body lumen. For example, stents with substantial elasticity can be used to exert a radial force on a constricted portion of a lumen wall to open the lumen to near normal size.
These stents can be delivered into the lumen using a system which includes a catheter, with the stent supported near its distal end, and a sheath, positioned coaxially about the catheter and over the stent, to prevent abrasion between the stent and body wall as the catheter is directed through torturous body pathways. The catheter may have an enlarged tip adjacent the distal end of the stent that also helps to atraumatically advance the system and protects the stent.
Once the stent is located at the constricted portion of the lumen, the sheath is removed to expose the stent, which is expanded so it contacts the lumen wall. The catheter is subsequently removed from the body by pulling it in the proximal direction, through the larger lumen diameter created by the expanded prosthesis, which is left in the body.
SUMMARY OF THE INVENTION
This invention provides prosthesis delivery systems with tips constructed to permit both easier advance into the body and easier removal from the body after expanding the prosthesis. The tip includes a distal taper that can gently widen a lumen during advance in instances where the lumen is narrower than the tip and a proximal taper that can gently widen the lumen on retraction in instances where the prosthesis does not immediately expand the lumen to provide clearance for the larger diameter tip. The features of the following aspects can be combined in various ways.
In a one aspect the invention features a system for delivering a prosthesis into the body of a patient. The system includes an elongated catheter having a proximal end that remains outside the body, a distal end, and a supporting portion supporting a prosthesis in a radially compacted form for delivery of the prosthesis to a desired location inside the body, and an dilating tip distal of the prosthesis. The tip has a maximum diameter about equal to or greater than the radially compacted prosthesis and is shaped to include a distal portion that smoothly extends distally to smaller diameters,and a proximal portion that smoothly extends proximally to smaller diameters for enhancing withdrawal after expanding the stent.
Various aspects may also include one or more of the following features. The distal and proximal portions of the tip include tapers to smaller diameter. The tip is formed with a proximal taper an angle of 20 degrees or less. The tip is smoothly shaped in the proximal portion without abrupt edges. The prosthesis is expandable to diameters less than the maximum diameter of the tip and the proximal portion of the tip engages the prosthesis during withdrawing the catheter proximally to widen the passage through the prosthesis for removing the catheter. The proximal portion includes taper of about 20° or less. The tip has a maximum diameter of about 8 mm. The proximal and distal portions have an axial length greater than the maximum diameter of the tip. The tip has transition regions between portions of different diameter and the transition regions are smoothly formed, without abrupt edges. The prosthesis is self-expanding. The system has a retractable protective sheath over the prosthesis, that engages the tip to form a seal that protects the prosthesis from exposure to body fluids during delivery into the body. The protective sheath engages the tip at a step region, which has smooth transitions to different diameters. The sheath has a flexible proximal portion with a smaller diameter than a distal portion positioned over the sheath during delivery into the body.
In another aspect, the invention features a method for delivering a prosthesis into the body of a patient that includes, providing an elongated catheter having a proximal end that remains outside the body, a distal end, and a supporting portion supporting a prosthesis in a radially compacted form, the catheter further including a dilating tip distal of the supporting portion and having a diameter about equal to or greater than the radially compacted prosthesis, and being shaped to include a distal portion that smoothly extends distally to smaller diameters, and a proximal portion that smoothly extends proximally to smaller diameters for enhancing withdrawal after expanding the stent. The method also includes placing the catheter into a body lumen and positioning the prosthesis at a desired location, expanding the prosthesis to a diameter no larger than the maximum diameter of the tip, withdrawing the catheter to engage the proximal portion of the tip and the prosthesis, and continuing to withdraw the catheter so the tip widens the passage through the prosthesis so the catheter can be removed from the body.
Various aspects of the invention may also include one or more of the following features. The method includes selecting a self-expanding prosthesis to provide axial force to the interior of the lumen to fully expand the lumen after an extended period of time, and withdrawing the catheter prior to fully expanding the prosthesis. The method includes crossing a region of a lumen constricted to a diameter smaller than the maximum diameter of the tip by urging the distal or proximal portion of the tip against the region to widen the region.
The inventions have many advantages. For example, since the catheter can be easily removed from the body, the physician does not have to wait until the prosthesis expands to a radial dimension larger than the tip or use a separate dilatation catheter to expand the lumen so that the catheter can be removed. With systems according to the invention, the physician can even select a prosthesis that will produce a predetermined slow expansion of the lumen, over a period of hours or even days, which can have therapeutic benefits such as avoiding rupture of a lumen wall that has been weakened by a tumor. The catheter can be removed from the body immediately after release of the slow-expanding prosthesis. The system, since it can be used to widen the lumen while advancing it into the lumen, also may reduce the need for predilating the lumen with other devices.
Further features and advantages follow.
BRIEF DESCRIPTION OF THE DRAWINGS
We first briefly describe the drawings.
FIG. 1 is a cross-sectional side view of a system according to the invention configured for delivery into the body, while FIG. 1a is a similar view of the system in an alternate configuration, and FIG. 1b is a cross-sectional view of a safety sleeve.
FIG. 2 is a detailed side view of a dilating tip; and
FIGS. 3-3h illustrate positioning a stent in the esophagus of a patient with a system according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
STRUCTURE
Referring to FIGS. 1 and 1a, a delivery system 2 according to the invention for operation in the esophagus includes a catheter 4 with a stent 14 positioned near the distal end. The system also includes sheath 20, with a reduced diameter portion 24 proximal of a portion 22 for covering the stent 14 during entry into the body (FIG. 1). The sheath 20 can be retracted (arrow 17) to expose and expand (arrows 19) the stent (FIG. 1a). A dilating tip 26, permanently attached to the catheter, has a distal taper 28 to smaller diameter for atraumatic entry of the device into the body, and a proximal taper 29 which can engage the prosthesis and lumen to atraumatically widen the lumen during withdrawal.
The catheter 4 has an overall length, L 1 , about 100 cm, with a constant outer diameter of about 3.4 mm. The catheter 4 (Pebax, 70 durometer, Atochem, Philedelphia, Pa.) includes a handle 12 (nylon) on the proximal end, an inner lumen 6 (phantom), of about 1.1 mm inner diameter, for tracking over a guidewire (e.g., 0.038 inch). The catheter 4 may include a stainless steel hypotube (not shown) along the wall of its internal lumen and a permanently attached flexible distal end 8, of length, L 2 , about 3 cm, formed of a soft polymer (Pebax, 40 durometer, Atochem) that flexes easily when challenged by a lumen wall, for atraumatic advance.
The catheter 4 includes a supporting portion 10, of length L 3 , about 15 cm, for supporting the stent 14 in a radially compacted form during delivery into the body. The stent 14 is preferably a self-expanding knitted stent formed of a highly elastic material such as a nitinol-type material (Strecker Stent, Boston Scientific, Watertown, Mass.). Knitted stents are discussed in detail in Strecker, U.S. Pat. No. 4,922,905 PCT Publication No. 94/12136, the entire contents of these cases being hereby incorporated by reference. The stent has a maximum expanded diameter of about 20 mm. As mentioned, a stent may be selected to apply a constant, rather gentle radial force to the lumen wall that expands the wall to near normal diameter over an extended period, for example, 24 or 48 hours. The stent is radially compacted by wrapping it about the portion 10 and fixing it in this form using a body-fluid degradable gelatin material (DFG STOESS, Deutsch Gelatin Fabriken AG, Germany). The stent in the compacted form has an outer diameter of about 6.5 mm. Compacting the stent by wrapping it onto a catheter and holding it with gelatin is discussed in U.S. Pat. No. 5,234,457 the entire contents of which is also hereby incorporated by reference. Dissolvable polymers are also discussed in U.S. Pat. No. 5,049,138, which is also incorporated herein by reference.
The supporting portion 10 includes radiopaque markers 16, 16' which mark the location of the proximal and distal ends of the stent in the compacted form. The portion 10 also includes radiopaque markers 18, 18' which indicate the ends of the stent 14 in the expanded state.
Positioned coaxially about the catheter 4, and extending over the stent 14 during delivery into the body (FIG. 1), is protective sheath 20. The sheath 20 has an overall length L 4 , about 70 cm, is formed of a single piece of extruded flexible polymer (extruded Pebax, 70 durometer, available from Atochem) and has a constant wall thickness of about 0.5 mm. The sheath includes a distal portion 22 having a length, L 5 , about 17 cm, which corresponds approximately to the length of the stent in compacted form with some extension on either end. The outer diameter of the distal portion 22 of the sheath is about 8 mm and the inner diameter is slightly larger than the diameter of the stent 14 in its compacted form, to provide a clearance of about 0.5 mm between the inner wall of the sheath and the compacted stent. The sheath 20 further includes a tapered portion of length, L 6 , about 7-9 cm, from the larger diameter of the distal portion 22 to the smaller diameter, about 5 mm, of a proximal portion 24 which has a length, L 7 , about 53 cm. A handle 25 (nylon) allows the sheath to be retracted from the proximal end (arrow 17) to expose the stent so that it can be expanded (arrows 19). (The distance between the handle 25 on the sheath, and handle 12, on the catheter, corresponds approximately to the length of the compacted stent.) A safety sleeve 27 (FIG. 1b) with a slit 29 and pull tab 32 is positioned between the handles during delivery to prevent inadvertent exposure of the stent (FIG. 1). The sleeve 27 is stripped from the catheter once the system is properly placed so the sheath can be retracted to expose the stent (FIG. 1a). The diameter of the proximal portion 24 is selected to conform closely to the outer diameter of the catheter body 4. The clearance between the outer diameter of the catheter body 4 and the inner diameter of the proximal portion 24 of the sheath 20 is about 1.5 mm.
The sheath, having variable radial dimension along its length, is a particular feature of the invention which enhances positioning of a large stent with large delivery systems for use in a lumens having torturous pathways. Since the outer diameter of the proximal portion of the sheath is small, the flexibility is enhanced. It flexes more easily around torturous channels because there is less strain on the outside curved wall and less compaction on the inside curved wall. Since all portions of the sheath conform more closely to the outer diameter of the components within the sheath, kinking along the length is reduced. The gap between the outer diameter of the catheter and inner diameter of the sheath is small, so the catheter tends to support the relatively thin-walled sheath when the system is bent around a curve. In the distal portion of the sheath, the larger radial dimension is supported by the larger radial dimension of the stent, which is positioned around the catheter. Minimizing kinking is an important feature, since severe kinking can cause friction between the sheath and the catheter that can prevent the sheath from being retracted. In many body lumens, such as the esophagus, the most torturous portion of the lumen is near the point of entry of the body. The present system improves operation by enhancing flexibility and reducing kinking particularly in the proximal portions of the device typically located along a torturous bend. The sheath of the system described does not kink in the proximal portions when bent 90 degrees over a radius of about 6.35 cm, which is typical of the esophagus. Moreover, a sheath with reduced size in proximal portions presents a smaller inner surface area, which reduces friction against the catheter, and therefore makes operation smoother.
Referring particularly to FIG. 2, the system further includes a dilating tip 26 which is generally designed to contact the body lumen atraumatically and also can perform the additional function of dilating the lumen so the catheter can be urged through a narrow stricture, smaller than the tip, to widen and cross a lesion. After expanding the stent, the tip allows dilating the lumen and/or the passage through the stent during withdrawal of the catheter. The tip 26 has a length, L 8 , about 28 mm, and a maximum outer diameter, d 1 , about 8 mm. The maximum outer diameter of the tip 26 substantially corresponds to the maximum outer diameter of the distal portion 22 of the sheath 20 (phantom). The tip 26 includes a distal taper portion 28 of length, L g , about 12.5 mm, at an angle θ 1 , about 10 degrees, to present a gradual increase in diameter when the system is moved axially distally. The distal taper tapers to a diameter, d 2 , about 4.5 mm at its end 35, which has atraumatic rounded edges as shown. The tip 26 also provides a gradual profile to smaller diameters in the proximal direction. The tip includes a proximal taper 29 at an angle, θ 2 , about 20° (smaller angles can be used) that aids smooth engagement of the tip with portions of the stent and/or lumen and gentle expansion when removing the catheter during withdrawal. The proximal taper 29 has a length, L 12 , about 4 mm, and tapers to a diameter, d 3 , about 4.0 mm at the end 37 of the taper. The tip, generally, is elongated compared to its maximum diameter and, in particular, the proximal region is elongated compared to the maximum diameter for providing a gradual transition. The most proximal portion 39 of the tip is rounded to the outer diameter of the catheter 4 (phantom). The distal portion of the sheath meets the tip 26 along a shelf portion 30 of length, L 11 , about 7 mm and diameter, d 4 , about 6.8 mm. The shelf portion 30 also includes a slight taper 31, at an angle of less than 20 degrees, for example, around 10 degrees, with length L 10 , about 4 mm, to the maximum diameter d 1 . The transitions between all of the portions of the tip of different diameter, especially those in the proximal parts of the tip, are smooth or rounded for gradual, atraumatic movement and to avoid any sharp edges that could hang up when engaging a partially expanded stent or body lumen wall, especially during withdrawal. The smooth profile and rounded surfaces without blunt ends or abrupt edges substantially avoids the tip hanging up on the stent as the catheter is withdrawn. This feature is particularly important with knit-type stents formed of successive rows of loops. The length of the regions proximal and distal of the maximum diameter are relatively long compared to the maximum diameter to provide a gentle, gradual engagement and widening of the lumen during withdrawal. The shelf portion 30 of the tip 26 and the sheath 20 (phantom) form a seal that isolates the stent from body fluids during delivery into the body to avoid dissolving the gelatin prior to withdrawal of the sheath, which could cause premature expansion of the stent.
The tip 26 can be formed of a nondissolvable relatively noncompressible (i.e. rigid) polymer (Nylon, Vestamid, Hulls, Germany) and can be securely attached to the catheter by insert molding the tip onto the catheter. A compressible silicon O-ring 67, about 1 mm diameter, may be fitted into a groove (about 0.85 mm deep) in the shelf portion 30 to enhance the seal with the sheath. The tip may also be polyethylene.
Use
The following procedure may be used for treating a patient with a tumor in the esophagus. The patient is prepared on an endoscopic table. The physician passes an endoscope, which has a diameter of approximately 12 mm, through the patient's mouth into the esophagus to view both the proximal and distal portions of the tumor to determine its morphology and character. If the endoscope will not cross through the tumor, the physician will dilate the lumen with a rigid dilator tracked over a guidewire or a balloon dilator which tracks through the endoscope. The endoscope is then passed retroflex so it looks back on itself and up at the most distal portion of the tumor to view its makeup. The physician measures the length of the tumor using graduated centimeter markings on the endoscope and/or makes a notation of the patient's incisor as to the most distal segment of the tumor. The physician then withdraws the endoscope partially and finds the most proximal segment of the tumor and makes a similar notation to determine the length of the tumor. Generally, the length of the stent is selected so that it extends about 2 cm beyond each end of the tumor. As discussed, the tip 26 may also be used to widen the lumen in some cases, either initially or after the esophageal wall rebounds after dilatation by other means.
Referring to the series of FIGS. 3-3h, placement of a stent in the esophagus of a patient is illustrated. Referring to FIG. 3, the patient 50 having a tumor 52 in the esophagus 54, normally about 20 mm lumen diameter, but constricted to 8-12 mm by the tumor is treated by positioning a guidewire 56 through the throat into the esophagus to a position distal of the tumor 52, usually into the stomach.
Referring to FIG. 3a, the delivery system 2 is delivered over the guidewire by sliding the proximal portion of the guidewire through the guidewire lumen in the catheter. A lubricant, K-Y jelly, may be applied to the distal end 8 of the catheter and the tip 26. The physician then observes the placement with a fluoroscopic device using the radiopaque markers. As illustrated, the esophagus includes a highly torturous portion just distal of the throat including a 90 degree bend over a radius of about 6.35 cm. The distal end of the system, including the enlarged portion 22 of the sheath covering the stent, has sufficient strength to follow the contour of the wire without excessive kinking, which is enhanced by the support of the underlying stent. It should be appreciated that in this case, even if some kinking of the distal portion 22 of the sheath should occur as it passes the torturous bend, the kinks do not substantially impede the operation since the stent has not been located at a position at which the sheath would be withdrawn. As illustrated, the tip 26 provides a gradual increase in diameter, providing an atraumatic advance of the system into the esophagus.
Referring to FIGS. 3b and 3c (an enlarged view of the area in circle c) the distal portion of the system, corresponding to the position of the stent and the enlarged portion 22 of the sheath, is located across the constriction caused by the tumor 52. In this position, the portions of the system including the reduced diameter portions 24 of the sheath are easily bent around the initial curve. The tip 26, with the gradual transition to larger diameter, aids in crossing the constricted region. As discussed, the tip may also be used to urge open the region.
Referring to FIGS. 3d to 3h, enlarged views of the constricted region are shown to further illustrate the operation. Referring particularly to FIG. 3d, with the stent properly located about the constriction, the sheath is slid axially proximally to expose the stent to the body lumen. The gelatin holding the stent in compacted form is dissolved by body fluids and the stent self-expands to larger diameter. As illustrated, in many instances, the stent initially expands the constriction to a small degree with a waist-shaped constriction still providing a rather narrow passageway with radial dimension somewhat smaller than the maximum radial dimension of the tip 26. The initial opening through the constriction may be formed, as mentioned, by a dilating means, so the opening is initially large enough to allow the system to cross with some clearance. However, the opening can be reduced somewhat after the system has crossed by a rebounding of the esophageal wall. In some cases,, the system, with the atraumatic tip may be used to widen the constricted portion slightly so that the system can pass. Further, the stent, upon release from the catheter unwraps partially, leaving fold portions 58 that occlude the lumen partially. All of these conditions can create situations in which the tip is of a larger diameter than the constricted region of the lumen.
Referring to FIG. 3e, under these conditions, upon withdrawing the catheter, the proximal portion of the tip 26 engages the stent in the region of the constriction. The smooth gradual profile to larger diameters and rounded transitions keep the tip from hanging up or catching on the stent as the tip is drawn proximally.
Referring to FIG. 3f, as withdrawal of the catheter continues, the proximal portion of the tip gradually enlarges the passage thought the constricted area by either or a combination of expanding the body lumen (arrow 61) and the stent or gently pushing the folds of the stent out of the way to form a larger passageway, allowing the tip to pass through and the catheter to be withdrawn.
Referring to FIGS. 3g to 3h, after a short time the radial force provided by the stent further widens the esophagus providing a large open lumen that facilitates swallowing.
Other Embodiments
Many other embodiments are possible. For example, the maximum diameter of the tip may be selected to be much larger than the diameter of the stent in the compacted form so the tip dilates the lumen to a desired diameter before expanding the stent. The sheath may be modified to enhance pushability or pullablity when the tip is used to widen lumens. The tip may be formed integrally with the catheter. The delivery systems can be sized and configured for use in various body lumens, the prostate, urethra or the biliary tree including the common bile duct, pancreatic duct and left and right hepatic ducts, and with particular benefit in alimentary tract lumens, such as the esophagus, stomach, pilorus, small intestine, colon or rectum. As will be appreciated, most of the latter applications involve relatively large lumens, about 1 to 1.5 cm or more, with torturous bends requiring relatively large stents to be delivered with large flexible delivery systems that resist kinking. As mentioned above, aspects of this invention provide particular advantages for delivering large stents, greater than about 10 mm expanded diameter, using larger delivery systems, greater than 6 mm maximum diameter. Like the esophagus, most of these lumens also have an extreme curvature near the entry point of the delivery system, such as the rectal sigmoid area in the colon. In the structure discussed in detail above, the stent is self-expanding and held compacted using a gelatin, but other embodiments uses a sheath that holds the stent in compacted form, without use of the gelatin. For example, the sheath may be constructed to hold the stent in compacted form by having a thicker wall in the distal portions and a thinner wall in proximal portions. The sheath may be formed in various ways, such as from polyethylene shrink tubing, which is reduced in diameter in proximal portions by heat application. In such cases, the wall thickness of the tubing is increased in the proximal portions, which can enhance the strength. The advantages of the invention can also be realized with stents that are not self-expanding, such as balloon expandable stents. A fluid, such as saline can be flowed into the lumen to more rapidly dissolve body-fluid dissolving portions.
Still further embodiments are within the following claims.
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This invention provides prosthesis delivery systems with tips constructed to permit both easier advance into the body and easier removal from the body after expanding the prosthesis. The tip includes a distal taper that can gently widen a lumen during advance in instances where the lumen is narrower than the tip and a proximal taper that can gently widen the lumen on retraction in instances where the prosthesis does not immediately expand the lumen to provide clearance for the larger diameter tip.
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BACKGROUND OF THE INVENTION
a) Field of the Invention
This invention relates to a container for dispensing a product. More particularly it relates to compact type container wherein a medicinal product can be dispensed according to a prescribed dosage format.
b) State of the Art
The dispensing of medicinal tablets from a compact type container is well known. For example, in U.S. Pat. No. 4,169,531, a pill is pushed by finger force from a container through a thin layer of material 40. Additional types of solid medicinal dispensing devices are described in U.S. Pat. No. 4,511,032 and 4,664,262, wherein capsules and pills are delivered from a container. All of these patents are concerned with the dispensing of pill or capsule one at a time. However, there is a need in many instances to dispense one or more pills or capsules at a given time. For example, in the treatment of ulcerative colitis with Pentasa® (mesalamine) the recommended dosage ranges from 2 to 4 capsules four times daily. In this instance, it would be helpful to have a container which would accommodate a daily dosage but would dispense a single dosage of more than one pill or capsule by a single actuation of the dispensing means in the container.
It is an advantage of the present invention to provide an improved dispensing container.
It is another advantage of the present invention to provide a container which can accommodate a cartridge of pills or capsules and can dispense more than one pill or capsule by a single actuation.
It is yet another advantage of the present invention to provide a container of the foregoing type wherein the dispensing of the pills or capsules can be effected in part by the actuation of a hinged panel or contacting member forming a part of the container.
It is still another advantage of the present invention to provide a container of the foregoing type which is adaptable to a wide variety of container configurations.
SUMMARY OF THE INVENTION
The foregoing advantages are accomplished and the shortcomings of the prior art are overcome by the present solid medicament dispensing device which includes a first member and a second member constructed and arranged to provide a container cavity. An opening is provided in one of the first and second members and a hinged contacting member in the other with the opening and the hinged contacting member being in alignment. A cartridge having a compartment for the solid medicament is positioned in the container cavity in a manner to align the compartment between the opening and the hinged contacting member. The compartment is composed in part of a severable material. When the compartment is aligned in the container as previously stated and the hinged contacting member moved inwardly toward the opening, the contacting member engages the compartment and forces the medicament through the severable material and out through the opening without damaging the contents.
In one embodiment, the dispensing device includes at least one post member extending from either the first or second member and the cartridge has an opening for placement over the post to align the compartment between the opening and the hinged contacting member.
In another embodiment, the dispensing device further includes a second post member extending from the other first or second member for telescoping over the first post member to contact the cartridge to hold it in place.
In other aspects, the first and second members telescope with respect to each other; are connected by a hinge member; or, one of the members has lateral support walls for slidingly receiving the other.
In yet other aspects, the hinged contacting member is a panel member and there are piercing means to precut the severable material of the cartridge to assist in releasing the contents.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the solid medicament dispensing container will be accomplished by reference to the drawings wherein:
FIG. 1 is a top perspective view of the medicament dispensing container of this invention.
FIG. 2 is an assembly view of the dispensing container shown in FIG. 1.
FIG. 3 is a view in vertical section taken along line 3--3 of FIG. 1.
FIG. 4 is a partial view in vertical section illustrating the dispensing of a capsule from the dispensing container of this invention.
FIG. 5 is a view in horizontal section taken along line 5--5 of FIG. 4.
FIG. 6 is a top perspective view showing an alternative embodiment and in an opened position.
FIG. 7 is a view similar to FIG. 6 of yet another alternative embodiment in a preassembled condition.
FIG. 8 is a view in vertical section of the container of FIG. 7 when in an assembled condition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Proceeding to a detailed description of one embodiment of the invention, and referring specifically to FIGS. 1 and 2, the dispensing device generally 10 includes a cover member 11 for placement over a tray member 12 in a telescopic manner. The cover member 11 has a cover wall 13, end walls 14 and 15 (see FIG. 3), as well as side walls one of which is shown at 16. It is seen that there are four hinged panels 23, 24, 25 and 26 provided by the slots 19.
The tray member 12 has the end walls 17 and 18, a base wall 22 and the side walls 20 and 21. The tray member 12 has the openings 28, 29, 30 and 31. As best seen in FIGS. 2 and 3 there are four piercing spikes 52 supported adjacent the openings 28-31 by the extension portions 59. The purpose of these will be explained later. Two posts 50 and 51 extend from the base wall 22. The purpose of these posts are to fit into the openings 45 and 46 of the cartridge generally 34 when the cartridge is placed inside the cavity 27 of the tray member 12 and under the cover member 11. The cartridge 34 includes a backing 35 and four compartments 37, 38, 39 and 40. Inside each compartment are contained four capsules each designated at 42.
Referring specifically to FIG. 3, it is seen that when the cartridge 34 is placed between the tray member 12 and the cover member 11 the posts 48 and 49 which extend from the cover member 11 telescope over the posts 50 and 51 in the tray member 12. In this manner, the posts 48 and 49 engage the surface portion 35 of the cartridge so as to hold the cartridge 34 in place. The posts 50 and 51 serve the function of orientating the cartridge 34 so that the compartments 37-40 are aligned over the openings 28-31. With the cartridge 34 in the previously described orientated position with respect to the openings 28-31 they will also be aligned under the hinged panels 23-26 in the cover member 11.
Referring specifically to FIG. 4, each of the compartments such as 39 is composed of a flexible material 53 at the top and a tear away material 54 at the bottom. In this instance, the flexible material 53 is a laminate material composed of layers of polyvinyl chloride, polyethylene and saran with the saran layer placed for contact with the hinged panel as later described. The tear away material 54 is aluminum foil. The flexible material 53 and the tear away material 54 are sealed to a backing material 55 which has an opening such as 57 over which extends the tear away material 54. In order to dispense the capsules 42 from the cartridge 35, the hinged panel such as 25 is moved downwardly such as indicated in FIG. 4. This can be effected by the force of one's finger 56 as shown in FIG. 3. This causes an inward flexing of the flexible material 53 which causes the tear away material 54 to be punctured by piercing spike 52 and, in turn pushes the capsule 42 through the tear away material 54 and out through the opening 57 in the cartridge 34 as well as the opening 30 in the tray member 12. The capsule will assume a position such as shown in FIG. 4 prior to dropping into one's hand. As illustrated in FIG. 5, the aluminum foil 47 will provide an adhesive surface 58 for the capsule 42 when the capsule is in a slightly warm condition.
Referring to FIGS. 6 and 7, there are shown alternative embodiments generally 110 and 210. Similar components are referred to with similar numbers as were used in conjunction with embodiment 10 except they are numbered in the "100", "200" series. With respect to the embodiment 110 in FIG. 6, it has many of the same components as described for embodiment 10 and operates in substantially the same way. It has the posts 150 and 151 over which can be placed a cartridge such as 34 and held by the posts 148 and 149 when the cover member 111 is placed over the tray member 112. The difference between the embodiment 10 and 110 is that the cover member 111 and the tray member 112 are connected by an integral hinge member 160. Also there is provided a snap fitment closure as provided by the projection 172 and the undercut 173.
Concerning embodiment 210, this embodiment also includes many of the same components as described for embodiment 10 and operates in the same manner with respect to the dispensing of the capsules 42. It receives the cartridge 35 over the posts 250 and 251 in the tray member 212. A sliding relationship is effected between the cover member 211 and the tray member 212 by the lateral support walls 261 and 263 over which portions of the base wall 222 slide. Unlike the previous embodiments, there are no posts extending from the cover wall 213. In this embodiment these could interfere with the sliding relationship between the cover member 211 and the tray member 212 and would not telescope with the posts 250 and 251. Instead, there are two flanges 265 and 267 which slide through the openings 269 and 270 when the cover member 211 and the tray member 212 are slidably engaged. These flange members 265 and 267 contact the cartridge 35 to hold it in place. This is best seen in FIG. 8.
It will thus be seen that through the present invention there is now provided a unique container and dispensing system wherein a cartridge of capsules can be placed in a container. To dispense the capsules from the container, only the movement of a contacting member such as a hinged panel member need be moved in the direction of the capsules so as to move them out of the cartridge as well as out of the container. As seen from the embodiments herein, the container of this invention lends itself to various styles of fabrication whether of the telescoping, hinged or slidable relationship type with respect to the cover and the bottom tray member.
In the previously described embodiments, there have been shown four capsules in cartridge compartments such as 37-40. It is obvious that a compartment could contain as few as one capsule or as many as could be conveniently dispensed through an opening in a tray-like member. While certain materials have been indicated for use in fabricating the cartridge 34, it is obvious that any number of materials which can function as a flexible material for contact with the hinged contacting member as well as for use as a tear away material could be substituted for those previously designated. For example, and in a preferred manner the tear away material 54 is a laminate of aluminum foil, polyester film and paper with the paper on the outside and the foil in contact with the capsule. In this instance the backing material 55 and opening 57 would not be used and the flexible material 53 and the tear away laminate would be directly sealed together. This is what is known as a child resistant package and where the spikes serve to precut the tear away laminate. It should be further understood that in the case where the tear away material 54 is aluminum foil only, the use of the spikes 52 is optional. While in one embodiment one spike 52 has been shown adjacent each opening 28-31, alternatively a plurality of spikes or small serrations could be used with respect to each opening.
The materials for fabricating the cover and tray members 11 and 12, respectively, are styrene, polyethylene or prolypropylene with polypropylene being preferred for the embodiment 110 because of the hinge 160. Other resinous plastics could be employed as long as they afford a durable container system and permit the hinging actions of the panels such as 23-26. Capsules 42 are described as the preferred solid medicament for use with the dispensing device. Any solid medicament such as tablets or pills could be used. Further, the flanges 265 and 267 have been described in place of the posts such as 148 and 149. If desired, these flanges 265 and 267 could be replaced with grooved tracks inside the cover member 211 and the posts 250 and 251 designed to ride therein. This would give added stability.
The foregoing invention can now be practiced by those skilled in the art. Such skilled persons will know that the invention is not necessarily restricted to the particular embodiments presented herein. The scope of the invention is to be defined by the terms of the following claims as given meaning by the preceding description.
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A solid medicament dispensing device having a cover and tray to provide a container for a cartridge for the solid medicament. The cover has hinged panel members and the tray an opening in the floor. When the hinged panel members are moved against the cartridge, it forces the medicament out of the cartridge and through the tray opening. The dispensing device is particularly suited for dispensing large dosages of capsules.
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BACKGROUND OF THE INVENTION
This invention relates to self-leveling systems and more particularly to a refrigerator cabinet support that will maintain the cabinet level on a surface that is slanted, unlevel, or out-of-flat in such a way that there is equal weight distributed at the two front corners.
It is highly desirable that appliances generally be provided with adjusting means to insure that all four support feet are firmly positioned on the floor and the appliance level on the floor even when the floor or surface itself is unlevel or out-of-flat.
Frequently, appliances such as washing machines and refrigerators, are placed on sloping surfaces. Usually, manually adjustable supports are affixed to the front underside of the cabinets of the appliances. These supports are individually adjustable so that they can be employed for compensating for slope in a supporting surface from front to back and also for slope from side to side. The front supports, usually two in number, must often be adjusted to unequal lengths to compensate for the side-to-side slope in the supporting surface. Where the cabinet has two fixed rear supports, the cabinet may then rock on three of its four supports. In the case of an appliance such as a washing machine, this may result in undesirable "walking." Of potentially greater concern, the weight of the cabinet may cause twisting of the cabinet to bring all four supports into engagement with the supporting surface. This is particularly of concern in a refrigerator cabinet for it is very heavy when a normal amount of food is stored therein. Because a refrigerator cabinet is tall and not as rigid as more compact cabinets, it has a greater tendency to twist when not supported on all of the supporting elements. This twisting action of the cabinet may cause distortion of the front face of the cabinet against which the door closes and thereby prevent the door from properly sealing its gasket with respect to this front face of the cabinet. Without proper sealing, heat will leak into the refrigerator's cooling compartment and result in inefficient refrigeration and waste of electrical energy. Moreover, in the case of refrigerator-freezers which have two doors, either one above the other or side by side, this twisting may prevent the doors from lining up well enough to be aesthetically acceptable.
Since the above-mentioned appliances are heavy and are often placed in confined areas, it is difficult or impossible to provide access to the rear supports for adjusting such supports to compensate for a sloping surface, particularly one which slopes from side to side. Hence, it is important to provide a means for effecting automatic adjustment of a rear support of the cabinet of the appliance to conform to the adjustment of the front supports in order that the cabinet may be uniformly supported, front and back, in an upright position, and to do this without requiring access to the rear supports.
The problem of providing self-adjusting supports for facilitating the leveling of appliances such as refrigerators and washing machines when such appliances are positioned on sloping floor surfaces is well-known, and the prior art discloses many examples of self-adjusting assemblies adapted especially for facilitating the leveling of such appliances without requiring access to the rear support structure and without requiring the use of manual procedures or tools. For example, U.S. Pat. No. 3,954,241 teaches a self-adjusting assembly especially adapted for facilitating the leveling of an appliance, such as a washing machine or the like, on a sloping floor in order that the appliance be firmly positioned thereon. The assembly includes a pair of brackets located at the two rearmost, lower corners of an appliance, and a flexible cable element extending from one bracket to the other. Each bracket is provided with an independently adjustable leg member, with the members being interconnected by the cable. If both rear legs do not engage the floor, the leg which first engages the floor is forced upwardly by the weight of the cabinet. Through the cable, this causes a corresponding downward movement of the other leg until it is brought into engagement with the floor.
Another example of a support with automatic adjustment is taught by U.S. Pat. No. 3,880,388. The support is of the leg-type, comprising two vertically movable legs coupled together, in one embodiment, by a chain of rigid thrust elements encased by a tubular guide. These elements are arranged such that as the weight of the supported structure causes one leg, which engages the surface upon which the structure is placed, to move upwardly, the other leg is urged downwardly until it engages the surface.
Still another example of a support with automatic adjustment is taught by the U.S. Pat. No. 2,695,147. The support includes a pair of cams at the rearmost corners of an appliance, which cams are connected together by a connecting rod. The cams are shaped to slope in opposite directions and are arranged for rotation about vertical axes. The cams are rotatably connected to plungers which support the cams, the plungers forming feet or legs which actually support the appliance on a floor or other surface. If greater pressure is applied to one of the plungers than is applied to the other, the cam in engagement with the plunger having the greater pressure applied thereto tends to rotate about a vertical axis so as to shorten that plunger relative to the base of the appliance. This rotation is transmitted through the connecting rod to the other cam and causes rotation of this other cam in a corresponding direction, but, because of the opposite slope of the cams, this tends to lengthen the plunger connected thereto relative to the base. This produces an equalizing action that automatically provides uniform support for the appliance on the supporting surface.
In lieu of leg-type supports, some prior art cabinet structures employ a single, rear roller-type support in combination with two adjustable front supports. If a single roller-type support is utilized, it is necessary to provide a roller of reasonable length to assure adequate stability of the rear portion of a cabinet. This is especially important where the supporting surface is a soft floor covering. If the weight of the rear portion of the cabinet is supported on a short roller, this may result in a substantial depression in the supporting surface. Such depression, aside from marring the appearance of the floor covering, would hinder the moving of the appliance from the confined space. However, where the two front supports are adjusted to unequal lengths on a floor which slopes from side to side and a roller of adequate length is employed, another problem is encountered in that one end of the rear roller may engage the floor covering and tend to press into the soft floor covering. A U.S. Pat. No. 4,102,556-William M. Webb is directed to this particular problem.
Some prior art cabinet structures, for example, that shown in U.S. Pat. No. 3,222,021 employ a mechanism comprising two oppositely sloped ramps in lieu of leg-type supports. The ramps are formed at the two rear corners of a cabinet and the cabinet is supported on these ramps in such a manner that a slight sideward movement of the cabinet results in one rear corner sliding up one ramp and the other rear corner sliding the same distance down the opposite ramp. The ramp construction provides substantial resistance to movement at the rear corners. This ramp-type support is frequently utilized with washing machines because washing machines usually shake while spin drying, and the friction of the ramp is quite helpful in preventing unwanted rocking while being easily overcome for automatic adjustment during a spin cycle. However, since refrigerators shake very little and since refrigerator cabinets are tall and not as rigid as more compact cabinets, such as washing machine cabinets, and, therefore, have a greater tendency to twist, the rear support should be able to adjust with very little frictional resistance. Hence, the ramp-type support, with its substantial friction, is not particularly useful in supporting refrigerator cabinets on surfaces which slope from side to side.
One example of which the present invention is an improvement is U.S. Pat. No. 2,540,750-Morrison issued Feb. 6, 1951, wherein automatically adjustable legs are mounted on bearings attached to the appliance to permit vertical movement relative thereto. Cranks, each having a horizontally disposed arm bearing on the top of one of the legs and a vertically disposed arm extending downwardly, are pivotally supported from the appliance. A bar is pivotally attached to the two downwardly extending crank arms to cause each crank to urge its corresponding leg downwardly with like force. The bar is tensioned by increased load and when the appliance is placed upon an uneven or tilted supporting surface, the legs move up and down until the forces supported by each are equal.
One problem with such prior art self-adjusting leg-type support is that the mechanisms employed are of expensive and complex construction due to the use of many parts and to the functional relationships of these parts.
By this invention, these disadvantages and limitations of the prior art are overcome, and a support for cabinets, such as refrigerators and washing machines, is provided which is simple in construction, which can be manufactured economically and which readily and automatically adjusts itself for uniformly supporting the cabinet on a surface which slopes from side to side.
Accordingly, it is an object of this invention to provide an improved construction of a rear support structure for a cabinet which automatically adjusts itself to a supporting surface sloping from side to side.
It is another object of this invention to provide such a rear support structure which proportionately distributes the weight of the rear of the cabinet to insure that all four corners of the cabinet will be uniformly supported on the supporting surface to prevent any rocking or twisting.
SUMMARY OF THE INVENTION
This invention is directed to a load equalizing support structure for uniformly supporting an appliance cabinet on a supporting surface which slopes from side to side. The support structures include a bracket that extends across the lower end of one side wall of the cabinet. The lower wall of the bracket is provided with spaced apart openings that have upwardly extending flange portions adjacent opposite side of the openings. A wheel assembly is arranged for vertical movement in each of the openings. The wheel assembly includes a generally U-shaped housing having a wheel supported between the legs thereof. The wheel assembly is arranged for vertical movement with the axis of the wheel being maintained parallel with the supporting surface.
A member is associated with each of the wheel assemblies that maintains the cooperating wheel assembly in its respective bracket opening. The member includes a first portion having a segment in engagement with the housing for transmitting a force on the housing substantially perpendicular to the axis of the wheel and a second portion engaging locating means on the bracket. A connecting member is connected to each of the members at a point intermediate the first and second portions thereof. This arrangement transmits movement between the members in the same direction, whereby when one of the wheel assemblies raises to move one of the members by its movement relative to the supporting surface, the other member moves to cause a lowering of the other wheel assembly relative to the surface with the axis of both of the wheels being parallel to the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of the lower portion of a refrigerator cabinet incorporating the support system of the present invention;
FIG. 2 is a rear elevational view showing the elements on a level support surface;
FIG. 3 is a view similar to FIG. 2 but showing the elements on an uneven support surface; and
FIG. 4 is an enlarged perspective view showing one the cooperating parts of one portion of the support system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is shown in FIG. 1 a portion of a refrigerator cabinet 10. At the front lower corners of the cabinet 10 are disposed a pair of independently adjustable threaded supports 12 and 14 for adjusting the front of the cabinet 10 to compensate for any slope of the floor or other supporting surface 16 as shown in FIGS. 2 and 3. The adjustable threaded supports 12 and 14 may be of conventionally type, including ones having rollers, and have not been shown in detail since they do not form part of the present invention.
Insofar as the front of the refrigerator is concerned, the independently adjustable supports 12 and 14 can be employed to compensate for the slope of the floor 16, both in a back-to-front direction and in a side-to-side direction. Thus, if the floor should slope from back-to-front of the cabinet, for example, it is merely necessary to adjust both supports 12 and 14 by equal amounts until the cabinet 10 is level. If the floor slopes to the left, then the left (as viewed from the front of the cabinet) front support 14 is adjusted to a greater length than the right front support 12 to compensate for the slope of the floor and thereby support the front of the cabinet in a level position. However, in the usual case, the cabinet, such as a refrigerator, is placed in a confined space where access to the rear of the cabinet is difficult or impossible. It is, therefore, unsatisfactory to use manually adjustable supports at the rear of the cabinet because of the difficulty or impossibility of obtaining access to such rear supports. If, on the other hand, two fixed supports are employed at the rear corner, it will be appreciated that on a floor which slopes from side-to-side the cabinet will tend to rock on three of the four supports. Alternatively, the cabinet may tend to distort or twist in order to bring all four supports into engagement with the floor. This is particularly so in the case of relatively tall appliances such as refrigerators and significant distortion or twisting of the refrigerator cabinet may result in unsatisfactory sealing of the refrigerator door.
In the present invention, the rear support structure is formed in a manner which overcomes all of these problems. This is done by providing a rear support structure 20 which includes provision whereby the support structure automatically adjusts itself so as to engage the floor regardless of the slope of the floor.
Referring to FIGS. 1, 2 and 3, the rear support structure 20 comprises a mounting means or channel shaped bracket 22 which extends transversely of the cabinet 10 and is affixed to the rear side wall of the cabinet adjacent the bottom thereof as by fastening means 24. The channel 22 comprises a bottom wall 26 and side walls 28 and 30. In the bottom wall 26 of the channel 22, adjacent the right and left ends thereof, are rectangular apertures 32 and 34 (FIGS. 2, 3 and 4) respectively for receiving therethrough leveling elements or wheel assemblies 36 and 38 respectively which support the rear of the cabinet 10 on the supporting surface 16. The bottom wall 26 of channel 22 is formed adjacent the longitudinal sides of apertures 32 and 34 to provide oppositely disposed guide means or flanges 40 extending upwardly substantially perpendicular to wall 26 for as will be explained hereinafter guiding vertical movement of the cooperating wheel assemblies 36, 38. The assemblies 36 and 38 are identical and accordingly one will be explained with like parts having the same reference numerals. The assembly 38, as shown in FIG. 4, comprises a housing 50 having a generally U-shaped configuration including a central upper wall 52 and downwardly extending spaced apart legs or side walls 54 and 55. A wheel or roller 56 is rotatably mounted between the downwardly extending legs 54 and 55. Extending outwardly from the vertically disposed edge portions of legs 54 and 55 are tabs 58. With reference to FIG. 4, it will be seen that the width of the legs 54 and 55 of housing 50 and the dimension between tabs 58 are substantially the same as the width of flanges 40; accordingly, the outwardly extending tabs 58 provide a channel in which the flanges 40 are located. This arrangement allows vertical movement of assembly 38 relative to the bracket 22 while, at the same time, preventing rotation of the assembly 38 relative thereto.
The present configuration of parts for arranging the wheel housing 50 relative to the cabinet 10 through bracket 22 allows movement of the wheel assembly along a vertical axis so that the axis of the wheel 56 is always parallel to the supporting surface 16 while, at the same time, preventing movement of the wheel assembly about the vertical axis in a plane defined by the axis of the wheel 56.
The assemblies 36 and 38 are interconnected by movable members 60 and 62 respectively that, as will be apparent from the foregoing description, also function to maintain the assemblies 36 and 38 in their respective apertures 32 and 34. Each of the members 60 and 62 includes a first portion 64, including a central vertically arranged section 66, and a second portion 68 including a pair of parallel arranged arms 70 extending from either side of the central section 66. The portions adjacent the distal ends of the arms 70 engage the upper surface of central portion 52 of housing 50. The spaced arms 70 engage the housing at two points to stabilize vertical movement of the housing 50. The members 60 and 62 are arranged for movement relative to the bracket 22. To this end, the lower wall 26 of bracket 22 includes a holding means 72 which includes a section 74 extending upwardly from wall 26 and a central portion or tab 76 extending outwardly from a portion 77 arranged parallel to the wall 26. Located adjacent the lower distal end of portion 66 is an aperture 78 dimensioned to receive the tab 76. As can be seen, the provision of holding means 72 and aperture 78 provides a pivot arrangement for the movable members 60, 62 that does not require exacting dimension or machining relative to the cooperating relationship between the members 60, 62 and the cooperating wheel assemblies 36 and 38.
The members 60 and 62 are further provided with tangs 80 located at the upper portion of section 66 intermediate the first and second portions 64 and 68 respectively. The tangs 80 are formed to include a slot or central opening 82. A rod 84 extending between the members 60 and 62 is provided with portions 86 at each end extending at right angles thereto. The portion 86 of the rod 84 is arranged in the slot 82 with the portions 86 bearing on the outside portion of the tangs 80. Further, as seen in FIGS. 2 and 3, the actual pivot is about the contact surface of section 66 and the end edge of portion 77 so that a minimum wear area is provided.
In the view of FIG. 2 the members 60, 62 are shown in the position corresponding to a level support surface 16. As will be evident from this view, the two wheel assemblies 36 and 38 extend an equal distance about the surface 26 of bracket 22 and bear against the distal ends of arms 70 of members 60 and 62 respectively. Since member 60 tends to rotate in a clockwise direction by reason of the upward force exerted by wheel assembly 36 and the member 62 tends to rotate in a counterclockwise direction by reason of the upward forces exerted by the assembly 38, the rod 84 is in tension and holds both of the assemblies 36 and 38 in position.
In the view of FIG. 3, however, the mechanism is shown for the condition wherein the support surface 16 is not level. In this case, the forward legs 12 and 14 are individually adjusted to align the cabinet in a vertical direction. The wheel assemblies 36 and 38 thereupon assume positions corresponding with this alignment with the axis of the wheels parallel to the support surface. The wheel assembly 38 is shifted upwardly relative to the bracket 22 and rotates member 62 in the clockwise direction. This pulls rod 84 and rotates the member 60 in the same direction, thereby forcing the wheel assembly 36 downwardly until the supporting effort by wheel assembly 36 is equal to that of wheel assembly 38.
From the above description, it can be seen that an effective load equalizing support system has been provided that utilizes the support channel 22 that is customarily arranged on the cabinet, together with the wheel assemblies 36, 38, their cooperating movable members 60, 62 and the rod 84. This arrangement of parts lends itself to a load leveling assembly that is easily assembled during manufacture of the refrigerator without adjustments or the use of tools. With the bracket 22 in place on cabinet 10, the wheel assemblies 36 and 38 are placed in their respective apertures 32 and 34. Their cooperating movable members 60 and 62 are then arranged relative thereto with the aperture 78 mounted on the holding apertures 32 and 34 in the channel 22. With the wheel assemblies positioned in the apertures and arranged for vertical movement with respect to the guide provided by the tabs 58 cooperating with the flanges, the next step in assembling the system is to place the members 60, 62 relative to their respective wheel assemblies 36, 38 so that the apertures 78 on the portions 66 are positioned on their respective tabs 76. The final step is placing the rod 84 so that its end portions 86 engage the tangs 80. All of the above steps, as mentioned hereinbefore, are carried out without the assistance of tools with the entire system held in position relative to the cabinet 10 by the rod 84.
It should be apparent to those skilled in the art that the embodiment described heretofore is considered to be presently preferred form of this invention. In accordance with the Patent Statutes, changes may be made in the disclosed apparatus and the manner in which it is used without actually departing from the true spirit and scope of this invention.
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A refrigerator cabinet is supported at the rear corners by vertically adjustable legs and at the front by a pair of widely-spaced front wheel assemblies that are connected through a self-leveling system. Movable members associated with each of the wheel assemblies are connected by a rod that serves to cause each movable member to urge its corresponding wheel assembly downwardly with like force. When the cabinet is placed on an uneven supporting surface, the wheel assemblies move up and down until the forces supported by each are equal.
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BACKGROUND OF THE INVENTION
The present invention relates to a system for controlling an electromagnetic clutch for an automatic transmission.
An automobile provided with a continuously variable belt-drive transmission with an electromagnetic clutch is disclosed in EP-A No. 151038. The electromagnetic clutch of the transmission is controlled by a control system to provide various operational modes such as a starting mode, reverse excitation mode, drag mode, and two modes of lock-up engagement which are an accelerator pedal releasing condition and depression condition. One of the modes is selected in accordance with a position of a selector lever and driving conditions to control the electromagnetic clutch.
In the system, as shown in FIG. 8, relationships between engine speed and vehicle speed are illustrated. At the start of the vehicle, the transmission ratio is set at a maximum value. When the accelerator pedal of the vehicle is depressed and engine speed becomes higher than a set value, the electromagnetic clutch is engaged to start the vehicle. The vehicle speed and engine speed increase along the set maximum transmission ratio represented by (line L,Ne/V). When the engine speed and vehicle speed reach set values at point A under a driving condition, the transmission ratio starts to change (it upshifts) at point A of FIG. 8. At that time if the engine speed is kept constant, the transmission ratio is automatically and continuously reduced along horizontal line m (representing engine speed as constant) and finally reaches a minimum transmission ratio (line H). When the accelerator pedal is released, the engine speed and vehicle speed reduce along the line H. When both speeds reach a point B, the transmission ratio begins to increase. Thus, the transmission ratio is increased (downshifted) along a line M and reaches the maximum transmission ratio (line L). However under certain driving conditions the engine speed becomes Neu, as shown by a line M' in FIG. 8, namely, the engine speed becomes higher than the predetermined engine speed, which corresponds to the minimum changing line M of the transmission ratio, in a low vehicle speed range under V H when a choke valve is closed. In such a state, the vehicle is accelerated because of the high engine speed regardless of the intention of the driver. In order to prevent the acceleration of the vehicle, the driver depresses a brake pedal to brake the vehicle. However, since the electromagnetic clutch is locked at a vehicle speed higher than a predetermined speed V L (FIG. 8), a large force must be applied to the brake pedal.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a system which operates to slip the electromagnetic clutch, when a vehicle is driven in lock-up state of the clutch under the choking condition, whereby the vehicle can be braked by a small braking force, moreover preventing elevation of the temperature of the clutch by a necessary minimum slipping.
According to the present invention, there is provided a system for controlling an electromagnetic clutch for a motor vehicle having a continuously variable transmission, which has a drive range, reverse range and neutral range, and a selector lever for selecting the ranges. The system comprises vehicle speed detecting means for producing a first vehicle speed signal at a predetermined low speed and a second vehicle speed signal when vehicle speed is between the predetermined low speed and a predetermined speed higher than the low speed, first switch means for detecting the position of the selector lever and for producing a drive signal when the selector lever is at drive range position, second switch means for producing a release signal dependent on the release of an accelerator pedal of the vehicle, third switch means for producing a choke signal when a choke valve is closed, first control means responsive to the first vehicle speed signal and to the drive signal for producing a lock-up current signal, second control means responsive to the second vehicle speed signal and to the release signal for producing a current reducing signal, and output decision means responsive to the lock-up current signal for controlling the current passing through a coil in the electromagnetic clutch to lock-up the clutch and respectively to the current reducing signal for reducing the current to slip the clutch.
The other objects and features of this invention will become understood from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b are sectional views of a continuously variable belt-drive transmission to which the present invention is applied;
FIG. 2 is a schematic diagram showing a control system according to the present invention;
FIGS. 3a and 3b show a block diagram of a control unit according to the present invention;
FIG. 4 is a flow chart showing the operation of the control system;
FIG. 5 is a graph showing regions of various modes;
FIGS. 6 and 7 are graphs showing variation of clutch current;
FIG. 8 is a graph showing relationships between engine speed and vehicle speed in the prior art and the present invention;
FIG. 9 is a graph showing relationship between vehicle speed and clutch current; and
FIG. 10 is a flowchart showing the operation of the system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1a and 1b, a continuously variable belt-drive automatic transmission for a vehicle, to which the present invention is applied, comprises an electromagnetic powder clutch 1, a continuously variable belt-drive transmission 2, a selector device 3, pulleys and belt device 4, final reduction device 5, and a pressure oil control circuit (not shown). The electromagnetic powder clutch 1 is provided in a housing 6. The selector device 3, pulleys and belt device 4, and final reduction device 5 are provided in a main housing 7 and a side housing 8. A crankshaft 10 of an engine E is connected to an annular drive member 12 through a drive plate 11 of the electromagnetic powder clutch 1. The electromagnetic powder clutch comprises a driven member 14, an a magnetizing coil 15 provided in the driven member 14. The driven member 14 has its outer periphery spaced from the inner periphery of the drive member 12 by a gap 16, and a powder chamber 17 is defined between the drive member 12 and driven member 14. Magnetic powder is provided in the powder chamber 17. The driven member 14 is secured to an input shaft 13 of the belt-drive transmission. A holder secured to the driven member 14 carries slip rings 18 which are electrically connected to the coil 15. The coil 15 is supplied through brushes 19 and slip rings 18 with current from a control circuit for the electromagnetic powder clutch.
When the magnetizing coil 15 is excited by the clutch current, the driven member 14 is magnetized to produce a magnetic flux passing through the drive member 12. The magnetic powder is aggregated in the gap 16 by the magnetic flux and the driven member 14 is engaged with the drive member 12 by the powder. On the other hand, when the clutch current is cut off, the drive and driven members 12 and 14 are disengaged from one another.
In the belt-drive transmission 2, the selector device 3 is provided between the input shaft 13 and a main shaft 20. The main shaft 20 is cylindrical and is disposed coaxially with the input shaft 13. The selector device 3 comprises a drive gear 21 integral with input shaft 13, reverse driven gear 22 rotatably mounted on the main shaft 20, and a synchronizer 27 mounted on the main shaft 20. The drive gear 21 meshes with one of counter gears 24 rotatably mounted on a shaft 23. Another of the counter gears 24 engages with an idler gear 26 rotatably mounted on a shaft 25, which in turn engages with the driven gear 22.
The synchronizer 27 comprises a hub 28 secured to the main shaft 20, a synchronizer sleeve 29 slidably engaged with the hub 28 with splines, and synchronizer rings 30 and 31. The synchronizer sleeve 29 is adapted to engage with splines of the drive gear 21 or with splines of driven gear 22 through rings 30 or 31.
At a neutral position (N-range) or a parking position (P-range) of a selector lever 50 (FIG. 2), the sleeve 29 does not engage either gear, so that the main shaft 20 is disconnected from the input shaft 13. When the sleeve 29 is engaged with the gear 21, the input shaft 13 is connected to the main shaft 20 through the gear 21 and synchronizer 27 to provide a drive range (D-range) or a high engine speed drive range (Ds-range).
When the sleeve 29 is engaged with the gear 22, the input shaft 13 is connected to the main shaft 20 through gears 21, 24, 26 and 22 to provide a reverse driving position (R-range).
The main shaft 20 has an axial passage in which an oil pump driving shaft 42 directly connected to the crankshaft 10 is mounted. An output shaft 35 is provided in parallel with the main shaft 20. A drive pulley 36 and a driven pulley 37 are mounted on shafts 20 and 35. A fixed conical disc 36a of the drive pulley 36 is integral with main shaft 20 and an axially movable conical disc 36b is axially slidably mounted on the main shaft 20. The movable conical disc 36b also slides in a cylinder secured to the main shaft 20 to form a servo device 38. A chamber 38b of the servo device 38 communicates with an oil pump 41 through the pressure oil control circuit. The oil pump 41 is driven by the shaft 42.
A fixed conical disc 37a of the driven pulley 37 is formed on the output shaft 35 opposite the movable disc 36b and a movable conical disc 37b is slidably mounted on the shaft 35 opposite disc 36a. The movable conical disc 37b has a cylindrical portion in which a piston portion of the output shaft 35 is slidably engaged to form a servo device 39. A chamber 39b of the servo device 39 is communicated with the oil pump 41 through the pressure oil control circuit. A spring 40 is provided to urge the movable conical disc 37b toward the fixed conical disc 37a. A drive belt 34 engages with the drive pulley 36 and the driven pulley 37.
Secured to the output shaft 35 is a drive gear 43 which engages with an intermediate reduction gear 44a on an intermediate shaft 44. An intermediate gear 45 on the shaft 44 engages with a final gear 46. Rotation of the final gear 46 is transmitted to axles 48 and 49 of the vehicle driving wheels through a differential 47.
The pressure oil control circuit is responsive to vehicle speed, engine speed and throttle valve position for controlling the oil from the oil pump 41 to the servo devices 38 and 39 thereby to move discs 36b and 37b. Thus, the transmission ratio is continuously changed. When the Ds range is selected, the transmission ratio is increased by the operation of the pressure oil control circuit.
Referring to FIG. 2 showing a control system, an R-range switch 51, D-range switch 52, and Ds-range switch 53 are provided to produce high level output signals at respective positions of the selector lever 50. An accelerator pedal switch 55 is provided to produce an output signal when an accelerator pedal 54 of the vehicle is depressed, and an accelerator pedal position switch 56 is provided to produce an output signal when the accelerator pedal is depressed over a predetermined degree. The accelerator pedal switch 55 and accelerator pedal position switch 56 may be substituted with a throttle valve switch and throttle position switch, respectively. A choke switch 57 produces an output signal when a choke valve of the engine is closed, and an air conditioner switch 58 produces an output signal at the operation of an air conditioner. An ignition pulse generator 60 produces pulses dependent on the ignition signal from an ignition coil 59, representing engine speed. A vehicle speed signal generator 62 produces pulses dependent on an output from a speedometer 61. These output signals and pulses are applied to a control unit 63 which controls the clutch current in dependency on the input signals.
Referring to FIGS. 3a and 3b, the control unit 63 is provided with an engine speed deciding section 64 applied with the ignition pulses from the generator 60, and a vehicle speed deciding section 65 applied with the pulses from the generator 62. A reverse excitation mode deciding section 66 decides that output signals from R-range switch 51, D-range switch 52 and Ds-range switch 53 are at low levels, and the transmission is at P-range or N-range, and produces a reverse excitation signal. The reverse excitation signal is applied to an output deciding section 67, so that a small reverse current flows in the coil 15 to excite the coil in reverse. When engine speed is below 300 rpm, an engine speed deciding section 64 produces a low engine speed signal which is applied to the reverse excitation mode deciding section 66 to excite the coil 15 in reverse. The output signals of the accelerator pedal depression switch 55 and vehicle speed deciding section 65, and the drive range select signals from the reverse excitation mode deciding section 66 are applied to a clutch current mode deciding section 68, outputs of which are applied to a start mode providing section 69, drag mode provide section 70, clutch lock-up mode (A) provide section 71 at releasing the accelerator pedal and clutch lock-up mode (B) provide section 72 at depression of the accelerator pedal.
The start mode provide section 69 decides clutch current dependent on the engine speed represented by the output from the engine speed deciding section 64. When the choke switch 57 or air conditioner switch 58 is turned on, clutch current having a high stall speed is decided. When the accelerator pedal is released, the drag mode provide section 70 decides a small drag current dependent on an output representing low vehicle speed from the vehicle speed deciding section 65 and on the output of the clutch current mode deciding section 68 at the release of the accelerator pedal. When the vehicle speed decreases below a predetermined low speed, the clutch current becomes zero to disengage the clutch. The clutch lock-up mode (A) provide section 71 decides a small lock-up current in response to the output of the accelerator pedal switch 55 at the release thereof at middle and high vehicle speed. In accordance with present invention, when the choke switch 57 is ON, the characteristic of the clutch current is decided dependent on output signals of the accelerator pedal position switch 56, engine speed deciding section 64 and vehicle speed deciding section 65. While the vehicle speed is below a predetermined speed V H (FIG. 8), which is higher than the lock-up speed V L , and the engine; speed is above predetermined speed (for example speed M), the clutch current is decreased so as to increase slipping of the clutch. The clutch current is increased to reduce the slipping of the clutch when the engine speed decreases below the predetermined speed. When Ds-range switch 53 is ON, the clutch current is cut off at a lower vehicle speed than the D-range. The clutch lock-up mode (B) provide section 72 decides a large lock-up current in response to the output of the accelerator pedal switch at the depression at middle and high vehicle speed. Clutch current at the Ds-range is the same as the mode (A). Outputs of sections 69 to 72 are applied to the output deciding section 67 to control the clutch current.
Describing the operation of the control system with reference to FIGS. 4 and 5, at a deciding step 80 (FIG. 4), it is determined whether the vehicle is at the reverse excitation mode. If the reverse excitation mode is detected, reverse clutch current flows in the coil 15. When engine speed is at a very low speed, for example below 300 rpm, the reverse clutch current flows at all ranges (FIG. 5). At a deciding step 81, clutch current supply mode is determined. If the accelerator pedal is released at a low vehicle speed, the clutch current is cut off or a small drag current flows. If the accelerator pedal is depressed, clutch current for starting the vehicle flows. At middle or high vehicle speed, when the accelerator pedal is released, a small lock-up current (mode A) flows, and at the depression of the pedal, a large lock-up current (mode B) flows.
When the choke switch 57 is ON, the clutch current is controlled in accordance with the flowchart in FIG. 10. At a step S1, it is determined whether the accelerator pedal is released. If the accelerator pedal is released, the vehicle speed is detected at a step S2. If the vehicle speed is lower than the predetermined low speed V H , (FIG. 8) the clutch current I (FIG. 9) is decreased at a step S3 by subtracting ΔI from the amount of the basic current Ic (which is in the present case, a lock-up current). Thus, slipping of the clutch increases. At a step S4, it is decided whether the engine speed Ne is higher than a predetermined speed Neu or not. When Ne is higher than Neu, the program is returned to step S3 for further reducing the clutch current, thereby increasing the slipping of the clutch. If the engine speed Ne is lower than Neu, the clutch current I is increased by adding ΔI to Ic (Ic+ΔI) at a step S5. At a step S6, it is further decided whether the vehicle speed is higher or lower than the predetermined lock-up speed V L of FIG. 8. If the vehicle speed is higher than the predetermined speed, the program is returned to step S4. If it is lower, the program ends. Thus, the vehicle speed is controlled to a proper speed without braking the vehicle, avoiding the elevating of the temperature of the clutch
Referring to FIGS. 6 and 7, at the N-range or P-range, a reverse current flows in the coil. At the D-range, if the accelerator pedal is not depressed, a small drag current b flows to produce a small drag torque, thereby reducing the amount of backlash between gears and decreasing the static friction torque in the belt and pulley device. When the accelerator pedal is depressed, a clutch current c 1 flows in proportion to engine speed. Clutch current c 2 flows under the operation of the air conditioner, and clutch current c 3 is for the operation when the choke valve is closed. When vehicle speed reaches a predetermined speed (V 3 or V 4 in FIG. 5), a large lock-up current d for entirely engaging the clutch flows to lock up the clutch. When the accelerator pedal is released to decelerate the vehicle, a small lock-up current flows, so that electric power consumption is reduced. When the vehicle speed decreases below a predetermined value (V 4 in FIG. 5), the clutch current becomes zero f. When the vehicle speed further decreases below a predetermined value (V 3 or V 2 ), the small drag current b flows. When the vehicle is decelerated at the Ds-range or R-range, the small drag current b flows at a lower vehicle speed than the D-range as shown by reference e' in FIG. 7. Thus, sufficient engine braking effect is provided in a lower vehicle speed range.
From the foregoing, it will be understood that in the system of the present invention, when the choke valve is closed, the clutch in lock-up mode slips, so that acceleration of the vehicle is controlled. Accordingly, since braking of the vehicle is not necessary, elevation of the temperature of the clutch can be prevented.
While the presently preferred embodiment of the present invention has been shown and described, it is to be understood that this disclosure is for the purpose of illustration and that various changes and modifications may be made without departing from the spirit and scope of the invention as set forth in the appended claim.
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A system for slipping an electromagnetic clutch when a motor vehicle is driven at a low speed in a closed choke valve condition. The system is provided with a choke switch for producing a choke signal, accelerator pedal position switch for producing a release signal and a vehicle speed signal detector in order to reduce current passing in the clutch to cause the clutch to slip at the release of an accelerator pedal in a low vehicle speed range. The slipping is controlled to keep the vehicle speed constant.
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FIELD OF THE INVENTION
The present invention is drawn to a process for providing emolliency to the skin using a series so called “spider esters”. These esters are derived from poly-hydroxy functional compounds sequentially reacted with ethylene oxide or propylene oxide, followed by the reaction of the alkoxylate with fatty acid. The resulting products are called spider esters because they resemble the spider, wherein appendages are alkoxylated esters. The restrictions this orientation imposes on rotation allows for the preparation of polar esters that have little or no water solubility, and provide both moisturization to the skin and emolliency by reducing transepidermal water loss.
BACKGROUND OF THE INVENTION
The use of alkoxylated non-ionic as surface active agents is well known. The ethoxylation of fatty alcohols results in compounds that have both water soluble and oil soluble groups. The result is a so called “surfactant”, a contraction for surface active agent. The addition of ethylene oxide to fatty alcohol results in increasing water solubility.
The term “HLB” was first employed by the lab staff of the Atlas Powder Co. in America. This means the balance between the oil soluble and water soluble moieties in a surface active molecule, and is expressed as the “Hydrophile—Liphophile Balance”. A more oil-soluble emulsifier shows a lower HLB and a more water-soluble emulsifier shows the reverse. HLB is a very useful method in selecting an emulsifier, but it still has several limitations to application for every surfactant.
The HLB system developed by Griffin some 50 years ago. The system depends upon the observation that the solubility of the surfactant is related to the percentage by weight of polyoxyalkylene portion of the molecule and is relatively independent of the nature of the fatty group.
Water Dispersibility
HLB
% EO.
Not dispersible
1-4
up to 20%
Poorly dispersible
4-6
20%-30%
Milky dispersion
6-8
30%-40%
Stable milky dispersion
8-10
40%-50%
Translucent to clear
10-13
50%-65%
Clear Solution
13+
Over 65%
HLB
Application.
4-6
W/O Emulsifier
7-9
Wetting Agent
8-18
O/W Emulsifier
13-15
Detergents
15-18
Solubilizers
The HLB system has some very distinct situations I which the applicability breaks down. It is designed for ethoxylated products, specifically linear alcohol ethoxylates. It is not useful when applied to Guerbet alcohol ethoxylates due to the branching. We have also surprisingly and unrepentantly found that certain ester that are linked together through a linking group are not surfactants, despite high levels of ethoxylates. We have dubbed these spider esters since the structure is reminiscent of a spider. The crosslinking group is the body of the spider and the ethoxylated fatty esters are the legs. A specific order is also needed. The ethoxylated needs to be closest to the body of the spider and the fatty group at the foot end. While not wanting to be limited by any one theory we believe this orientation limits rotation of the polyoxyalkylene group and causes the molecule to be incapable of orientation at the surface of a water oil interface. Such orientation results in water solubility caused by the polyoxyalkylene groups going into the water and the oil soluble group going into the oil phase. The result is an ester that contains an appreciable amount of polar polyoxyalkylene group but is water insoluble. This is a very interesting material in that it represents a polar rich oil in which polar and ionic materials may be dissolved and applied in an oil phase. This is a critical concept for delivery of antioxidants, free radical scavengers, sun screens and the like to the skin.
Surfactants are by definition compounds that remove natural oils from the skin. The removal of oil from the skin is a stripping process that damages the skin and provides dry chapped skin. Surfactants in the process of emulsification, detergency or wetting have a cleaning effect in removing soil from the skin, but concurrently cause dry skin. This process results in dry skin and cosmetically unacceptable appearance to the skin. Dry skin is a major consumer problem in the cosmetic industry.
It is generally accepted that there are different mechanisms of providing emolliency to the skin. The first is to provide moisture in so called moisturizing compounds. These compounds allow moisture to penetrate the skin. The alternate method is to trap moisture inside the skin providing a barrier that does not allow moisture to be lost. The barrier is a water insoluble oil that when placed on the skin keeps moisture from evaporating. It is clear that the two different mechanisms are mutually exclusive. That is, if an emollient oil is applied to the skin, not only can moisture not exit the skin, but moisture cannot enter, traversing the barrier. If a moisturizer is applied to the skin it must be applied to a barrier free skin. Simply put you cannot have effective moisturization on skin with a barrier present, since it will not penetrate. There is a long felt need for a technology that provides moisturization and emolliency. This requires a non-surface active polar oil that can simultaneously have water binding sites and oil soluble sites. Such a combination of properties has been elusive until the process of the current invention was discovered.
We have unexpectedly and surprisingly found that molecules of the present invention, by virtue of having the polyoxyalkylene group bonded on one side to a fatty group and on the other to a common backbone, compounds that have polyoxyalkylene contents that would render them water soluble if they were present in non-spider esters. These polar esters link a fatty group through a polyoxyalkylene group to a common polymeric backbone. While not wanting to be held to one specific theory, the functionality of the present molecules has to do with the balance between the fatty group and the water soluble group and requires limitation on the orientation of the resulting polymer. The result is an ester that has little or no water solubility, an ability to deliver water and no surface activity.
By polyoxyalkylene groups is meant polyethylene groups —(—(CH 2 CH 2 O) a H), polyoxypropylene groups (—CH 2 CH(CH 3 )O) b H) or mixtures thereof (—(CH 2 CH 2 O)a—CH 2 CH(CH 3 )O) b H).
THE INVENTION
Object of the Invention
One objective of the present invention is to provide a series of unique spider esters that are water insoluble yet contain large polar groups. These polar groups solubilize ionic and polar materials providing delivery of polar materials that would otherwise be oil insoluble from a polar oil phase.
Another objective of the present invention is to provide a vehicle to improve oil solubility of antioxidants, sunscreens and free radical scavenger to allow for through and efficient delivery of these materials to the skin in a polar oil phase.
Other objects of the invention will become clear as one reads the following specifications and disclosures.
SUMMARY OF THE INVENTION
The present invention relates to a process for providing moisturization and emolliency to the skin in a simultaneous process. The process comprises contacting the skin with an effective moisturization concentration of a so called “spider ester”.
These so-called spider ester of the present invention have a fatty group connected through a short polyoxyalkylene group to a common linkage group. The so-called linkage group is a consequence of the choice of the proper poly-hydroxy compound. The resulting ester looks like a spider, having a body (linkage group) and multi legs, having a low number of polyoxyalkylene groups present (the leg) and fatty ester groups (the spider's feet). This type of molecule allows groups that are oil soluble (fatty ester “feet”), water attracting (polyoxyalkylene groups (the spider's legs) and a linkage group (poly hydroxy raw material group). The compounds when applied to the skin allow for moisturization, by delivery of moisture from the spider's leg (polyoxyalkylene group), protection from evaporation of moisture (the spider's “fatty feet”), and no surface active properties, due to the lack of rotation caused by the linkage group, resulting in a very efficient multi-dimensional moisturizing agent. The process of using this compound in moisturization of the skin comprises contacting the skin with an effective moisturizing concentration of the spider esters of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a process for moisturizing the skin which comprises contacting the skin with an effective moisturizing concentration of a compound selected from the group consisting of:
(a) glyceryl spider esters conforming to the following structure;
wherein;
a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 4; R 1 is alkyl having 7 to 21 carbon atoms;
(b) glycol spider esters conform to the following structure;
(CH 3 ) x —C—(CH 2 —O—(CH 2 CH 2 O) a —CH 2 CH(CH 3 )O) b —C(O)—R 1 ) y
wherein;
a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 5; R 1 is alkyl having 7 to 21 carbon atoms; y is 4 or 3; x equals 4−y; R 1 is alkyl having 7 to 21 carbon atoms;
and
(c) sorbitol spider esters conforming to the following structure;
wherein;
R 2 is —(CH 2 CH 2 O) a —CH 2 CH(CH 3 )O) b —C(O)—R 1 a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 5; R 1 is alkyl having 7 to 21 carbon atoms; y is an integer 1,2,3, or 4; x equals y−4.
PREFERRED EMBODIMENT
In a preferred embodiment the process is conducted using a glyceryl spider ester.
In a preferred embodiment the glyceryl spider ester b is 0.
In a preferred embodiment the glyceryl spider ester a is 0.
In a preferred embodiment the glyceryl spider ester a is not 0 and b is not 0.
In a preferred embodiment the glyceryl spider ester a is 1, b is 1.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 7 carbon atoms.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 9 carbon atoms.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 11 carbon atoms.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 13 carbon atoms.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 19 carbon atoms.
In a preferred embodiment the glyceryl spider ester R 1 is alkyl having 21 carbon atoms.
In another preferred embodiment the process is conducted using a glycol spider ester.
In a preferred embodiment the glycol spider ester y is 4.
In a preferred embodiment the glycol spider ester y is 3.
In a preferred embodiment the glycol spider ester y is 4, a is 0 and b is 2.
In a preferred embodiment the glycol spider ester y is 3, a is 0 and b is 2.
In a preferred embodiment the glycol spider ester b is 0.
In a preferred embodiment the glycol spider ester a is 0.
In a preferred embodiment the glycol spider ester a is not 0 and b is not 0.
In a preferred embodiment the glycol spider ester a is 1, b is 1.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 7 carbon atoms.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 9 carbon atoms.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 11 carbon atoms.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 13 carbon atoms.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 19 carbon atoms.
In a preferred embodiment the glycol spider ester R 1 is alkyl having 21 carbon atoms.
In a preferred embodiment the process is conducted using a sorbitol spider ester.
In a preferred embodiment the sorbitol spider ester b is 0.
In a preferred embodiment the sorbitol spider ester a is 0.
In a preferred embodiment the sorbitol spider ester a is not 0 and b is not 0.
In a preferred embodiment the sorbitol spider ester a is 1, b is 1.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 7 carbon atoms.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 9 carbon atoms.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 11 carbon atoms.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 13 carbon atoms.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 19 carbon atoms.
In a preferred embodiment the sorbitol spider ester R 1 is alkyl having 21 carbon atoms.
EXAMPLES
Glyceryl Alkoxylates
Glyceryl Alkoxylates were prepared by Siltech LLC, of Dacula, Ga. They are made by addition of ethylene oxide, propylene oxide or mixtures thereof to glycerin. They conform to the following structure;
wherein;
a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 4.
Raw Material Examples
Example
a
b
1
0
1
2
1
1
3
2
2
4
1
0
5
3
1
6
1
3
Glycol Alkoxylates
Glycol Alkoxylates were prepared by Siltech LLC, of Dacula, Ga. They are made by addition of ethylene oxide, propylene oxide or mixtures thereof to pentaerythritol (y=4), trimethyol propane (y=3). They conform to the following structure;
(CH 3 ) x —C—(CH 2 —O—(CH 2 CH 2 O) a —CH 2 CH(CH 3 )O) b —H) y
wherein;
a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 5; R 1 is alkyl having 7 to 21 carbon atoms; y is 4 or 3; x equals 4−y.
Examples 7-12 Pentaerythritol Examples (y=4 and x=0)
Example
a
b
7
0
1
8
1
1
9
2
2
10
1
0
11
3
1
12
1
3
Example 13-20 Trimethyol Propane Examples (y=e and x=1)
Example
a
b
13
0
1
14
1
1
15
2
2
16
1
0
17
3
1
18
1
3
Sorbitol Alkoxylates
Sorbitol is hexane-1,2,3,4,5,6-hexaol. It as a CAS number of 50-70-4
Sorbitol alkoxylates were prepared by Siltech LLC, of Dacula, Ga. They are made by addition of ethylene oxide, propylene oxide or mixtures thereof to sorbitol. They conform to the following structure;
wherein;
R 2 is —(CH 2 CH 2 O) a —CH 2 CH(CH 3 )O) b —H a is an integer ranging from 0 to 4; b is an integer ranging from 0 to 4, with the proviso that a+b ranges from 1 to 5;
Examples 19-24
Example
a
b
19
0
1
20
1
1
21
2
2
22
1
0
23
3
1
24
1
3
Fatty Acids
Fatty Acids useful in the practice of the present invention are items of commerce they are available as either single components or mixtures.
Fatty Aid Names
Fatty Acids
Fatty acids useful as raw materials in the preparation of the compounds of the present invention are commercially available from a variety of sources including Procter and Gamble of Cincinnati Ohio. The structures are well known to those skilled in the art.
R—C(O)—OH
Saturated
Example
R Formula
Common Name
Molecular Weight
25
C 7 H 5
caprylic
144
26
C 9 H 19
capric
172
27
C 11 H 23
lauric
200
28
C 13 H 27
myristic
228
29
C 14 H 29
pentadecanoic
242
30
C 15 H 31
palmitic
256
31
C 17 H 35
stearic
284
32
C 19 H 39
arachidinic
312
33
C 21 H 43
behenic
340
34
C 26 H 53
cetrotic
396
35
C 33 H 67
geddic acid
508
Unsaturated
Example
R Formula
Common Name
Molecular Weight
36
C 17 H 33
oleic
282
37
C 17 H 31
linoleic
280
38
C 17 H 29
linolenic
278
39
C 15 H 29
palmitoleic
254
40
C 13 H 25
myristicoleic
226
41
C 21 H 41
erucic
338
Esterification Reactions
In addition to the ratio of polyoxyalkylene groups to fatty group and the linkage group chosen, it is very important for the practice of the current invention resulting in compounds of the present, the reaction of all of the hydroxyl groups to make esters is very important. The presence of unreacted hydroxyl groups in the compounds of the present invention is undesirable. The compounds of the present invention have very low amount of unreacted hydroxyl groups.
General Procedure
To the specified number of grams of the specified alkoxylate (Examples 1-24) is added the specified number of grams of the specified fatty acids (Example 25-41). Next add 0.1% by weight, based upon the total number of grams added of both alkoxylate and fatty acid. The reaction mass is heated to 190-200° C. Water is generated as the reaction proceeds. The reaction is followed as the acid value becomes vanishingly low. As the reaction proceeds vacuum is applied slowly to keep the water distilling off.
Examples 25-48
Alkoxylate
Fatty Acid
Example
Example
Grams
Example
Grams
42
1
89.0
25
144.0
43
2
133.0
26
172.0
44
3
236.0
27
200.0
45
4
74.0
28
228.0
46
5
221.0
29
242.0
47
6
251.0
30
256.0
48
7
87.0
31
284.0
49
8
146.0
32
312.0
50
9
249.0
33
340.0
51
10
87.0
34
396.0
52
11
191.0
35
508.0
53
12
221.0
36
282.0
54
13
102.0
37
280.0
55
14
161.0
38
278.0
56
15
254.0
39
254.0
57
16
92.0
40
226.0
58
17
239.0
41
338.0
59
18
269.0
25
144.0
60
19
89.0
26
172.0
61
20
133.0
27
200.0
62
21
236.0
28
228.0
63
22
74.0
29
242.0
64
23
221.0
30
256.0
65
24
251.0
31
284.0
The reactions are held at temperature until the acid value and hydroxyl become vanishinlgy small and the saponification reacted almost theoretical. Produces are used without additional purification. They are light in color and low in odor.
Applications Examples
Typical of the properties of the spider esters of the present invention are examples 44 and 53. Example 44 contains 45% by weight polyoxyalkylene group, having an HLB of 9. By HLB, this produce should be milky in water forming a stable dispersion quite to the contrary it is a water insoluble oil. It is low in odor and has a very appealing feel on the skin. This ester solubilizers sunscreens to a much greater extent than mineral oil. The product of example 44 can be emulsified as an oil using a HLB of 5.6 emulsifier to make a cosmetically acceptable water resistant sun screen. Example 44 provides outstanding moisturization to the skin when evaluated by consumer panel.
Example 53 is 44% polyoxyalkylene containing. It has an HLB of 8.8. By HLB, this product should be milky in water forming a stable dispersion quite to the contrary it is a water insoluble oil. It is low in odor and has a very appealing feel on the skin. This ester solubilizers sunscreens to a much greater extent than mineral oil. The product of example 53 can be used to solubilize a variety of antioxidants and deliver them in an oil to the skin, providing protection from UV degradation. Example 53 provides outstanding moisturization to the skin when evaluated by consumer panel.
Properties
Example 44
Example 53
Appearance
Lt. Yellow Liquid
Yellow Liquid
Viscosity @ 25° C.
120 cps
260 cps
Water Solubility
Insoluble
Insoluble
Calculated HLB
9.0
8.8
Sun Screen Solubility
Initial
% weight
Sunscreen
Appearance
Age Appearance (1)
1%
Benzophenone 3
Clear
Very Slight Haze (2)
3%
Benzophenone 3
Clear
Very Slight Haze (2)
1%
Octylmethoxyciminate
Clear
Clear
(1) Appearance after 48 hours at room temperature, 24 hours in refrigerator (37° F.) and 48 hours at room temperature.
(2) Slight haze was there since initial dissolution and did not increase with time.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth hereinabove but rather that the claim be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains.
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The present invention is drawn to a process for providing emolliency to the skin using a series so called “spider esters”. These esters are derived from poly-hydroxy functional compounds sequentially reacted with ethylene oxide or propylene oxide, followed by the reaction of the alkoxylate with fatty acid. The resulting products are called spider esters because they resemble the spider, wherein appendages are alkoxylated esters. The restrictions this orientation imposes on rotation allows for the preparation of polar esters that have little or no water solubility, and provide both moisturization to the skin and emolliency by reducing transepidermal water loss.
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This application claims priority to provisional application No. 60/197,614 filed Apr. 18, 2000.
FIELD OF THE INVENTION
The present invention relates to a plurality of robots positioned on a turntable at spaced locations along the periphery, where the turntable is movable in rotation to predetermined angular positions independently of movement of the individual robots disposed thereon.
BACKGROUND OF THE INVENTION
A modular robotic finishing work center is disclosed in U.S. Pat. No. 4,644,897. The patent discloses an elevated platform with a turntable mounted thereon which is rotatable about a vertical axis, and a robot manipulator fixedly mounted relative to the vertical axis, wherein the turntable ends are rotatable through a circular path where at least part of the path includes a partially protected booth for collecting paint residue and overspray. The robot manipulator has a movable arm and spray applicator capable of movement along a limited range so as to provide a predetermined envelope of possible work areas for spray finishing, where a portion of the turntable end path and at least a portion of the spray booth are included within this envelope.
A tool turntable for a manufacturing system is disclosed in U.S. Pat. No. 5,186,304. The production line manufacturing system includes a programmable multi-position rotatable unit that can be used in each of the work stations to accommodate both changes in workpieces to be processed and tools. The rotatable unit includes a four-position horizontally arranged fixture table including four vertically arranged fixtures movably mounted thereon. A precision locator key on each of the fixtures positions each individual fixture on the table and also serves as a positive fixture stopped in the work position.
SUMMARY OF THE INVENTION
It would be desirable in the present invention to provide a turntable or a carousel with a plurality of robots positioned thereon in peripherally spaced locations with respect to one another for movement about a vertical axis of the turntable while allowing independent movement of each of the individual robots positioned thereon. The apparatus for manufacturing parts according to the present invention can include a turntable having an outer periphery and a centrally located axis of rotation, a plurality of robots positioned at peripherally spaced locations about the turntable with respect to one another for independent movement with respect to one another and with respect to movement of the turntable, and a control system for controlling and synchronizing independent individual movements of the robots with rotation of the turntable to move each individual robot from one work station at a first angular position to another work station at a second angular position.
Other objects, advantages and applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 is a simplified plan view of a robotic turntable or carousel according to the present invention for manufacturing parts; and
FIG. 2 is a side elevational view of a robotic turntable according to the present invention including a plurality of robots individually operating with respect to different work stations on opposite sides of the turntable.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus 10 according to the present invention provides for the manufacturing of parts 12 by a plurality of robots 14 positioned on a turntable 16 for rotation about an axis 18 . The robots are positioned at different locations spaced along the outer periphery of the turntable 16 . In the illustrated embodiment, there are an equal number of robots 14 to the number of work stations 20 positioned around the periphery of the turntable 16 , although an equal number of robots to work stations is not required to practice the present invention. By way of example, and not limitation, the present invention will be described in detail with respect to the manufacture of particular parts 12 , such as a side panel sub assembly of a motor vehicle.
Referring now to FIG. 1, the turntable 16 is illustrated having eight robots 14 a , 14 b , 14 c , 14 d , 14 e , 14 f , 14 g , 14 h disposed at evenly spaced angular positions around the outer peripheral edge of the turntable 16 . The robots 14 a - 14 h are independently movable with respect to one another, and are movable independent of movement of the turntable 16 . When the turntable 16 is disposed at a first angular position, such as that illustrated in FIG. 1, each robot 14 is capable of performing various independent work cycles at the individual work station 20 corresponding to its current location. By way of example and not limitation, in the position illustrated in FIG. 1, the robot 14 a is positioned at work station 20 a for unloading parts that have been processed. After unloading a part, the turntable 16 can be rotated about the axis 18 to now position the robot 14 a at the position previously occupied by robot 14 b . In this position, the robot has access to a tool change work station 20 b in order to provide the opportunity to change the tooling as required for the particular part to be processed next.
After completion of the tool change, if any, at work station 20 b , the turntable 16 can be rotated again about the axis 18 to move the robot 14 a from the position previously shown for robot 14 b to the position previously shown for robot 14 c . When in this position, the robot can pick up a part to be processed at the part loading fixture 22 at work station 20 c . Preferably, the fixture 22 located at the work station 20 c is an indexing part load fixture 22 c capable of positioning a plurality of fixtures corresponding to the desired body style and model to be processed through the work station 20 c . In its most preferred configuration, the indexing fixture 22 c includes four different fixtures positioned on four major surfaces of a rectangular fixture rotatable about a horizontal axis to position one of the four major surfaces in an upright ready position for receiving parts to be loaded onto or picked up by the robot at work station 20 c.
After the robot has retrieved the part to be processed from the work station 20 c , the turntable 16 is rotated about the axis 18 to bring the robot 14 a into the position previously illustrated for robot 14 d corresponding to work station 20 d . At work station 20 d , the robot 14 a positions the part 12 into the fixture 22 d allowing additional work to be performed on the part. The fixture 22 d is preferably an indexing part fixture similar to fixture 22 c . The fixture 22 d preferably has four major surfaces with different fixtures for various models and body styles to be processed. The fixture is rotatable about a horizontal axis to bring a selected one of the four major surfaces into an upright ready position for receiving the next part to be processed. The additional work can include the attachment and assembly of various sub components to the part, or the clamping and welding of various components at different positions on the part, or any other automated processing required with respect to the particular part being processed through the apparatus 10 according to the present invention. The processing can include assembly and/or welding by additional robots 24 a - 24 d disposed at work station 20 d . One or more robots 24 can be positioned at the work station 20 d as required for the particular part processing to take place at the particular work station. After the processing of the part is completed at work station 20 d and the robot 14 a retrieves the part from the fixture 22 d , the turntable 16 is rotated about the axis 18 to move the robot 14 a to the position previously illustrated for robot 14 e . At this position, additional processing can take place as required for the particular part. By way of example and not limitation, the illustration shows a respot work station 20 e for welding areas of the part inaccessible while resting in the fixture 22 d of work station 20 d . A respot welder 26 can be positioned at each respot work station, such as welder 26 e at work station 20 e.
After respotting has been completed at the work station 20 e , the turntable 16 can be rotated about axis 18 to position the robot 14 a in the position previously shown for robot 14 f . The part can be loaded by the robot into the fixture 22 f at the work station 20 f . The fixture 22 f preferably can be an indexing part fixture similar to 22 d and 22 c previously described. In the most preferred configuration, the indexing part fixture 22 f is provided as a rectangular fixture having four major surfaces with different fixtures for the various models and body styles to be processed through the apparatus 10 according to the present invention. The rectangular fixture is rotatable about a horizontal axis to bring a selected one of the four major fixture surfaces into an upright ready position for receiving the part to be processed. The processing at the work station 20 f can include assembly of additional sub components to the primary part being assembled, or additional clamping and welding of various portions of the part to one another. Additional robots 26 a - 26 d can be provided at the work station 20 f to perform the assembly or welding operations as required.
When processing of the part has been completed at the work station 20 f , the turntable 16 can be rotated about the axis 18 to position the robot 14 a at the position previously illustrated for robot 14 g . Additional processing of the part can take place at work station 20 g when the robot is in this position. By way of example and not limitation, a respot welding apparatus 26 g can be provided to weld portions of the part 12 being assembled that could not be accessed while the part was positioned in the fixture at work station 20 f.
After respotting has been completed, the turntable 16 can be rotated about the axis 18 to position the robot 14 a at the position previously illustrated for robot 14 h . At this position, the part can be subjected to additional processing, by way of example and not limitation, such as additional respot welding by a respot welding apparatus 26 h at work station 20 h . When the additional processing is completed at work station 20 h , the turntable 16 can be rotated about the axis 18 to again bring the robot 14 a to the position illustrated as 14 a in FIG. 1 where the processed part can be unloaded at the work station 20 a.
While the invention has been described in detail with respect to a single robot 14 a being rotated through the various work stations around the periphery of the turntable 16 , it should be apparent to those skilled in the art that the additional robots 14 b , 14 c , 14 d , 14 e , 14 f , 14 g , 14 h positioned on the turntable 16 perform the same operations at the various work stations while rotated through the various work station positions 20 b , 20 c , 20 d , 20 e , 20 f , 20 g , 20 h , and that work is simultaneously performed at each work station by each of the robots 14 a - 14 h prior to the turntable being moved to transfer the robots 14 a - 14 h and parts carried by the robots 14 a - 14 h to the next work station 20 a - 20 h in the processing system.
Referring now to FIG. 2, a cross-sectional elevational view is shown of the robots 14 d , 14 f on the turntable 16 according to the present invention through work station 20 d and work station 20 f . As previously described, the robots 14 d and 14 f can transport workpieces 12 to the work station 20 d and 20 f respectively and can load the parts into a corresponding fixture 22 d , 22 f for the particular part to be processed. Each of the indexing fixtures 22 d , 22 f at the work stations 20 d and 20 f can be in the form of a rectangular fixture having four major surfaces with different fixture configurations for the various body styles and models to be processed through the work stations. Each of the fixtures 22 is rotatable about an axis 30 to position the desired fixture in the upright ready position for receiving the part to be delivered by the corresponding robot presently positioned at that work station. Welders 32 can be positioned above each of the robots 14 , as can best be seen in FIG. 2 where welder 32 d is positioned above robot 14 d and welder 32 f is positioned above robot 14 f . The welders 32 positioned above the robots 14 allow additional welding to be performed during a movement cycle of the turntable 16 , or while one work station is waiting for completion of work being performed at another work station. In this way, additional work can be performed by the robot 14 and welder 32 between cycles performed at various work stations. The part can be manipulated and moved as required to perform multiple welds with the welders 32 , or the respot welders 26 e , 26 g , 26 h at the work stations 20 e , 20 g and 20 h.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
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A plurality of robots are positioned on a rotatable table for transporting parts to be processed through a plurality of work stations positioned around the periphery of the table. Each robot can carry a workpiece from one work station to the next. The rotation of the table moves the robot from one workstation to the next while carrying a part to be processed. Each robot can be independently movable relative to the other robots and each robot can be independently movable relative to the table. Each robot can include a welder for processing the workpiece independent of the workstation or during movement between work stations. Each robot can carry a plurality of differently configured workpieces between the work stations.
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BACKGROUND OF THE INVENTION
The present invention relates to the art of steam pressure regulation. More particularly, the invention relates to a method and apparatus for controlling steam flow through heated cylinders. The present invention finds particular application in conjunction with drying cylinders for paper making machinery and will be described with particular reference thereto. It is to be appreciated, however, that the invention is also applicable to other steam and condensable vapor heated structures.
In paper making machinery, the paper products are passed over a series of drying cylinders or drums. The drying cylinders are commonly heated by passing selected amounts of steam thereinto where the steam condenses into water condensate releasing its heat to the cylinder. During the removal of the condensate from the cylinder, some steam is also removed. Various systems have been developed for recovering and minimizing the amount of heat which is lost in steam removed with the condensate.
One system of controlling heat loss is disclosed in U.S. Pat. No. 4,222,178, issued September, 1980 to T. L. Moran. The Moran system seeks to maintain a preselected ratio between the flow rate of the condensate and the flow rate of the removed steam. Specifically, a controller compares the condensate and removed steam flow rate ratio with a preselected ratio for the current operating conditions, and controls an atmospheric relief valve in such a manner that the monitored ratio converges upon the selected ratio.
Others have monitored the temperature of the removed steam and condensate and utilized that monitored temperature to control the amount of steam fed to the drying cylinder. Also, others have suggested controlling the pressure differential between the inlet and the outlet of the drying cylinder in accordance with the amount or rate of the paper passing over the cylinder. Still others have adjusted the pressure of the removed steam as a function of the temperature of the removed steam and condensate.
The prior art control systems have tended to be relatively complex. Monitoring the flow rate of steam, for example, requires apparatus which is relatively expensive, yet relatively inaccurate. Further, steam flow measuring apparatus costs energy by creating a pressure loss.
The present invention contemplates a new and improved steam pressure control system for drying cylinders and the like which overcome the above referenced problems and others, yet maximizes the efficiency of steam usage.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method of minimizing the quantity of steam blown through a drying cylinder or like structure is advantageously provided. The quantity of condensate removed from the cylinder is monitored, and in response to monitoring a steady state rate of condensate removal, the pressure differential across the cylinder is reduced. Such reduction continues until the minimum pressure differential which is capable of maintaining the steady state condensate removal condition is achieved.
In accordance with a more limited aspect of the present invention, the method further includes periodically checking to be sure that the steady state condition is continuing to occur. More specific to the preferred embodiment, the pressure differential is periodically increased to determine whether the amount of condensate increases. If the amount of condensate does not increase, the pressure differential is reduced until a minimum pressure differential is again achieved.
In accordance with another aspect of the present invention, there is provided a drying cylinder, steam feeding means for feeding steam to the drying cylinder, fluid removal means for removing steam and condensate from the drying cylinder, removed steam pressure controlling means for controlling the pressure of the removed steam, condensate monitoring means for monitoring the quantity of removed condensate, verifying means for verifying that the monitored rate of condensate removal is substantially constant, and pressure differential control means for controlling a pressure differential between the feed and removed steam. The pressure differential control means varies the pressure differential in response to the verifying means failing to verify a steady condensate removal rate.
One advantage of the invention is that it removes a maximum amount of condensate with the minimum pressure differential across the drying cylinder.
Another advantage of the invention is that it minimizes steam loss without monitoring the steam flow rate.
Still further advantages of the invention will become apparent to others upon reading and understanding the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
FIG. 1 is a diagrammatic illustration of a drying cylinder such as used in a paper making process in conjunction with associated steam feeding, steam and condensate collection, and control apparatus formed in accordance with the present invention; and,
FIG. 2 is a flowchart for computerized control of the apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for purposes of illustrating the preferred embodiment of the invention only and not for limiting same, FIG. 1 shows a supply of steam fed to a steam heated structure 10, such as a drying cylinder, by a steam feeding means 12 at a controllable rate. As the steam gives up its heat to the drying cylinder, it condenses into water or condensate. A fluid removal means 14 removes the condensate along with some steam from the cylinder. The steam feeding means and the fluid removal means each controls the pressure of the steam passing therethrough. In this manner, the steam feeding means and the fluid removal means set a steam pressure differential across the drying cylinder.
A controller 16 is operatively connected with the steam feeding means and fluid removal means to control the pressure differential as a function of the condensate removal rate. More specifically, the controller reduces or optimizes the differential pressure to a minimum differential pressure at which substantially all condensate is removed from the drying cylinder. Thereafter, the controller maintains the pressure differential to substantially the lowest pressure differential which successfully removes substantially all condensate.
When all of the condensate is being removed, the condensate removal rate is independent of the differential pressure, ie., the condensate removal rate remains constant with changes in the differential pressure. If the differential pressure becomes too small to remove all of the condensate, the condensate removal rate decreases. As explained in greater detail below, to minimize the pressure differential, the controller 16 decreases the pressure differential until the condensate removal rate decreases, ie., until the differential pressure becomes too small. When the condensate removal rate starts decreasing, the differential pressure is increased by an amount which is sufficient to cause the condensate removal rate to become constant.
In the preferred embodiment, the steam feeding means 12 includes a main steam feed line 20 which is connected with a boiler or other source of steam (not shown). A steam line pressure control valve 22 controls the feed pressure of steam in a feed line 24 which feeds the steam into the drying cylinder 10. The feed pressure control valve 22 is operated by an electromechanical servomechanism 26 under the control of the control means 16.
The fluid removal means 14 includes a discharge line 30 which is connected with a syphon or other mechanism (not shown) within the drying cylinder for removing the condensate. The discharge line is connected with a steam/condensate separator 32. Steam is removed from the top of the separator along steam discharge line 34 at a pressure which is controlled by a removed steam pressure control valve 36. The removed steam pressure control valve 36 is operated by an electromechanical servomechanism 38 under the control of the control means 16. The removed steam pressure control valve 36 vents the removed steam to the atmosphere, passes it to other drying cylinders, returns it to the steam supply, or the like, as is conventional in the art.
A condensate removal or discharge line 40 and a condensate pump 42 return the condensate to the boiler or the like, as is conventional in the art. A condensate level control means 44 monitors the level of condensate in the separator 32 and controls the degree of throttling of a discharge valve 46. Rising and falling condensate levels in the separator indicate that the condensing rate is varying. The level control means 44 opens and closes the throttle valve to a greater or lesser degree to control the flow rate therethrough such that the separator level remains substantially constant. A flow meter or other condensate removal monitor 48 monitors the flow through the discharge valve 46, ie., monitors the condensate removal or discharge rate. The flow meter 48 produces a flow rate output signal which varies in proportion to the condensate removal rate. The flow rate signal is conveyed to the control means 16 to be used in implementing a pressure differential control algorithm.
In normal operation, the condensate is removed or discharged at a constant rate, ie., a steady state removal condition. A variation in the condensate removal rate generally connotes a change in operating conditions. If the removal rate fails to return to the steady state, ie., a constant removal rate, after an operating condition change, condensate is normally accumulating in the cylinder. To remove the accumulation from the cylinder and return to the steady state condensate removal condition, the steam pressure differential is adjusted by the control means 16.
With particular reference to FIG. 2, the controller 16 in the preferred embodiment includes a minicomputer which monitors the condensate removal or discharge rate from the flow meter 48 and controls the steam feed and removal pressure differential in accordance therewith. The computer is programmed with a suitable software programming that performs and includes an initializing step or means 50 for selecting an initial differential pressure for use during start-up or restart after a paper product sheet breaks. In the preferred embodiment, the initial differential pressure is relatively high, sufficiently high that achieving the steady state condensate removal condition is assured under normal operating conditions.
A coarse or large first increment differential pressure adjustment step or means 52 adjusts the differential pressure in relatively large or coarse first increments toward the optimal differential pressure, ie., the minimum differential pressure which removes substantially all of the condensate from the drying cylinder. In the preferred embodiment, the first adjustment means decreases the initial differential pressure in relatively large first increments or steps toward the optimal differential pressure. The first adjustment means reduces the differential pressure until it falls below the optimal differential pressure and condensate starts accumulating in the cylinder. Then, the first adjustment means increases the differential pressure by one first increment.
After the first differential pressure adjustment step or means 52 brings the differential pressure to approximately the optimal differential pressure, a fine or small second increment differential pressure adjustment means or step 54 further adjusts differential pressure toward the optimal differential pressure. The second adjustment is conducted in second increments or steps which are relatively small compared to the first increments. In the preferred embodiment, the second adjustment reduces the pressure differential in the small second increments until it falls below the optimal differential pressure. Then, it increases the differential pressure by one second increment. In this manner, the actual steady state differential pressure is within one second increment of the theoretically optimal differential pressure.
A condensate removal check means 56 periodically checks to determine whether substantially all condensate is being removed. In the preferred embodiment, the condensate check means periodically increases the differential pressure. If substantially all the condensate is being removed, increasing the differential pressure will not result in an increase in the condensate removal rate. However, if substantially all of the condensate was not being removed, the increase in differential pressure will cause a corresponding increase in the condensate removal rate. The condensate removal check step or means artifically increases the differential pressure and monitors for a change in the condensate removal rate to determine whether or not substantially all condensate is being removed. If substantially all the condensate is being removed, the second differential pressure adjustment means 54 readjusts and returns the actual differential pressure to the steady state differential pressure.
The initializing step or means 50 includes a step or means 60 for setting an initial differential pressure. In the preferred embodiment, this includes a keyboard or the like on which an operator can enter a preselected initial differential pressure. Once entered, the initial differential pressure can be stored in a memory and retrieved at the start of each run. The most recent differential pressure of the current run may also be stored and retrieved as the initial differential pressure after a temporary stoppage or at the beginning of the next run of the same type.
A timing step or means 62 provides a preselected time delay after the beginning of the run for the actual condensate removal rate to stabilize. After the stabilization time delay, an initial rate of condensate removal determining means 64 determines whether the condensate removal rate is substantially constant. The condensate removal rate determination may be made by reading the output from pump rate controller 46 two or more times and comparing the read rates to determine if they are substantially the same, are increasing, or are decreasing. If the condensate removal rate is increasing or decreasing, the initial differential pressure change determining means returns to the initializing differential pressure setting means or step 60 and the initializing timing means or step 62 to provide another stabilization delay. If the initializing condensate removal rate determining means 64 determines that the amount of condensate being removed is substantially constant, ie., substantially all condensate is being removed, the first differential adjustment means or step 52 is actuated.
When a sheet breaks during a run, a differential pressure retrieving means or step 70 retrieves the most recent prebreak differential pressure which produced steady state condensate removal. A sheet break timing means or step 72 provides a preselected stabilization time delay and actuates a sheet break condensate removal rate determining means or step 74. The sheet break condensate removal rate determining means or step determines whether the condensate removal rate is steady or varying. If the condensate rate is varying, the program returns to the retrieval and timing steps or means to provide another stabilization delay. Optionally, the differential pressure may be incremented if the condensate removal rate fails to stabilize. If the condensate removal rate is substantially constant, the first differential adjustment step or means 52 is actuated.
The first differential pressure adjustment step or means 52 includes a first decrementing means or step 80 which decreases the differential pressure by a preselected, relatively large first differential pressure increment, ΔP 1 . The first differential pressure increment is selected to be about 10 to 20 percent of the initial differential pressure. A first adjustment timing step or means 82 times a first stabilization interval, after which it actuates a first adjustment condensate rate determining means or step 84. If the condensate removal rate is substantially constant, the rate determining step or means returns to the first decrementing step or means 80, and differential pressure is decreased by the first increment. That is, if the monitor means 84 determines that substantially all of the condensate is being removed with the present differential pressure, the differential pressure is again decremented by the first increment. If the condensate flow rate is increasing, the first adjustment timing step or means 82 is reactivated so that the controller waits the first stabilization interval again. After another stabilization interval, the condensate flow rate is again determined. If the condensate flow rate is decreasing, which indicates that the differential pressure is insufficient to remove all the condensate, then a first adjustment incrementing means or step 86 increases the differential pressure by the first increment, ΔP 1 .
The fine adjustment step or means 54 includes a second or fine pressure differential decrementing means or step 90 which decreases the differential pressure by a second preselected differential pressure increment, ΔP 2 . In the preferred embodiment, the second pressure increment is approximately one quarter of the first increment. A second adjustment timing step or means 92 times a second adjustment stabilization interval, after which it actuates a second adjustment condensate rate determining means or step 94. If the condensate removal rate is substantially constant, the second rate determining step or means 94 returns to the second decrementing step or means 90, and the differential pressure is decreased again by the second differential pressure increment. That is, if the second rate determining step or means 94 determines that substantially all of the condensate is being removed with the present differential pressure, the differential pressure is decremented by the second pressure increment. If the condensate flow rate is increasing, the fine adjustment timing step or means 92 is repeated, and the controller waits another stabilization duration for the condensate flow rate to stabilize. If the condensate flow rate is decreasing, which indicates that the differential pressure is insufficient to remove all the condensate, a second differential pressure incrementing means or step 96 increases the differential pressure by the second increment, ΔP 2 . With this increase in the differential pressure, substantially the minimum differential pressure which is capable of removing substantially all the condensate has been attained. More specifically, the resultant optimal pressure differential is within the second differential pressure increment of the theoretical minimum. This small deviation allows for minor fluctuations in the operating conditions without necessitating readjustment.
The condensate removal check step or means 56 includes an intertest timer or hold means or step 100 which times for an extended between test duration after the optimal differential pressure has been attained in the second adjustment step or means. After the intertest duration, a check differential pressure incrementing means or step 102 increments the differential pressure. In the preferred embodiment, the check incrementing means increments the differential pressure by the second pressure increment. A check timing means or step 104 times a sufficient interval for the condensate removal rate to stabilize. A check condensate removal rate determining means or step 106 determines whether the condensate removal rate is constant. If the condensate removal rate remains substantially constant, indicating that all of the condensate is being removed, the program returns to the second adjustment means or step 54. The second adjustment means or step repeatedly decreases the differential pressure by the second increment until the minimum differential pressure is passed and increments it one second increment.
If the condensate flow rate is increasing, indicating insufficient differential pressure to remove all the condensate, the program returns to the check pressure incrementing means or step 102 and increments the differential pressure another time by the second pressure increment, and the process is then repeated. If the condensate removal rate is decreasing, indicating an unstable condition, the condensate rate determining means returns to the check timing means or step 104 to provide an additional duration for the system to stabilize.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A supply of steam is fed to a drying cylinder (10) from a steam line (20) through a steam pressure control valve (22). Condensate and steam are removed from the drying cylinder to a separator (32). The pressure of the removed steam is controlled by a steam pressure control valve (36) and the rate of condensate removal is monitored by a condensate removal monitor (48). A computer controller (16) adjusts the steam feed and removal pressure control valves to maintain the smallest differential pressure therebetween which will maintain the condensate removal rate substantially constant. The computer controller sets an initial pressure differential during an initializing step (50). In a first pressure differential adjustment step (52), the computer decreases the pressured differential in first increments until the condensate removal rate begins to decrease. In response to the decrease, the first pressure differential adjusting step increases the pressure differential by the first increment. A second pressure differential adjusting step (54) functions like the first pressure differential adjusting step but uses a smaller increment. A checking step (56) periodically increases the pressure differential by the second increment and returns the program to the second pressure differential adjusting step to reestablish an optimal pressure differential.
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BACKGROUND
1. The Field of the Invention
The present invention relates generally to apparatus and methods for stabilizing, restraining, and positioning a portion of the body of a patient during a medical procedure. More specifically the present invention relates to apparatus and methods for stabilizing, restraining, and comfortably positioning a portion of the body of a patient, while improving image quality during Magnetic Resonance Imaging and Computerized Tomography scanning procedures.
2. The Background Art
Computerized Tomography (“CT”) scanning and Magnetic Resonance Imaging (“MRI”) are procedures used for obtaining unique cross sectional views of a patient's internal anatomy, thereby aiding in diagnosis and treatment. CT scanning involves the use of many low dosage x-rays being passed through the body at different angles to produce cross sectional images of body tissue with the aid of a computer. MRI involves the use of electromagnets and short bursts of powerful magnetic fields and radio waves, rather than x-rays, being passed through the body. The bursts stimulate the hydrogen atoms in the patient's tissue to produce a signal that a magnetic coil detects and a computer transforms into an image.
Both of these procedures require a patient's absolute stillness in the area of the body being imaged. Patient motion is an ever-present problem for the radiologist. During the actual sequence the patient must remain absolutely motionless or the images will be blurred, often rendering them uninterpretable. This disruption in the images is known as “motion artifact.”
Motion artifact is a constant problem in all MRI because this procedure requires a relatively long period of time to obtain the images. In MRI, the patient must remain motionless for multiple imaging sequences that comprise the total exam. The exam may last 30 to 60 minutes and each sequence typically takes about 4 to 9 minutes to run. While CT scanning has much shorter imaging times than MRI, there are motion considerations in patients who are unable to cooperate. Many head CT scans are performed for the acutely injured patient and for those with sudden mental status changes. Both groups of patients are compromised in their ability to hold still and would benefit from a motion-limiting device.
In either MRI or CT scans, maintaining absolute stillness can be a challenge for an otherwise healthy adult. For an adult afflicted with tremors (such as in Parkinson's Disease), pediatric patients, patients with altered mental status from stroke or trauma, intoxicated patients, and those patients who simply fall asleep during the imaging test and are twitchy sleepers, maintaining stillness may be virtually impossible.
Patient motion can be divided into two categories: macro motion and micro motion. Macro motion occurs on the scale of centimeters and results in the body part of interest actually moving out of the field of view. This results in images that do not include the body part of interest. The patient then has to be “re-scouted” and the sequence repeated once the body part has been re-localized. This results in a loss of about 5 to 7 minutes. Micro motion occurs on a scale of millimeters and may be the result of a patient tremor, cardiac pulsation, breathing, patient restlessness, or patient discomfort resulting in unconscious twitching and shifting. This micro motion results in blurred images, which also have to be repeated. Fortunately, the patient does not need to be re-localized for these repeat sequences.
Radiologists expend extensive effort to combat patient movement. The current practice for combating patient movement involves the use of make-shift restraints from foam pads, pillows, and/or towels. Patients are brought into the MRI machine (or CT scanner) and positioned with their limb or head in the appropriate coil or imaging device. The foam pads, pillows and/or towels are then used with tape and straps to stabilize the body part and obtain a comfortable position. This positioning often takes several minutes and is fraught with poor success. Patient motion occurs because the pads, pillows, etc., do not create a custom fit and are limited in their restraining ability. Likewise, the lack of custom fit cannot create or maintain patient comfort. There are inevitable pressure points that result from a fold in the pillow, the corner or seam of a pad, and/or the edge of the coil or imaging device. The patient may have started the exam feeling quite comfortable, but after 20-30 minutes, an intolerable pressure point develops and the patient is ultimately compelled to shift his body. This even occurs in the normally conscious and cooperative patient despite his best efforts to hold still.
Fundamentally, the foam pad/pillow system is neither comfortable nor does it provide an adequate level of restraint. In addition, foam pads and pillows inherently lack the custom fit or restraint of the limb necessary to avoid all micro and macro motion.
Motion degradation leads to a significant number of non-diagnostic studies and also to considerable waste of resources. MRI time is expensive; rescanning a 5 minute sequence costs about $50 in lost magnet time. If only one sequence is rescanned on every patient on a busy MRI scanner performing 25 exams per day, roughly 125 minutes of imaging time is lost representing about 4 patient slots of at least about $1400 in technical income and roughly $400 in professional income. Clearly, motion can have a significant impact on MRI productivity. Furthermore, the delays related to patient motion will make all the subsequent patients wait, leading to customer dissatisfaction. There are approximately 6000 MR scanners in the United States. Typically, each scanner performs 5-10 brain and/or extremity examinations daily that would benefit from improved restraint and comfort.
While the time penalty for motion on a CT scanner is less severe, many of the studies on acutely head injured patients are impossible to obtain due to motion. There are approximately 6000 CT scanners in the USA. Roughly 5 head CT exams are performed each day per scanner yielding 30,000 studies. Perhaps, half of these are in patients with altered mental state, and therefore high risk of motion. Often times these scans have to be repeated to obtain better images.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to provide methods and apparatus for comfortably positioning a patient in an MRI or CT scanner or other imaging device (hereinafter “MRI”).
It is another object of the present invention to provide methods and apparatus for comfortably positioning a patient's head or limb in an MRI.
It is a further object of the present invention to provide methods and apparatus for providing a custom fit of a patient's head or limb in an MRI.
It is another object of the present invention to provide methods and apparatus for providing optimal placement of a patient's head or limb in an MRI.
Still another object of the present invention is to provide methods and apparatus having a level of restraint that substantially diminishes or precludes all micro and macro motion of a patient's head or limb in an MRI.
Yet another object of the present invention is to provide methods and apparatus for a low cost, disposable restraining device, which will decrease the time to set up a patient for scanning, thereby further improving MRI productivity.
Yet another object is to provide a custom fit for the flex/wrap or surface coils used in some MRI imaging that comfortably secures and restrains the body part and achieves rigid, yet comfortable fixation of the coil to the patient and to the MRI.
It is another object of the present invention to provide methods and apparatus for improving the intrinsic imaging quality of the MRI due to, for example, improved field homogeneity, signal to noise ratio, fat saturation, etc.
Still another object of the present invention is to provide methods and apparatus for improving patient tolerance of the imaging procedure by improving patient comfort.
These and other objects and advantages of the invention will be better understood by reference to the detailed description or will be appreciated by the practice of the invention. Consistent with the foregoing objects, and in accordance with the embodiments as embodied and broadly described herein, the restraining apparatus of the present invention will limit motion on the macro and micro scales by providing a custom fit, while also improving patient comfort. The restraining apparatus preferably comprises a disposable component, including a castable sleeve and, in a preferred embodiment, an expandable sleeve, both of which are used to fix the patient into the coil. The castable sleeve encircles the limb of a patient, and is filled with a quickly casting material. The casting material is MRI compatible, safe and rapid setting, which will decrease the time to set up a patient for scanning, thereby further improving MRI productivity. In addition, the casting material may augment the quality of the image, such as by improving the signal to noise ratio, the field homogeneity, and the fat saturation. The resulting cast sleeve is also MRI compatible and provides a comfortable custom fit for the patient that helps restrain the patient in the imaging device.
In one preferred embodiment, the expandable sleeve encircles the castable sleeve and expands to conform to the inner dimensions of a particular MRI coil or CT scanner.
Alternatively, the apparatus includes a castable sleeve that conforms via the castable material to both the limb of the patient and the inner dimension of a particular MRI coil or CT scanner.
Alternatively, the apparatus includes a castable sleeve for casting around a flex/wrap or surface coil. In one embodiment, the surface coil is wrapped around the limb of a patient and the castable sleeve is positioned over the surface coil or the castable sleeve is integrated into the surface coil to ensure rigid fixation and custom fit of the coil between the limb and the coil, as well as the coil and the MRI scanner.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present embodiments will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments and are, therefore, not to be considered limiting of the invention's scope, the embodiments will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is perspective view of an embodiment of an apparatus with a patient's limb fixed therein, being inserted into an MRI coil.
FIG. 2 is a cross-sectional view of an embodiment of an apparatus with a patient's limb fixed therein, and further fixed within an MRI coil.
FIG. 3 is cut-away view of an end of an embodiment of the apparatus of the present invention.
FIG. 4 is a cut-away longitudinal view of the apparatus depicted in FIG. 3 .
FIG. 5 is a perspective view of a mock coil in accordance with an embodiment of the present invention.
FIG. 6 illustrates a cross section of an embodiment of the apparatus of the present invention positioned within a mock coil.
FIG. 7 illustrates the apparatus of FIG. 6 with the castable material casting the limb of a patient, and conforming to the inner dimension of the mock coil.
FIG. 8 illustrates the apparatus of FIG. 6 with the castable material casting the limb of a patient and leaving a void between the inner dimension of the actual MRI coil and the expandable sleeve of the apparatus.
FIG. 9 illustrates the apparatus of FIG. 8 with the expandable sleeve inflated so as to conform to the inner dimensions of the MRI coil.
FIG. 10 illustrates an embodiment of the apparatus of the present invention after the completion of use of the apparatus with the rip cord tearing apart the apparatus for removal from the patient's limb.
FIG. 11 is an illustration of an alternate embodiment of the present invention comprising an apparatus for securing the head of a patient in an MRI or CT scan or other imaging device.
FIG. 12 is an illustration of an alternate embodiment of the present invention comprising a castable sleeve cast about a surface coil, and fixed into and MRI scanner via clamps.
DETAILED DESCRIPTION
It will be readily understood that the components of the embodiments, as generally illustrated in the Figures and described herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus and methods disclosed, as represented in FIGS. 1 through 12, is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments.
The presently preferred embodiments will be best understood by reference to the Figures, wherein like parts are designated by like numerals throughout. While the preferred embodiments pertain to MRI and to CT scanners, and to other imaging devices, the following detailed description will focus on use with an MRI. It will be appreciated that MRI and CT scanners, and other imaging devices for use with different body parts are within the scope of the present invention. For ease of the present discussion, however, a preferred embodiment of the invention will be described with reference to a small MRI coil such as for use imaging the wrist of a patient.
FIG. 1 is a visual representation of the features of the present invention that solve the problems encountered with conventional stabilizing and restraining devices. FIG. 1 depicts one presently preferred embodiment of an apparatus generally labeled 20 for stabilizing and restraining a limb of the patient in a medical apparatus. In FIG. 1 the medical device illustrated is a small MRI coil 10 such as for use on the wrist of a patient. As will be discussed further herein, the dimensions inside of the MRI coil 10 (the inner dimensions 14 ) correspond to the outside of apparatus 20 .
The apparatus of one presently preferred embodiment includes both a castable sleeve 22 and an expandable sleeve 32 . The castable sleeve preferably comprises concentric layers of plastic or other suitable fluid-impermeable material designed for comfortable contact with the patient. In one embodiment, the material provides thermal comfort, and is safe and easily removable.
As best illustrated in FIG. 3, castable sleeve 22 comprises a proximal concentric layer 24 and a distal concentric layer 26 . The proximal concentric layer 24 circumscribes a void 28 through which the limb of the patient is inserted. The castable sleeve may be open at one end only to receive the limb of the patient, or alternatively, at both ends. In either embodiment, the quick cast material will expand to consume the available space and to cast the limb. Upon introduction of a quick cast material into the castable sleeve, proximal concentric layer of the castable sleeve will form a custom fit about the patient's limb, while distal concentric layer will expand only to a limited degree.
The tactile elasticity and strength of the proximal and distal layers are preferably optimized for patient comfort and for rigidity and fixation to the imaging device. For example, in a preferred embodiment, distal layer 26 comprises limited elasticity to limit expansion outward of the casting material, while proximal layer 24 comprises greater elasticity and pliability to optimize conforming to the contours of the patient.
In the inner space 25 between the concentric layers, the castable sleeve permits the introduction of quick cast material. Preferably this material comprises an expandable and castable foam. Alternatively, the material may comprise an expandable and castable gel. One of ordinary skill in the art will understand that other expandable and castable materials are within the scope of the present invention. The quick cast material preferably expands due to intrinsic expansion of the material. Alternatively, the quick cast material expands due to pressure of the injection.
Upon introduction between the concentric layers of the castable sleeve, the quick cast material forms a custom fit cast around the patient's limb, thereby securing the limb from movement at a joint, and diminishing the degrading effects of macro and micro motion to imaging as described above. The proximal concentric layer forms a custom fit due to the expansion of the quick cast material and/or due to the pressure of introduction of the casting material. The pressure is controlled for patient safety, such as with, but not limited to, a relief valve or a pressure regulated delivery system.
As depicted in FIG. 1, the limb of the patient 12 is inserted into the void area 28 of the castable sleeve, the void area being defined by proximate concentric layer 24 . A valve 30 is provided within the castable sleeve to provide fluid communication with the castable sleeve and a quick cast material. Upon introduction of a patient's limb into the void formed by the castable sleeve, the quick cast material is introduced through connective tubing 40 connected to valve 30 . In a preferred embodiment, inner tubing 31 is connected to valve 30 . Inner tubing 31 preferable extends in the inner space 25 between proximal 24 and distal 26 concentric layers and includes a plurality of dispersion holes 33 that permit the quick cast material to be introduced quickly and optimally dispersed along the entire length of the limb in the castable sleeve, as illustrated in FIG. 4 .
Alternatively, tubing 31 may just extend slightly into the castable sleeve for introduction of the quick cast material therein, as illustrated in FIG. 1 . Alternatively, valve 30 may open into the castable sleeve for introduction of the quick cast material therein, without tubing 31 , as illustrated in FIG. 6 . In an alternate embodiment, a plurality of valves and/or tubes for introduction of the quick cast material are provided along the castable sleeve.
An expandable sleeve 32 is also provided in the apparatus illustrated in FIG. 1 . The expandable sleeve preferably comprises concentric layers of plastic or other suitable fluid-impermeable material. Between the concentric layers, the expandable sleeve permits the introduction of a material capable of expanding and/or inflating the expandable sleeve. Preferably this material comprises air. One of skill in the art will recognize that other materials that will expand and/or inflate the expandable sleeve are within the scope of the present invention. While in no way limiting the scope of the present invention, the term “inflation” will be used herein after to describe the expansion of the expandable sleeve.
The expandable sleeve preferably surrounds the castable sleeve and is attached thereto. The expandable and castable sleeves are permanently attached to one another, or alternatively are removably attached, such as with hook and loop fasteners, straps, and the like. In an alternate embodiment, the expandable sleeve contacts the castable sleeve but is not attached thereto. For example, the expandable sleeve is attached to the MRI coil such that upon insertion of a cast sleeve into the coil, the expandable sleeve is inflated to hold the cast sleeve in place.
In the embodiment of the invention illustrated in FIG. 3, the distal concentric layer 26 of the castable sleeve is attached to the expandable sleeve 32 of the apparatus 20 . Similar to the castable sleeve, the expandable sleeve includes concentric layers: an inner layer 34 and an outer layer 36 . The inner layer 34 contacts the distal concentric layer 26 of the castable sleeve 22 . The outer layer 36 contacts the inner dimensions of a coil. Preferably, upon inflation of the expandable sleeve 32 , the outer layer 36 of the expandable sleeve 32 will precisely correspond to the inner dimensions of an MRI coil such that the apparatus is fixed within the MRI coil.
The tactile elasticity and strength of the inner and outer layers are preferably optimized for patient comfort and for rigidity and fixation to the imaging device. For example, in a preferred embodiment, inner layer 34 comprises limited elasticity to limit expansion outward toward the castable sleeve, while outer layer 36 comprises greater elasticity and pliability to optimize conforming to the contours of the imaging device.
Turning to FIG. 1, the expandable sleeve 32 is preferably inflated via valve 38 with air through connective tubing 42 , which will be attached thereto for inflation and deflation of the expandable sleeve. Alternatively, as noted above, one of skill in the art will recognize that other materials that provide ease of inflation and deflation are within the scope of the present invention.
The expandable sleeve is preferably inflated upon introduction of the patient's limb (already cast in the castable sleeve) into the MRI coil. The expandable sleeve is inflated to fill all available space and thereby conform precisely to the inner dimensions of the coil. Once the expandable sleeve is inflated with the cast limb in the castable sleeve, it stabilizes the limb from both micro and macro movement within the MRI coil.
Upon completion of the imaging procedure, the expandable sleeve is easily evacuated by releasing the connective tubing 42 from the valve 38 . Alternatively, a vacuum is pulled through the connective tubing to evacuate the air. In one embodiment, the apparatus of the present invention is removed from the limb of a patient via at least one rip cord 44 , as illustrated in FIG. 10 . The rip cord 44 tears along the quick cast material in the castable sleeve, thereby aiding in removal of the apparatus from the limb of the patient. Alternatively, scissors or other implements are used to aid in removal of the castable sleeve. Alternatively, a substance that breaks down the quick cast material is introduced into the castable sleeve to aid in removal thereof.
In an alternate embodiment, the apparatus comprises a castable sleeve. In this embodiment, the limb of the patient is inserted into the castable sleeve, which is then inserted into the MRI coil. The quick cast material, which expands due to pressure of injection or due to intrinsic expansion of the material, is then introduced into the castable sleeve, thereby casting the limb and conforming to the inner dimensions of the MRI coil, without the need for the expandable sleeve. A substance that breaks down the quick cast material can be injected into the castable sleeve upon completion of imaging for removal of the limb from the coil. Alternatively, as described above, scissors, a rip cord, or other implement are used to remove the castable sleeve. In such an embodiment, the MRI coil preferably includes a clam shell opening for removal of the cast sleeve from the coil.
Turning to FIG. 2, there is illustrated a cross section of an embodiment of the apparatus and the patient's limb 12 including the castable sleeve 20 cast thereon, which have been inserted into MRI coil 10 . One will note that the expandable sleeve 32 has been sufficiently inflated to correspond to the inner dimensions 14 of the MRI coil 10 such that a tight fit has been accomplished. In addition, castable sleeve 22 has been expanded with quick cast material such that the patient's wrist is restrained from micro and macro motion within the MRI coil.
FIG. 4 is yet another illustration of a preferred embodiment of the present invention with portions cut away to illustrate the castable and expandable sleeves and the void areas in the apparatus. In particular, FIG. 4 illustrates the inner space 25 of castable sleeve 22 for introduction of the quick cast material. FIG. 4 also illustrates the inflatable space 35 in expandable sleeve that inflates to conform to the inner dimensions of an MRI coil.
FIG. 5 illustrates a mock coil 46 that emulates an actual MRI coil. Such a mock coil is used for pre-molding the apparatus of the present invention to accommodate a particular MRI coil. This mock coil 46 will save valuable MRI coil time by enabling the user to properly mold and configure an apparatus according to the present invention to conform to the actual inner dimensions of an MRI coil without actually using the MRI coil time to do so. Preferably, a mock coil is configured to correspond internally to the internal dimension of an actual MRI coil. Alternatively, the inner dimensions of the mock coil are slightly smaller than the inner dimensions of the actual coil to allow for void space in the actual coil. The void space is then filled by the expandable sleeve upon inflation thereof. It will be appreciated that numerous such mock coils would be available to the imaging practitioner to correspond to the actual MRI coils needed for patient tests. Further, such mock coils are preferably formed from light weight materials to promote ease of handling.
In one preferred method of the present invention, a patient's limb is inserted into the void space of the castable sleeve such that the proximal layer is in contact with the patient's limb. A quick cast material is then inserted into the inner space between the proximal and distal layers. The quick cast material conforms to and casts the patient's limb. The cast limb is then inserted into an MRI coil. The expandable sleeve is inflated to conform to the inner dimensions of the coil and to restrain and secure the patient's limb therein. The patient and coil may then be positioned within the MRI scanner for imaging.
Upon completion of the imaging, the patient and coil are removed from the MRI scanner. The expandable sleeve of the apparatus is deflated and the apparatus still cast about the limb are removed from the coil. The rip cord is then torn along the length of the apparatus to tear apart the cast material such that limb can be removed from the apparatus. Alternatively, the apparatus is cut from the limb. Alternatively, a substance that breaks down the quick cast material is inserted into the castable sleeve.
Turning the figures to illustrate a method incorporating a mock coil, FIG. 6 illustrates the limb 12 of a patient inserted into apparatus 20 . Castable sleeve 22 is not yet expanded to cast the limb or conform to the inner dimensions of the mock coil 46 , and expandable sleeve 32 is not yet inflated to conform to the inner dimensions of the actual coil (not pictured).
FIG. 7 illustrates the limb 12 of the patient within the apparatus of the present invention wherein the quick cast material 23 has been introduced into the castable sleeve 22 and has conformed to the limb of the patient thereby casting the limb of the patient. In addition, the quick cast material has expanded to substantially fill the volume of space inside of the mock coil 46 .
In FIG. 8, the cast limb from FIG. 7 has been inserted into an actual MRI coil 50 . The expansion of the castable sleeve has significantly filled the inner volume of the coil. The volume 52 left in the inside of the coil 50 between the expandable sleeve 32 and the coil will require inflation of the expandable sleeve. FIG. 9 illustrates such inflation. In this figure, the expandable sleeve 32 has been inflated to conform to the inner dimensions of the coil. The limb 12 is thereby prevented from micro and macro movement within the coil.
Turning to FIG. 10, apparatus 20 is illustrated after having been removed from the MRI coil upon completion of a scan. Further, the rip cord 44 is illustrated being used to tear apart the apparatus to release it from patient's limb.
As an alternative to the standard coils described above, imaging practitioners utilize surface coils, which are positioned around the limb or portion of the body of a patient. Such a coil is flexible and wraps around the limb or portion of the body thereby placing the coil directly on the surface or skin of the patient. The surface coil, as will be appreciated by those of skill in the art, provides improved imaging from standard coils described above. This improved imaging derives from the improved signal to noise ratio by placing the coil as close as possible to the limb or portion of the body being imaged, thereby diminishing dead space that can interfere with the image. Yet, the surface coil still suffers from motion degradation. Existing surface coils have no fixation system, thus both macro and micro motion negatively affect the imaging.
Thus, in an alternate embodiment, a castable sleeve is used as a cast to surround the surface coil and cause the surface coil to conform to the limb of the patient, thereby diminishing image degradation via micro motion. The limb with the surface coil cast to it is then secured in the MRI scanner with a clamp or other fixation means, thereby diminishing image degradation via macro motion. Thus, the advantage of the surface coil is combined with rigid immobilization and perfect positioning within the MRI scanner.
In the embodiment depicted in FIG. 12, patient limb 212 is surrounded by surface coil 210 , which is surrounded by castable sleeve 220 . In one embodiment, the castable sleeve is unattached to the surface coil. In an alternate embodiment, the castable sleeve is removably attached to the surface coil. In yet another alternate embodiment, the castable sleeve is integrated with the surface coil.
The castable sleeve 220 includes valve 230 for introduction of quick cast material into castable sleeve as described above with respect to a standard coil. Upon expansion of the quick cast material, the surface coil is fixed in place snuggly about the patient's limb, thereby substantially diminishing any micro motion. The castable sleeve is then secured vis-a-vis the MRI magnet, thereby substantially precluding the castable sleeve, surface coil, and limb from gross motion. In FIG. 12, clamps 240 secure the casted flex coil in place in the magnet. The clamps are preferably adjustable for height and lateral positioning of the limb within the MRI scanner, which thereby optimizes imaging and patient comfort. One of skill in the art will appreciate that other means for securing the cast surface coil and limb in place include, but are not limited to, straps and the like.
Turning to the method for casting and restraining a surface coil in and MRI scanner, a surface coil is wrapped about the limb of a patient. The castable sleeve is positioned about the surface coil. The quick cast material is then introduced into the castable sleeve, thereby casting the surface coil in place about the limb. The limb with the coil cast thereon is then secured in the MRI scanner such as with clamps as described above. The clamps are then adjusted so that the limb is precisely positioned within the MRI scanner for optimum imaging.
In an alternate embodiment depicted in FIG. 11, an apparatus is provided for a head MRI or CT scan. The head apparatus 120 includes castable chambers 122 and expandable chamber 124 . The apparatus surrounds the patient's head 112 without obstruction of the patient's airway, eyesight, or vessels. As illustrated in FIG. 11, belt 170 secures the head to the MRI coil 110 . Valve 130 permits introduction of an expandable material such as air to inflate expandable chamber 124 . Valve 138 permits introduction of a quick cast material into castable chambers.
In an alternate embodiment of any of the aforementioned embodiments, the castable sleeve or chamber, and/or the expandable sleeve or chamber, may include a plurality of sub-chambers therewithin. Such subchambers may form a plurality of fluidly interconnected individual pillow-like expansions, expandable via introduction of castable or expandable material through at least one valve. Alternatively, each of the plurality of subchambers may have its own valve for introduction of expandable or castable material.
As will be appreciated by those skilled in the art, there are a variety of means to implement the present embodiments to various configurations of MRI and CT scanners. Further, it is understood that the above description is not meant to limit the scope of the present invention.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A restraining apparatus and method for limiting motion on the macro and micro scale during MRI and CT scans, by providing a custom fit, while also improving patient comfort. The restraining apparatus includes a disposable component, including castable and expandable sleeves used to fix the patient into a coil. The castable sleeve encircles the limb of a patient, and is filled with a quickly casting material. The cast material is patient compatible and preferably designed to augment imaging. The resulting cast is MRI compatible, safe and rapid setting, which will decrease the time to set up a patient for scanning, thereby further improving MRI productivity. The expandable sleeve encircles the castable sleeve and is inflatable such that the expandable sleeve conforms to the inner dimensions of a particular MRI coil, CT scanner, or other imaging device. Alternatively, the apparatus includes a castable sleeve for casting around a flex/wrap or surface coil. The surface coil is first cast around the limb of a patient, then the patient is fixed to the magnet.
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SUMMARY
[0001] A shield with inner walls surrounds a main pole. The inner walls of the shield have wall angles with respect to a down track direction that exceed the wall angles of the main pole with respect to a down track direction. One embodiment of the shield resembles a wine glass shaped cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a cross sectional view of a perpendicular magnetic recording head according to an embodiment.
[0003] FIG. 2 is an air bearing surface view of a writer pole and “wine glass” shaped trailing shield according to an embodiment.
[0004] FIG. 3 is a plot of effective magnetic write field as a function of magnetic write width for a writer pole trailing shield with trapezoidal-shaped cavity and for the writer pole wine glass trailing shield cavity of FIG. 2 .
[0005] FIG. 4 is an air bearing surface view of a writer pole and wine glass trailing shield cavity according to an embodiment.
[0006] FIG. 5 is an air bearing surface view of a writer pole with wine glass trailing shield cavity according to an embodiment.
[0007] FIG. 6 is an air bearing surface view of a writer pole with trailing shield cavity with greater wall angles according to an embodiment.
DETAILED DESCRIPTION
[0008] FIG. 1 is a cross sectional view of an example perpendicular writer 10 in accordance with various embodiments, which includes main pole 12 , return pole 14 , and write coils 16 . Conductive write coils 16 surround back gap closure 17 that magnetically couples main pole 12 to return pole 14 . Perpendicular writer 10 confronts magnetic medium 18 at an air bearing surface (ABS) of main pole 12 and return pole 14 . Main pole 12 includes main pole body 20 , yoke 21 , and main pole tip 22 . Yoke 21 is coupled to an upper surface of main pole body 20 . Main pole tip 22 has a leading edge 24 and a trailing edge 26 . Main pole tip 22 is separated from return pole 14 at the ABS by insulating material 28 . Write gap 35 is defined by the distance between leading edge 24 and return pole 14 .
[0009] Magnetic medium 18 may include magnetically soft underlayer 32 and magnetically hard recording layer 34 . It should be noted that the configuration for perpendicular writer 10 is merely illustrative and many other configurations may alternately be employed in accordance with the present invention. For example, perpendicular writer 10 may include trailing shields, side shields, or wrap around shields that absorb stray magnetic fields from main pole tip 22 , magnetic side tracks on recording layer 34 , and other sources, such as the trailing edge of return pole 14 , during recording. Trailing shield 36 is shown proximate insulating layer 28 that surrounds main pole tip 22 of perpendicular writer 10 .
[0010] Magnetic medium 18 travels or rotates in a direction relative to perpendicular writer 10 as indicated by arrow A. To write data to magnetic medium 18 , an electric current is caused to flow through conductive write coils 16 , which passes through write gap 35 , between main pole 12 and return pole 14 . This induces a magnetic field across write gap 35 . By reversing the direction of the current through conductive coils 16 , the polarity of the data written to magnetic medium 18 is reversed. Main pole 12 operates as the trailing pole and is used to physically write the data to magnetic medium 18 . Accordingly, it is main pole 12 that defines the track width of the written data. More specifically, the track width is defined by the width of trailing edge 26 of main pole tip 22 at the ABS. Main pole 12 may be constructed of a material having a high saturation moment such as NiFe or CoFe or alloys thereof. More specifically, in various embodiments the main pole 12 is constructed as a lamination of layers of magnetic material separated by thin layers of nonmagnetic insulating material 28 such as, for example, aluminum oxide.
[0011] One embodiment is shown in FIG. 2 , which is a schematic representation of an ABS view of perpendicular writer 110 . As shown in FIG. 2 , writer 110 includes return pole 114 , main pole 122 , insulator 128 , and trailing shield 136 . Main pole 122 has a trapezoidal pole tip with leading edge 124 , trailing edge 126 and sides 140 and 142 . In this embodiment, shield 136 includes inner sidewalls 150 and 152 , leading edge 154 , trailing edge 156 , throat sidewalls 162 and 164 , and mouth sidewalls 166 and 168 . Leading edge 154 preferably is located closer to return pole 114 than is leading edge 124 of main pole 122 , wherein any stray field may be effectively prevented from reaching the magnetic medium. Inner sidewalls 150 and 152 of shield 136 may not be parallel to sides 140 and 142 of main pole 122 . As one possible result, wall angles θ 2 of shield 136 may be larger than wall angles θ 1 of main pole 122 . The trapezoidal shape is narrower at leading edge 124 than at trailing edge 126 to aid in preventing skew related adjacent track interference during writing while the write head is located at inner and outer portions of a magnetic disc.
[0012] In writer 110 , throat sidewalls 162 and 164 and mouth sidewalls 166 and 168 are adjacent leading edge 154 , thereby possibly minimizing magnetic field concentration in that vicinity during writing. The significance of increasing the wall angle and introducing throat sidewalls 162 and 164 is that, as the size of main pole 122 decreases in response to a demand for higher areal density recording, the effective writing field of magnetic writer 110 may significantly exceed the effective writing field of a writer with a main pole having identical dimensions with shield walls parallel to main pole walls 142 . The shape of the cavity in shield 136 surrounding main pole 122 in writer 110 resembles a wine glass. The length of main pole 122 , L 1 , may be less than the length of shield cavity L 2 and spacing S 1 toward the front of the cavity may be less than spacing S 2 at the back of the cavity.
[0013] To assess how shield shape impacts writing performance, a series of calculations were made of the performance of a writer having a trapezoidal shaped cavity with walls parallel to walls 140 and 142 and writer 110 with a wine glass shaped cavity for a shield. Measured variables were main pole write width, write pole wall angles θ 1 , side shield spacing, and side shield wall angles θ 2 . In the trapezoidal shaped cavities, θ 1 =θ 2 . The dimensions of main poles were the same in both writer configurations.
[0014] Exemplary results of such calculations are shown in FIG. 3 . In FIG. 3 , the maximum effective write field H eff (max) is plotted versus the magnetic writer width. The data represent a series of H eff (max) for both writer configurations with identical write current, main pole wall angle, and main pole writer width. The average results for a trapezoidal shaped cavity magnetic writer design with θ 1 =θ 2 are given by curve A. The average results for wine glass writer design 110 are given by curve B. For each case studied in the simulation, the wine glass design gave both consistently higher effective writing fields at a given magnetic write width and narrower magnetic write widths at the same write field.
[0015] FIG. 4 shows a schematic representation of an ABS view of an example perpendicular writer 110 A, which also features a shield with a wine glass shaped cavity. In FIG. 4 , elements of writer 110 A that are similar to elements of writer 110 are designated with the same reference number followed by the letter “A”. Thus, main pole 122 A of writer 110 A is similar to main pole 122 of writer 110 . In this embodiment, inner sidewalls 150 A and 152 A, throat sidewalls 162 A and 164 A, and mouth sidewalls 166 A and 168 A of shield 136 A are concave, further minimizing magnetic field concentrations in the vicinity of the throat area defined by sidewalls 162 A and 164 A. Wall angles θ 2 of sidewalls 150 A and 152 A may be larger than wall angles θ 1 of main pole 122 A. Length L 1 A of pole 122 A may be less than length L 2 A of the shield cavity and spacing S 1 A toward the front of the cavity may be less than spacing S 2 at the back of the cavity. This design may result in greater effective magnetic fields during writing due to the narrower magnetic footprint of pole 122 A at the ABS.
[0016] FIG. 5 is a schematic representation of an ABS view of perpendicular writer 110 B illustrating another embodiment of the invention featuring a shield with a wineglass shaped cavity. Perpendicular writer 110 B is similar to writers 110 and 110 A, and similar elements are designated with the same reference number followed by the letter “B”. In this embodiment, shield 136 B completely surrounds writer pole 122 B. In FIG. 5 , the cavity does not extend to leading edge 154 B of shield 136 B. Leading end wall 170 B of the cavity is positioned near, but spaced from shield leading edge 154 B. Curved sidewalls 150 B and 152 B, throat sidewalls 162 B and 164 B, mouth sidewalls 166 B and 168 B and cavity leading end wall 170 B resemble a wine glass. Length L 1 B of pole 122 C may be less than length L 2 B of the shield cavity and spacing S 1 B toward the front of the cavity may be less than spacing S 2 B at the back of the cavity.
[0017] FIG. 6 is a schematic representation of an ABS view of perpendicular writer 110 C illustrating another embodiment of the invention. Writer 110 C is similar to writers 110 , 110 A, and 110 B, and similar elements are designated with the same reference number followed by the letter “C”. In this embodiment, trailing shield 110 C completely surrounds main pole 122 C and the cavity does not extend to leading edge 154 C of shield 110 C. Sidewalls 150 C and 152 C form wall angles θ 2 that are larger than wall angles θ 1 of main pole 122 C. The cavity resembles a wine glass without a stem. That is, the cavity resembles the bowl of a wine glass. Length L 1 C of pole 122 C may be less than length L 2 C of the shield cavity and spacing S 1 C toward the front of the cavity may be less than length S 2 C at the back of the cavity.
[0018] Differences in the shape and dimensions of the trailing shield with respect to the main pole dimensions are key parameters in defining the magnetic bit shape on the recording medium. The wine glass writer design may allow the magnetic write width to be varied by the shield geometry as well as by the main pole geometry. As shown in FIG. 3 , the magnetic writer width of any effective write field can be decreased by the inventive shield geometries disclosed herein. As a result, referring to FIG. 2 , for instance, leading edge 124 , trailing edge 126 and wall angles θ 1 can be made smaller while pole 122 produces the same write field. Another benefit is that trapezoidal main poles with smaller wall angles are easier to fabricate, thereby decreasing the manufacturing costs.
[0019] Write pole fabrication by damascene processing is a fabrication method. Pole fabrication by damascene processing is described in commonly owned U.S. Pat. No. 6,949,833 and patent application Ser. No. 12/491,898 and incorporated herein in their entirety by reference. FIG. 7 illustrates exemplary steps to form a pole in an insulator layer such as layer 128 in FIG. 2 . First, an insulator layer is formed on a substrate (Step 200 ). The insulator layer is preferably aluminum oxide although other insulator materials known in the art such as SiOx, MgO, SiC, etc. may be used.
[0020] Next, a trench is formed in the insulator layer (Step 210 ). The cross section of the trench is preferably trapezoidal as shown by pole 122 in FIG. 2 . A seedlayer is then deposited on the walls and bottom of the trench to assist in formation of pole 122 (Step 220 ). A seedlayer is necessary to control the quality of subsequent layers deposited in the trench and can be deposited by plating, sputtering, or other material deposition techniques. An electrically conducting seedlayer is necessary if subsequent layers are to be deposited by electroplating.
[0021] A layer of magnetic material is then deposited on the seedlayer (Step 230 ). As discussed earlier, NiFe, CoFe, or alloys thereof are preferred. The magnetic layer can be deposited by electroplating, sputtering, or other methods of material deposition. Laminated pole structures provide improved write performance. The next step is to deposit a layer of nonmagnetic material on the magnetic material (Step 240 ). Nonmagnetic materials suitable for use as a spacer layer are tantalum, ruthenium, aluminum oxide, magnesium oxide, and others. In the next step, the process is repeated until the trench is filled and the pole is formed (Step 250 ). The process then proceeds to the next manufacturing cycle (Step 260 ).
[0022] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A write element for magnetic recording includes a main pole and a shield. The main pole has first and second sides with respect to a down-track direction. The shield at least partially surrounds the main pole with a continuously concave inner sidewall. The angle between the inner sidewall of the shield and the direction of motion of the write element is greater than the angle between the sides of the main pole and the direction of motion.
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